Nozzle Buffer Space for Uniform Honeycomb Joining

Solution Overview

Problem

The production of honeycomb structures for diesel and gasoline particulate filters faces issues with application unevenness and material dripping due to the properties of thixotropic joining materials, leading to inefficiencies in the production process.

Innovation Solution

The nozzle portion of the joining material applicator is designed with a buffer space that gradually expands the flow path cross-section, preventing pressure buildup and ensuring uniform application and reducing material dripping by smoothing the discharge through a slit-shaped port.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a joining material with higher thixotropic property is applied to improve joining performance, then the joining material cannot be uniformly applied due to poor responsiveness to stress

Engineering Contradiction:

Improvejoining performanceVSAvoidapplication uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The nozzle is pre-designed with a buffer space and gradually expanding flow path cross-section before the joining material reaches it. This preliminary structural preparation allows the thixotropic material to naturally flow smoothly without sudden pressure changes, enabling uniform application while maintaining the material's joining properties

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flow path cross-section of the nozzle is designed to gradually expand from the buffer space to the discharge port. This parameter change in the nozzle geometry allows the joining material to transition smoothly from a confined state to a spreading state, achieving uniform application width while maintaining application speed

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If the application amount of joining material is increased to solve non-uniformity, then excessive amount of joining material protrudes and decreases efficiency for using the joining material

Engineering Contradiction:

Improveapplication uniformityVSAvoidjoining material efficiency

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The nozzle flow path cross-section is designed to gradually expand from the buffer space to the discharge port. This controlled parameter change in the nozzle geometry allows the joining material to naturally spread to the desired application width without requiring excessive material input, thereby achieving uniform application while maintaining material efficiency

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the joining material is applied through the nozzle portion, then the joining material is not smoothly applied and an increased amount of the joining material dripped from the joining material discharge port

Engineering Contradiction:

Improveapplication speedVSAvoidapplication smoothness

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The nozzle is pre-designed with a buffer space and gradually expanding flow path cross-section before the joining material reaches it. This preliminary structural preparation allows the thixotropic material to naturally flow smoothly without sudden pressure changes, enabling uniform application while maintaining the material's joining properties

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flow path cross-section of the nozzle is designed to gradually expand from the buffer space to the discharge port. This parameter change in the nozzle geometry allows the joining material to transition smoothly from a confined state to a spreading state, achieving uniform application width while maintaining application speed

Inventive Principle:

Principle #35Parameter changes

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 design effectively suppresses application unevenness and prevents material dripping, thereby enhancing the production efficiency of honeycomb structures by maintaining consistent application widths and reducing the need for frequent nozzle cleaning.

Implementation Method 1

a buffer space configured such that a flow path cross section gradually expands toward the joining material discharge space on a downstream side of the bent portion

Methodology Applied

Scientific EffectPressure reduction through expansion: Pressure Gradient

Data Source

PatentUS11904264B2Method for producing honeycomb structure

Publication Date: 2024.02.20 NGK INSULATORS LTD

AI summary

A method for producing a honeycomb structure for fine particle collection filters, the honeycomb structure including a plurality of porous honeycomb structure segments. The method includes joining each of the porous honeycomb segments via a joining material layers by applying a joining material between joining surfaces of each of the porous honeycomb structure segments, through a nozzle portion of a joining material applicator. The nozzle portion of the joining material applicator includes: a joining material introduction port; a joining material discharge space; and a joining material flow path having a bent portion, through which the joining material passes from the joining material introduction port to the joining material discharge space. The joining material flow path of the nozzle portion includes a buffer space configured such that a flow path cross section gradually expands toward the joining material discharge space on a downstream side of the bent portion.