Plugged Honeycomb Structure Coating via Gas Current
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Solution Overview
Problem
Existing methods for manufacturing plugged honeycomb structures with trapping layers are inefficient, leading to waste of raw materials, non-uniform deposition of ceramic particles, and increased time for membrane formation, resulting in poor pressure loss management and trapping efficiency.
Innovation Solution
A method involving mixing ceramic particles with a gas on one end face of the honeycomb structure and sucking the gas containing the particles from the other end face to adhere them to the surfaces, with controlled aerosol density and flow rate to ensure uniform deposition and efficient formation of trapping layers, reducing waste and time required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic particles are conveyed by gas current and allowed to adhere to one side surface of porous article, then trapping layer is formed on the surface, but pressure loss increases rapidly due to PM clogging the pores
Solution Approach 1:
The filter element is divided into two functional segments: a porous article substrate and a separate trapping layer formed by ceramic particles. This segmentation allows the trapping layer to capture PM while the porous article maintains gas flow through its internal structure, preventing pressure loss while maintaining trapping efficiency.
Solution Approach 2:
The trapping layer acts as an intermediary between the gas flow and the porous article. It intercepts particulate matter before it reaches the porous article pores, preventing clogging while allowing gas to pass through to the other side opening ends.
2Stress or pressure
If trapping layers are provided on porous article to inhibit PM from entering substrate, then pressure loss is suppressed, but manufacturing time increases and raw material is wasted
Solution Approach 1:
Gas current is used to convey ceramic particles to the porous article surface. The gas flow creates a controlled environment where particles are deposited efficiently without requiring lengthy processing times, reducing both time and material waste while forming effective trapping layers.
Solution Approach 2:
The average particle diameter of ceramic particles is controlled to be 1/2 to 2/3 of the average pore size of the porous article. This parameter optimization allows particles to adhere effectively to the surface without blocking pores, reducing the time needed for membrane formation while maintaining trapping efficiency.
3Reliability
If ceramic particles are conveyed by gas current, then trapping layer is formed, but particles aggregate and deposit non-uniformly
Solution Approach 1:
The gas current is directed to flow through specific channels of the honeycomb structure, delivering ceramic particles locally to the appropriate surfaces. This localized delivery ensures uniform deposition across all cell surfaces while preventing particle aggregation in the gas stream.
Solution Approach 2:
The gas flow rate and particle concentration are dynamically adjusted during the coating process to maintain optimal conditions for uniform deposition. By controlling the gas current velocity and particle loading, the system prevents aggregation while ensuring even distribution of particles across the porous article surfaces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the efficient use of raw materials, uniform deposition of ceramic particles, and the formation of homogeneous trapping layers, effectively reducing pressure loss and improving trapping efficiency while minimizing material waste and production time.
Implementation Method 1
the ceramic particles adhere to the porous article due to the differential pressure on the upstream side and the downstream side of the porous article
Implementation Method 2
ceramic particles are conveyed by means of a gas current and allowed to adhere to one side surface of a porous article
Implementation Method 3
the ceramic particles adhere to the porous article due to the differential pressure on the upstream side and the downstream side of the porous article
Implementation Method 4
moisture (water or steam) is imparted to the adhering ceramic particles to allow the ceramic particles to be adsorbed to the one side face of the porous article
Data Source
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AI summary
A method for manufacturing a plugged honeycomb structure includes: a step of mixing ceramic particles with a gas on one end face side of the plugged honeycomb structure, and a step of sucking the gas containing the ceramic particles from the other end face side of the plugged honeycomb structure to send the ceramic particles mixed in the gas into cells of the plugged honeycomb structure to allow the ceramic particles to adhere to surfaces in the cells of the plugged honeycomb structure.