Honeycomb Plugging Apparatus Support Substructure
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Solution Overview
Problem
Existing methods for manufacturing plugged honeycomb bodies face challenges in minimizing the slump of plugging material during the process, leading to inefficiencies and inconsistencies in plug formation.
Innovation Solution
A honeycomb plugging apparatus with a support substructure within an open-ended cavity that reduces or eliminates slumping by providing horizontal and vertical support members or a grid structure to maintain the plugging material in place, allowing for precise and uniform plug formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If plugging material is loaded into the open-ended cavity for the next shot, then the apparatus is prepared for subsequent plugging operations, but the plugging material slumps downward due to gravity, causing inconsistent plug formation and material waste
Solution Approach 1:
A support substructure is introduced as an intermediary element between the plugging material and the cavity floor. This substructure acts as a mediator that prevents direct gravitational collapse of the material while allowing controlled flow during the plugging operation. The support substructure temporarily holds the material in place and can be selectively removed or collapsed after use.
Solution Approach 2:
The support substructure is designed to be dynamic rather than static. It provides rigid support during the loading and storage phase, then transitions to a removable or collapsible state after plugging. This dynamic behavior allows the system to adapt between different operational phases: supporting the material when needed and clearing the cavity when not needed.
2Speed
If the open-ended cavity is kept open for rapid loading and unloading of honeycomb bodies, then manufacturing speed is improved, but the plugging material is exposed to gravitational forces causing slumping and material loss
Solution Approach 1:
The support substructure serves as a protective intermediary that enables the cavity to remain open for rapid operations while preventing material loss. It decouples the necessity of an open cavity for speed from the harmful effect of gravity on loose material, allowing both requirements to coexist.
Solution Approach 2:
The support substructure is positioned and configured in advance before material is loaded. This preliminary arrangement ensures that as soon as material is introduced into the open cavity, it is immediately supported and prevented from slumping, eliminating the need for slower alternative handling methods.
3Ease of manufacture
If no support structure is used in the open-ended cavity, then the apparatus design is simple and easy to manufacture, but the plugging material slumps causing inconsistent plug depth and increased material waste
Solution Approach 1:
Rather than using a single complex support structure, the solution segments the support function into a modular substructure that can be easily fabricated and installed. This segmented approach maintains manufacturing simplicity while achieving the precision needed for consistent plug formation.
Solution Approach 2:
The support substructure is designed to be simple, inexpensive, and potentially disposable or easily replaceable. This approach prioritizes manufacturing ease and low cost over long-term durability, accepting that the support structure may need periodic replacement while consistently delivering precise plug formation.
Data Source
AI summary
A honeycomb plugging apparatus that reduces slumping of the plugging patty. Honeycomb plugging apparatus includes a plugging head having an open-ended cavity formed from an end wall and a peripheral wall, and a support substructure provided in the open-ended cavity. Methods of plugging and manufacturing honeycomb bodies using the honeycomb plugging apparatus are provided, as are other aspects.