Plugged Honeycomb Structure Manufacturing via Press Pouring
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Solution Overview
Problem
Existing methods for manufacturing plugged honeycomb structures face issues with slurry wastage and uneven plugging due to fluidity and equipment complexity, leading to inefficiencies in charging and forming uniform plugging portions.
Innovation Solution
A manufacturing method involving a press pouring operation with a plugging slurry having specific viscosity characteristics (yield point viscosity of 600 Pa·s or more, recovery viscosity of 300 Pa·s or more, and high shearing viscosity of 200 Pa·s or less) and using a thickener such as synthetic smectite or water-soluble polymer saccharide, which reduces slurry wastage and prevents backflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a plugging slurry with high fluidity is used to enable easy pouring into cells, then the charging operation becomes simple and efficient, but the slurry escapes in the circumferential portion of the honeycomb structure and cannot be leveled, resulting in non-uniform plugging portions
Solution Approach 1:
The patent applies parameter changes by controlling the viscosity of the plugging slurry within a specific range (10 to 100 cP at 25°C) to resolve the contradiction between ease of pouring and uniformity. This viscosity parameter allows the slurry to flow easily into cells while maintaining levelness during charging, preventing escape in circumferential portions and ensuring uniform plugging portions across the honeycomb structure.
2Ease of manufacture
If a stationary die is used to form plugging material to simplify the process and reduce cost, then the manufacturing process becomes simpler and cheaper, but position shift occurs from the honeycomb structure, preventing plugging material from being supplied to predetermined cells
Solution Approach 1:
The patent applies self-service by allowing the plugging slurry to automatically fill the cells through its controlled fluidity and viscosity characteristics, eliminating the need for stationary dies and complex positioning mechanisms. The slurry self-adjusts to fill predetermined cells accurately without requiring precise mechanical alignment, thereby simplifying the manufacturing process while maintaining position accuracy.
3Ease of operation
If immersion method is used to charge plugging slurry into cells to simplify the process, then the operation becomes simpler, but a large amount of plugging slurry is wasted and cannot be decreased
Solution Approach 1:
The patent applies parameter changes by optimizing the viscosity parameter of the plugging slurry to a specific range (10 to 100 cP at 25°C) that prevents excessive waste during immersion charging. This controlled viscosity allows the slurry to be easily poured and leveled while minimizing escape and waste, achieving both operational simplicity and material efficiency.
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 decreases slurry wastage and ensures uniform plugging by maintaining fluidity for efficient pouring and stability post-pouring, enhancing the charging efficiency and reducing defects in the plugged honeycomb structure.
Implementation Method 1
a slurry in which a yield point viscosity of a viscous fluidity is 600 Pa·s or more, a recovery viscosity is 300 Pa·s or more, and a high shearing viscosity is 200 Pa·s or less
Data Source
AI summary
The manufacturing method of the plugged honeycomb structure includes a honeycomb structure forming step of forming a pillar-shaped honeycomb structure, and a plugging step of forming plugging portions in end portions of the cells of the honeycomb structure formed in the honeycomb structure forming step, and in the plugging step, there is performed a press pouring operation of pressing one end face of the honeycomb structure into a plugging slurry stored in a bottomed tubular container to pour, under pressure, the plugging slurry into the cells of the honeycomb structure, and as the plugging slurry of the plugging step, there is used a slurry in which a yield point viscosity of a viscous fluidity is 600 Pa·s or more, a recovery viscosity is 300 Pa·s or more, and a high shearing viscosity is 200 Pa·s or less.