Plugged Honeycomb Structure Manufacturing Flat End Face
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Solution Overview
Problem
Conventional methods for manufacturing plugged honeycomb structures result in significant deposition on the end face, leading to increased costs and potential damage due to thermal stress, as well as pressure loss issues when used as filters like DPFs.
Innovation Solution
A method involving extrusion forming of ceramic materials to create a honeycomb structure with a mask-covered end face, applying and drying plugging slurry in a controlled manner to minimize end face depression, and using a flexible, flammable end face sealing member that burns off during firing to prevent shrinkage and deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plugging slurry is filled in the conventional manner without end face sealing, then the manufacturing process is simple, but a depression (shrunk dent) is formed on the end face causing deposit accumulation
Solution Approach 1:
An end face sealing member is introduced as an intermediary component between the plugging slurry and the honeycomb structure end face. This sealing member prevents slurry from protruding and forming depressions, while being removable after drying. The sealing member acts as a temporary mediator that ensures flat end face formation without complicating the overall manufacturing process.
Solution Approach 2:
The end face sealing member is installed before filling the plugging slurry to prevent depression formation in advance. By preparing the sealing arrangement beforehand, the patent ensures that the slurry will not cause end face irregularities during the filling process, thereby maintaining manufacturing simplicity while achieving precise end face flatness.
2Manufacturing precision
If the depression on the end face is flattened by filling plugging slurry again, then the end face flatness is improved, but the manufacturing process becomes complex and cost increases
Solution Approach 1:
The end face sealing member serves as a preventive intermediary that eliminates the need for corrective flattening operations. By installing this sealing component before slurry filling, the patent achieves end face flatness in a single operation, avoiding the complex multi-step process of filling, drying, checking, and refilling required by conventional methods.
Solution Approach 2:
The sealing member is installed in advance to prevent depression formation rather than correcting it later. This preliminary preventive measure simplifies the manufacturing process by eliminating the need for subsequent flattening operations, thereby reducing both process complexity and manufacturing costs while ensuring end face flatness.
3Ease of manufacture
If the plugging member is not unitarily formed, then the manufacturing process is simpler, but the plugging member peels off due to thermal stress
Solution Approach 1:
The plugging slurry is dried in a pressed state against the end face sealing member before final assembly. This preliminary drying under pressure ensures that the plugging member forms a unitary, integrated structure with strong adhesion to the honeycomb structure, preventing peeling off due to thermal stress while maintaining manufacturing simplicity through a single filling operation.
Solution Approach 2:
The patent changes the physical state parameters of the plugging slurry by controlling the drying process in a pressed state. By adjusting the pressure and moisture content parameters during drying, the plugging member transforms from a loose filled material to a unitary, stress-resistant structure that maintains durability without requiring complex multi-step manufacturing processes.
4Reliability
If deposit accumulates on the end face depression, then the filter functionality is maintained initially, but pressure loss increases and durability decreases
Solution Approach 1:
The patent converts the potential harm of deposit accumulation into a benefit by preventing depression formation in the first place. The end face sealing member ensures a flat surface that does not create shadow areas or irregularities where deposits could accumulate, thereby maintaining filter functionality while preventing the harmful effects of deposit buildup on pressure loss and durability.
Solution Approach 2:
The end face sealing member acts as a mediator that prevents the formation of surface irregularities during manufacturing. By ensuring a flat end face, this intermediary component eliminates the conditions that would lead to deposit accumulation, thereby protecting the filter from future pressure loss and durability issues without affecting its initial functionality.
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
The method effectively reduces end face deposition and pressure loss, enabling the production of plugged honeycomb structures with flat end faces, enhancing their durability and cost-effectiveness for use in high-temperature environments.
Implementation Method 1
limiting motion of the plugging slurry inside the predetermined cells by bringing the face into contact with the one end face of the masked honeycomb structure
Implementation Method 2
at least the plugging slurry at a portion in contact with the face of the end face sealing member is dried in a state that the face of the end face sealing member is pressed against the one end face of the masked honeycomb structure
Implementation Method 3
the mask and the end face sealing member are burnt up when the plugged honeycomb structure precursor is fired
Data Source
AI summary
A method for manufacturing a plugged honeycomb structure includes the steps of: applying a predetermined amount of the plugging slurry on a face of an end face sealing member, one end face of the masked honeycomb structure is pressed against the face to which the plugging slurry was applied of the end face sealing member to fill the plugging slurry in the predetermined cells on the one end face side, and drying at least the plugging slurry at a portion in contact with the face of the end face sealing member in a state that the face of the end face sealing member is pressed against the one end face of the masked honeycomb structure. The method can manufacture simply at a low cost a plugged honeycomb structure with reduced accumulation of deposit on an end face when the honeycomb structure is used as a filter or the like.