Honeycomb Filter Partial Cell Plugging
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Solution Overview
Problem
Diesel particulate filters with honeycomb structures often have partial cells at the periphery that are difficult to plug, leading to unfiltered exhaust gas containing particulate matter and NOx emissions flowing through them.
Innovation Solution
A method of applying a line of plugging material to the outermost row of partial cells at the periphery of the filter, which can be beveled and altered in profile to ensure complete blockage, thereby preventing exhaust gas flow and enhancing edge strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated plugging equipment is used to plug alternating cells in diesel filters, then the plugging process is efficient and automated, but the equipment has difficulty finding and plugging partial cells at the periphery, resulting in unplugged cells
Solution Approach 1:
The method applies plugging material to the outermost row of cells before the automated plugging process. This preliminary action ensures that partial cells at the periphery are blocked before the automated equipment attempts to plug alternating cells, preventing unfiltered exhaust gas from flowing through unplugged partial cells.
2Manufacturing precision
If the outermost row of partial cells is beveled and plugging material is applied, then complete blockage of partial cells is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The method applies plugging material specifically to the outermost row of partial cells rather than treating all cells uniformly. This localized approach targets the problematic peripheral area while maintaining the standard alternating plug pattern for interior cells, achieving complete blockage of partial cells without unnecessarily complicating the overall manufacturing process.
3Reliability
If a line of plugging material is applied to the outermost row of cells, then partial cells are effectively blocked preventing exhaust gas flow, but the application process requires additional steps
Solution Approach 1:
The plugging material is applied to the outermost row of cells as a preliminary step before the main automated plugging process. This ensures reliable blocking of partial cells to prevent unfiltered exhaust gas flow, while the subsequent automated plugging of alternating cells maintains manufacturing efficiency through automation.
Data Source
AI summary
A method of blocking partial cells at the periphery of diesel filters is disclosed. The method comprises plugging the partial cells with a suitable plugging material. In one embodiment, a line of plugging material is applied to either or both of the end faces of the diesel filter along an outermost row of partial cells to block same. In another embodiment, the outermost wall the diesel filter is first beveled to form a beveled edge and uniquely off-set the partial cells. Then the beveled edge has applied thereto a plugging material, such as a line or bead. A honeycomb structure having reduced number of unplugged partial cells at the periphery is also disclosed.