Honeycomb Structure Ultrasonic Welding Closing Method
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Solution Overview
Problem
The existing methods for producing honeycomb structures, such as those used in diesel particulate filters, face inefficiencies in closing through holes, requiring separate closing members and resulting in turbulence and pressure drop issues due to gas flow.
Innovation Solution
A production method that simultaneously closes through holes at both ends of a green honeycomb molded body by welding partition walls using a closing jig with ultrasonic protrusions, eliminating the need for separate closing members and reducing turbulence and pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If through holes are closed separately for each end surface using a closing member, then the through holes can be closed, but the closing efficiency is low and additional closing members are required
Solution Approach 1:
The patent merges the closing operations for both end surfaces into a single simultaneous operation. The closing jig is designed with multiple closing protrusions that engage with through holes at both end surfaces concurrently, allowing both ends to be closed in one step rather than requiring separate closing operations for each end.
Solution Approach 2:
The closing jig serves multiple functions: it simultaneously closes through holes at both end surfaces, supports the green honeycomb molded body during the closing operation, and provides a unified structure that eliminates the need for separate closing members for each end.
2Ease of manufacture
If closing paste is used to close through holes, then the through holes can be closed, but turbulence and pressure drop are generated at the end surfaces
Solution Approach 1:
The patent extracts and eliminates the closing paste material from the closing process. Instead of using paste that requires drying and curing, the invention uses a mechanical closing method where the closing jig directly closes the through holes by welding partition walls, removing the source of turbulence and pressure drop associated with paste-based methods.
Solution Approach 2:
The patent replaces the chemical/mechanical process of applying and curing closing paste with a direct mechanical welding process. The closing protrusions apply mechanical force to weld partition walls together, creating smooth closed surfaces without the irregularities and turbulence-generating features of dried paste.
3Productivity
If through holes are closed at one end surface only, then closing can be performed, but both ends cannot be closed simultaneously requiring multiple operations
Solution Approach 1:
The patent combines the closing operations for both end surfaces into a single simultaneous operation. The closing jig is designed with multiple closing protrusions that engage with through holes at both end surfaces concurrently, allowing both ends to be closed in one step rather than requiring separate closing operations for each end.
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 effectively closes through holes, reduces the need for closing pastes, and minimizes pressure drop by ensuring smooth welds and reduced turbulence in exhaust gas flow.
Implementation Method 1
the through holes of at least the one end surface of the green honeycomb molded body are closed by welding the partition walls with each other, by inserting each of a plurality of closing protrusions of a closing jig into the part of a plurality of the through holes
Implementation Method 2
the through holes of at least the one end surface of the green honeycomb molded body are closed by welding the partition walls with each other, by inserting each of a plurality of closing protrusions of a closing jig into the part of a plurality of the through holes
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
Regular hexagonal cells at both an top surface and a bottom surface of a green honeycomb molded body are closed at the same time. Therefore, the regular hexagonal cells can be closed effectively. In addition, the regular hexagonal cells of the green honeycomb molded body are closed by welding partition walls with each other, by inserting each of closing protrusions of a closing jig into the plurality of regular hexagonal cells. Therefore, a closing paste like the conventional method is not required. In a case where a honeycomb structure is used for a diesel particulate filter, turbulence of exhaust gas flow, at the end surface of the side to supply the exhaust gas and/or the side to discharge the exhaust gas, is reduced, and pressure drop can be reduced.