Honeycomb Filter Coating Apparatus Uniform Powder Distribution
Solution Overview
Problem
Honeycomb filters used in diesel particulate filters experience rapid pressure loss due to the accumulation of particulate matter, and existing methods for producing filters with uniform collection layers are not efficient in terms of productivity and yield.
Innovation Solution
A honeycomb filter production apparatus that secures a porous ceramic base and uses a powder transfer section with pressurized gas to disperse powder, which is then introduced into the base with a mixed air current, and a suction section to align the air current, ensuring a uniform and stable coating of the collection layer on the inner surface of the base.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a collection layer is formed on the surface of a honeycomb filter base to reduce pressure loss, then filtration performance is improved, but manufacturing complexity increases due to the need for precise powder coating control
Solution Approach 1:
The patent uses pneumatic systems to transport powder through pipelines and control its deposition on the honeycomb filter base. A powder conveying system with controlled airflow rates delivers powder to the coating position, and air pressure differential controls the powder release timing and distribution uniformity, enabling precise coating control without complex mechanical positioning systems.
Solution Approach 2:
The patent controls coating uniformity by adjusting operational parameters including airflow rate, powder feed rate, and base moving speed. By optimizing these parameters, the system achieves consistent powder layer thickness and uniform distribution, resolving the manufacturing complexity issue while maintaining high filtration performance.
2Manufacturing precision
If powder is transferred using pressurized gas to improve coating uniformity, then manufacturing precision is improved, but energy consumption increases
Solution Approach 1:
The patent employs continuous powder conveyance through pneumatic pipelines rather than batch transfer methods. The continuous airflow maintains steady powder delivery to the coating position, ensuring uniform coating while optimizing energy usage through sustained rather than intermittent operation. The system maintains efficient energy utilization by keeping the powder suspension in continuous motion throughout the transfer process.
3Manufacturing precision
If a suction section is added to align air current for uniform powder distribution, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent combines the suction function with the existing powder conveying system rather than adding a completely separate alignment mechanism. The suction section is integrated into the pipeline system, using the same airflow infrastructure to both transport powder and align the air current for uniform distribution. This merging approach achieves precise powder distribution while minimizing additional device complexity.
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
The apparatus produces filters with a uniform collection layer, reducing pressure loss and improving productivity and yield by ensuring uniform powder distribution and adherence to the filter's surface, thus enhancing the filtration efficiency and reducing environmental pollution.
Implementation Method 1
a powder transfer section that is disposed on one side of the workpiece securing section, and transfers a powder together with an air current by utilizing pressurized gas
Implementation Method 2
a suction section that is disposed on the other side of the workpiece securing section, and sucks the gas that has passed through the base secured by the workpiece securing section by reducing pressure on the other side of the workpiece securing section
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A honeycomb filter production apparatus 1 used for producing a honeycomb filter, the apparatus includes: a workpiece securing section for securing a base (workpiece 11) of a honeycomb filter; a powder transfer section 20 that is disposed on one side of the workpiece securing section, and transfers a powder together with an air current by utilizing pressurized gas; an introduction section 40 that is provided between the powder transfer section 20 and the workpiece securing section 10, the powder transferred from the powder transfer section 20 together with the air current being mixed with another gas in the introduction section 40, and introduced into the base (workpiece 11) secured by the workpiece securing section 10; and a suction section 30 that is disposed on the other side of the workpiece securing section 10, and sucks the gas that has passed through the base (workpiece 11) secured by the workpiece securing section 10 by reducing pressure on the other side of the workpiece securing section 10 as compared with the one side of the workpiece securing section 10 using suction means.