Plugging Permeable Porous Cellular Bodies
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Solution Overview
Problem
Current methods for introducing a plugging mixture into permeable porous cellular bodies in particulate filters often result in dimples and voids at the open end of the plug and within the plug depth, affecting the filter's efficiency.
Innovation Solution
A method involving forcing the plugging mixture into channels until a self-limiting depth is reached, then maintaining either a constant pressure until the flow rate falls below a threshold or a constant flow rate until the pressure exceeds a threshold, ensuring the mixture fills any voids and prevents dimple formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a piston forces the plugging mixture into the channels to achieve uniform plugging depth, then the plugging depth is uniform across all channels, but dimples and voids are formed at the open end and within the plug
Solution Approach 1:
The patent applies periodic action by using a two-stage plugging process: first forcing the plugging mixture to reach self-limiting depth, then applying additional pressure to eliminate voids. This periodic application of pressure in distinct phases resolves the contradiction between achieving uniform depth and eliminating defects.
Solution Approach 2:
The patent changes the pressure parameter dynamically during the plugging process. Initially, pressure is applied to achieve self-limiting depth uniformly across channels, then pressure is increased to a second level to fill voids and eliminate dimples. This parameter change resolves the contradiction by addressing different quality requirements at different stages.
2Reliability
If additional plugging mixture is forced into the channels after reaching self-limiting depth, then voids are filled and dimples are avoided, but the process complexity increases
Solution Approach 1:
The patent applies self-service by utilizing the natural self-limiting depth characteristic of the plugging mixture. The mixture automatically stops at a predetermined depth without requiring complex control mechanisms, and the additional pressure phase simply builds upon this self-regulated state to fill voids, minimizing process complexity while ensuring quality.
Solution Approach 2:
The patent uses feedback by monitoring the flow rate of the plugging mixture during injection. When the flow rate decreases to a predetermined level, indicating that self-limiting depth has been reached, the system automatically transitions to the second pressure phase to fill voids, thereby managing process complexity through intelligent control.
3Reliability
If the plugging mixture is introduced at constant flow rate until pressure exceeds threshold, then voids are filled and plug quality improves, but the energy consumption increases
Solution Approach 1:
The patent applies partial action by introducing the plugging mixture at constant flow rate only until the pressure reaches a predetermined threshold, rather than maintaining constant flow rate throughout the entire plugging process. This partial application of high energy input achieves void filling while avoiding excessive energy consumption that would result from continued high-rate injection.
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 approach ensures consistent and uniform plugging across channels, eliminating dimples and voids, thereby enhancing the filter's performance and longevity.
Implementation Method 1
forcing the plugging mixture into the plurality of channels until a maximum, self-limiting, depth of plugging mixture is disposed within the plurality of channels
Implementation Method 2
the additional plugging material forced into the channels fills any potential voids and avoids the formation of dimples
Data Source
AI summary
A method of plugging a permeable porous cellular body comprises: contacting the permeable porous cellular body with a plugging mixture, the permeable porous cellular body defining a plurality of channels; forcing the plugging mixture into the plurality of channels until a maximum, self-limiting, depth of plugging mixture is disposed within the plurality of channels; and maintaining a constant flow rate of the plugging mixture into the plurality of channels until a pressure on the plugging mixture elevates to a predetermined pressure. Alternatively, the method comprises forcing the plugging mixture into the plurality of channels utilizing the application of a constant pressure over time until a maximum, self-limiting, depth of the plugging mixture is disposed within the plurality of channels; and maintaining the constant pressure applied to the plugging mixture until flow of the plugging mixture into the channels decays from an initial flow rate to a predetermined flow rate.