Plugged Honeycomb Structure Manufacturing via Substrate Vibration
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Solution Overview
Problem
Conventional methods for manufacturing plugged honeycomb structures, such as diesel particulate filters, face challenges in achieving uniform permeation of plugging slurry into cells, leading to inconsistent pressure loss and deposition of filtered matter, due to non-uniform permeation depth and the complexity of required manufacturing facilities.
Innovation Solution
A manufacturing method involving the attachment of mask films to both ends of a honeycomb substrate, creating slurry permeation holes and deaeration holes of specific diameters, submerging in a plugging slurry with controlled viscosity, and firing, while optionally vibrating the slurry to ensure uniform filling and prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the plugging slurry is allowed to permeate the predetermined cells by submerging the honeycomb substrate into the slurry container, then the plugging process is simple, but the slurry does not permeate into the desired depth and the permeation depth is not uniform
Solution Approach 1:
The patent applies mechanical vibration to the honeycomb substrate during the slurry permeation process. The substrate is vibrated at a frequency of 20-2000 Hz while being submerged in the plugging slurry, which enhances the penetration of slurry into the cells and ensures uniform permeation depth. This vibration mechanism resolves the contradiction by maintaining process simplicity while achieving precise and uniform slurry distribution.
2Manufacturing precision
If a device for vibrating the plugging slurry is used to achieve uniform permeation, then the permeation uniformity is improved, but the manufacturing facilities become huge and complicated
Solution Approach 1:
Instead of using complex slurry vibration devices, the patent applies mechanical vibration directly to the honeycomb substrate. This approach achieves uniform permeation while keeping the manufacturing facility simple, as the vibration can be applied through straightforward mechanical means during the submergence process.
Solution Approach 2:
The patent inverts the conventional approach by vibrating the substrate rather than the slurry. This inversion simplifies the manufacturing facility requirements while achieving the same uniform permeation effect, resolving the contradiction between precision and device complexity.
3Device complexity
If the plugging slurry is allowed to permeate the cells without vibration, then the manufacturing facility is simple, but the permeation depth is not uniform and pressure loss fluctuates
Solution Approach 1:
The patent introduces mechanical vibration of the substrate during slurry permeation, which ensures uniform slurry distribution in the cells. This uniform distribution leads to consistent pressure loss characteristics and improved reliability, while the vibration mechanism remains simple enough to maintain facility simplicity.
4Ease of manufacture
If the opening end portions are plugged by conventional method, then the process is straightforward, but product defects such as plugging failure are generated
Solution Approach 1:
The patent applies mechanical vibration to the substrate during the plugging process, which ensures complete and uniform slurry permeation into all predetermined cells. This eliminates plugging failures and improves the success rate while keeping the process straightforward and easy to implement.
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 allows for uniform permeation of the plugging slurry to the desired depth, reducing defects and ensuring consistent performance of the plugged honeycomb structure by controlling the viscosity and air flow, thereby improving manufacturing yield and reliability.
Implementation Method 1
an end portion of the honeycomb substrate 1 is submerged into a container 5 in which a plugging slurry 6 is stored, whereby the plugging slurry 6 is allowed to permeate the predetermined cell opening end portions 7
Implementation Method 2
a method is disclosed in which the plugging slurry having thixotropy is used, and the plugging slurry is allowed to permeate the predetermined cells of the honeycomb substrate while vibrated
Implementation Method 3
a mask film 4 to constitute a mask is attached to an end surface of a honeycomb substrate 1, holes 3 are provided at positions corresponding to opening end portions (cell opening end portions 7) of predetermined cells 2a and 2b of the mask film 4
Implementation Method 4
a firing step of firing the resultant slurry filled substrate
Data Source
AI summary
A manufacturing method of a plugged honeycomb structure 30 which comprises a honeycomb substrate 1 and plugging portions 15 arranged so as to form complementary checkered patterns alternately at both end surfaces 11 and 21 of the honeycomb substrate 1. The method comprises attaching mask films 4a and 4b to both end surfaces 11 and 21 of the honeycomb substrate 1, respectively; forming slurry permeation holes 3a at portions of the mask films 4a and 4b corresponding to cell opening end portions 7, respectively; forming deaeration holes 3b at portions of the mask films 4a and 4b facing the portions provided with the slurry permeation holes 3a via cells 2; submerging both end surfaces 11 and 21 of the honeycomb substrate 1 to which the mask films 4a and 4b have been attached into a plugging slurry 6, respectively; and firing the resultant slurry filled substrate 20.