Honeycomb Filter Cell Plugging via Pressure-Monitored Mask Dispensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for plugging cells in ceramic structures and honeycomb filters lack precision and uniformity, leading to inconsistent plug lengths and reduced production efficiency.
Innovation Solution
A method involving a mask with openings coincident with cell openings, a plenum, a movable plunger, and a pressure sensor film to accurately dispense and pressurize a plug material into cells, ensuring uniform plug depth through pressure monitoring and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional plugging methods are used, then the process is simple, but plug length uniformity is poor
Solution Approach 1:
The plugging apparatus is segmented into distinct functional modules: a mask with openings aligned to cell positions, a plenum chamber for material storage, a flow plate with controlled openings, and a plunger mechanism. This segmentation allows each component to be optimized independently for its specific function while maintaining overall system precision for uniform plug dispensing.
Solution Approach 2:
A mask is introduced as an intermediary component between the plugging apparatus and the honeycomb structure. The mask with its precisely positioned openings serves as a mediator that ensures accurate alignment and uniform distribution of plug material into the cells, thereby improving plug length uniformity without requiring complex adjustment mechanisms.
2Manufacturing precision
If pressure monitoring is added, then plug placement precision is improved, but device complexity increases
Solution Approach 1:
A pressure sensor is integrated into the plenum chamber to provide real-time feedback on the pressure of plug material. This feedback mechanism allows the system to monitor and maintain optimal pressure levels for consistent plug dispensing, improving placement precision through automatic adjustment rather than complex manual control systems.
Solution Approach 2:
The pressure sensor enables the system to self-regulate the plug material flow by monitoring pressure conditions within the plenum. When pressure deviates from the optimal range, the system can automatically adjust the plunger position or speed to maintain precise plug placement without requiring external intervention or complex control algorithms.
3Manufacturing precision
If plug material is forced under high pressure, then plug depth consistency is improved, but material waste increases
Solution Approach 1:
The system controls the pressure parameter of plug material dynamically rather than using constant high pressure. By adjusting pressure levels based on real-time sensor feedback and the specific requirements of each cell position, the system achieves consistent plug depth while minimizing excess material forcing and subsequent waste.
Solution Approach 2:
The mask with its selectively positioned openings enables local quality control, where plug material is delivered only to specific cells that require plugging. This targeted approach ensures that pressure is applied only where needed, achieving consistent plug depth in targeted cells while avoiding unnecessary material waste in adjacent cells.
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 ensures improved plug length uniformity, enhances production yields, reduces inspection costs, and streamlines the production process by continuously monitoring and adjusting pressure for precise plug placement.
Implementation Method 1
determining the pressure within the cylinder during the step of moving the plunger, wherein the step of determining the pressure within the cylinder is conducted by evaluating output data from a pressure sensor film disposed between the flow plate and the mask
Data Source
AI summary
A method for plugging a subset of cells of a honeycomb structure that includes: covering a first end face of the honeycomb structure with a mask that comprises a body and a plurality of openings, wherein the plurality of openings of the mask is coincident with a plurality of cells of the honeycomb structure; providing a plenum, a movable plunger and a flow plate; positioning a cylinder between the honeycomb structure and the plenum; dispensing a plugging material into the plenum; moving the plunger toward the flow plate with a force to push the plugging material through the flow plate into the cylinder, the moving generating a pressure in the plenum and the cylinder that forces the plugging material through the mask into the plurality of cells of the honeycomb structure to a predetermined depth; and determining the pressure within the cylinder during the moving of the plunger.