Honeycomb Filter Cell Closure Without Sealing Paste
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Solution Overview
Problem
Conventional methods for producing honeycomb structures require sealing pastes and involve a cumbersome process of applying a sealing mask and opening holes, which is inefficient and troublesome.
Innovation Solution
A method that closes honeycomb structures by joining partition walls together using a closing tool with specific shapes, eliminating the need for sealing pastes and reducing turbulence and pressure loss in diesel particulate filters by varying the size and shape of through-holes at the end surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing pastes and sealing masks are used to close through-holes in the green honeycomb molded body, then the through-holes can be closed effectively, but the production process becomes complicated and time-consuming
Solution Approach 1:
The invention extracts and eliminates the sealing paste and sealing mask components from the closing process. Instead of adding external sealing materials, the partition walls themselves are directly joined together through welding or fusion, removing the need for separate sealing substances and masks.
Solution Approach 2:
The closing function is merged with the partition wall structure itself. The partition walls are directly joined together to form closed cells, combining the structural element (partition wall) with the closing function, eliminating the need for separate sealing components.
2Reliability
If sealing pastes and sealing masks are used to close through-holes, then the through-holes can be sealed, but the production time and operational steps increase significantly
Solution Approach 1:
The partition walls are positioned and prepared in advance during the extrusion process, with their ends already aligned for joining. This preliminary arrangement eliminates the need for time-consuming mask application and paste placement steps during the closing operation.
Solution Approach 2:
The closing operation is merged with the existing partition wall structure, allowing direct joining without separate sealing steps. This integration reduces the number of operational steps and minimizes production time while maintaining reliable closure.
3Productivity
If all through-holes are kept open in the honeycomb structure, then flow capacity is maximized, but turbulence and pressure loss increase at the end surface
Solution Approach 1:
Instead of uniformly keeping all through-holes open, the invention applies local quality by selectively closing certain through-holes (specifically those adjacent to octagonal through-holes) while leaving others open. This creates spatial variation in flow paths, reducing turbulence and pressure loss in specific regions while maintaining overall flow capacity.
Solution Approach 2:
The through-holes are segmented into different categories (open and closed) based on their position and function. By closing specific through-holes and keeping others open, the flow paths are segmented and redirected, reducing turbulence and improving flow efficiency without completely blocking the structure.
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 method allows for the simple closure of honeycomb structures without sealing pastes, reducing turbulence and pressure loss when used in diesel particulate filters by optimizing the arrangement and size of through-holes, enhancing the efficiency of the filtration process.
Implementation Method 1
a closing step of joining together partition walls of a green honeycomb molded body
Data Source
AI summary
A plurality of inlet-side octagonal cells and outlet-side quadrangular cells partitioned by partition walls on an upper surface and a lower surface are opened in a green honeycomb molded body in which a plurality of through-holes partitioned from each other by the partition walls are open in an end surface of a columnar body. Four outlet-side quadrangular cells having a smaller opening area adjoin around one inlet-side octagonal cell through the partition walls. The partition walls are joined together and the inlet-side octagonal cells are opened while closing the outlet-side quadrangular cells on the inlet side and the outlet-side quadrangular cells are opened while closing the inlet-side octagonal cells on the outlet side in a particulate-matter-removing filter such as a diesel particulate filter.