Honeycomb Filter Plug Depth Variability Reduction
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Solution Overview
Problem
Porous honeycomb ceramic filters face challenges in achieving consistent plug depth and mechanical strength due to variability in plug depth, which affects the efficiency and cost of filter manufacturing, as well as fuel economy and material utilization.
Innovation Solution
A composition comprising a refractory filler with a specific particle size distribution, an organic binder, and an inorganic binder is applied to honeycomb channels, resulting in plugs with a controlled average depth and depth range, minimizing variability and ensuring sufficient mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the amount of water in the plugging composition is reduced and particle size of batch components is increased, then voids in plugs are reduced and plug quality is improved, but plug depth becomes insufficient and mechanical strength decreases
Solution Approach 1:
The patent applies parameter changes by carefully controlling the water content (5-15 wt%) and particle size distribution (D10, D50, D90 values) of the plugging composition to achieve optimal plug quality and mechanical strength simultaneously
Solution Approach 2:
The patent uses a composite plugging composition containing multiple refractory materials (alumina, silica, magnesia) with different particle sizes and properties, combined with organic and inorganic binders, to achieve both high quality and sufficient mechanical strength
2Productivity
If plug depth is reduced, then back pressure is reduced, filter volume is increased, and fuel economy is improved, but mechanical strength becomes insufficient
Solution Approach 1:
The patent optimizes plug depth within a specific range (0.5-2.0 mm) and controls the particle size distribution and water content to ensure that even at reduced depths, plugs maintain sufficient mechanical strength while minimizing back pressure
Solution Approach 2:
The patent uses organic binders that create a green strength framework during plugging, allowing plugs to maintain structural integrity at reduced depths before final sintering
3Reliability
If plug depth variability is reduced, then mechanical strength consistency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent controls multiple parameters including water content (5-15 wt%), particle size distribution (D10, D50, D90), and binder ratios to minimize plug depth variability and ensure consistent mechanical strength across different channels
Solution Approach 2:
The patent incorporates flow rate monitoring and adjustment mechanisms to compensate for variations in channel resistance, ensuring uniform plug depth and mechanical strength across all channels
Data Source
AI summary
A composition for applying to a honeycomb body includes a refractory filler, an organic binder, an inorganic binder, and a liquid vehicle, wherein the refractory filler, the particle size distribution of the refractory filler, the organic binder, and the inorganic binder are selected such that, when the composition is applied to plug a plurality of channels of the honeycomb body, the plug depth variability is reduced.