Honeycomb Body Plugging via Mask Layer and Nozzle Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for plugging ceramic honeycomb bodies used in filters are inefficient and prone to leakage, leading to suboptimal performance in trapping particulates from exhaust gases.
Innovation Solution
A method involving the application of a mask layer with aligned holes, positioning a nozzle with a slot die opening, and moving the honeycomb body relative to the nozzle to pass plugging cement through the holes and into the channels, ensuring precise alignment and pressure control to form uniform plugs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional plugging methods are used, then the process is simple, but the production rate is low and leakage occurs
Solution Approach 1:
A mask layer is applied to the honeycomb body before plugging, with pre-formed holes positioned over the channels. This preliminary preparation enables precise control of plugging cement flow and eliminates leakage, while the continuous application process increases production rate by up to three times compared to conventional methods
Solution Approach 2:
The mask layer serves as an intermediary component between the plugging cement and the honeycomb body. It controls the flow path of the plugging cement through its aligned holes, ensuring uniform distribution into channels while preventing leakage, thus resolving the contradiction between simplicity and effectiveness
2Manufacturing precision
If plugging cement is applied without precise alignment, then the process is fast, but plug formation is non-uniform and adhesion is poor
Solution Approach 1:
The mask layer is pre-positioned on the honeycomb body with holes already aligned over the channels before plugging cement application. This preliminary alignment eliminates the need for time-consuming alignment adjustments during the plugging process, while ensuring uniform plug formation and strong adhesion through consistent cement distribution
Solution Approach 2:
The mask layer provides localized control of plugging cement flow by positioning holes specifically over individual channels. This local quality approach ensures uniform plug formation in each channel while maintaining overall process speed, as the mask layer is applied once to the entire honeycomb body rather than requiring continuous adjustment
3Reliability
If plugging cement flows without pressure control, then the process is simple, but leakage occurs and plug consistency is poor
Solution Approach 1:
The mask layer acts as an intermediary that controls plugging cement flow and prevents leakage without requiring complex pressure control mechanisms. The holes in the mask layer are positioned to align with channels, directing cement flow uniformly while preventing leakage, thus achieving reliability through structural design rather than complex pressure regulation
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 enhances the production rate of filters by up to three times conventional methods, achieving uniform and consistent plug formation with improved adhesion and reduced leakage, allowing for efficient trapping of particulates.
Implementation Method 1
passing a plugging cement through the opening defined by the nozzle against the mask layer such that the plugging cement passes through the plurality of holes in the mask layer and enters the plurality of channels of the honeycomb body
Implementation Method 2
applying a mask layer to a honeycomb body comprising a plurality of channels; forming a plurality of holes in the mask layer such that the plurality of holes are aligned with the plurality of channels
Data Source
AI summary
A method of plugging a honeycomb body is disclosed herein, the method comprising: applying a mask layer to a honeycomb body comprising a plurality of channels; forming a plurality of holes in the mask layer such that the plurality of holes are aligned with the plurality of channels; positioning a nozzle defining an opening proximate the mask layer; moving at least one of the nozzle and the honeycomb body relative to one another; and passing a plugging cement through the opening defined by the nozzle against the mask layer such that the plugging cement passes through the plurality of holes in the mask layer and enters the plurality of channels of the honeycomb body.