Segmented Screen Filtration for Ceramic Extrusion

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Solution Overview

Problem

Existing ceramic honeycomb molding technologies face issues with bent or broken cells due to foreign matter and insufficiently blended starting materials, leading to reduced strength and particulate-capturing efficiency, and existing solutions suffer from screen deformation and breakage during repeated extrusion-molding.

Innovation Solution

A method and apparatus that fix a screen between porous plates in the material-flowing path, with varying opening ratios and orientations, to effectively remove foreign matter and prevent screen deformation, ensuring consistent extrusion and preventing bent or broken cells in ceramic moldings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a screen is used to remove foreign matter from molding material, then foreign matter removal is improved, but screen deformation and breakage occur during repeated extrusion-molding

Engineering Contradiction:

Improveforeign matter removal effectivenessVSAvoidscreen structural integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The screen is divided into multiple sections with different opening ratios. The first screen section has a smaller opening ratio for effective foreign matter removal, while the second screen section has a larger opening ratio to reduce deformation and breakage during repeated extrusion-molding operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the screen are given different properties (opening ratios). The upstream portion has a smaller opening ratio optimized for filtration, while the downstream portion has a larger opening ratio optimized for resisting deformation under extrusion pressure.

Inventive Principle:

Principle #3Local quality

2Duration of action of stationary object

If the screen opening ratio is increased to prevent screen breakage, then screen durability is improved, but foreign matter removal effectiveness decreases

Engineering Contradiction:

Improvescreen service lifeVSAvoidforeign matter removal effectiveness

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

The screen is segmented into multiple sections with different opening ratios. The first section maintains a smaller opening ratio for effective foreign matter removal, while the second section has a larger opening ratio for reduced deformation and extended service life.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The screen has non-uniform opening ratios at different locations. The upstream region uses a smaller opening ratio for filtration, while the downstream region uses a larger opening ratio for durability, optimizing both functions simultaneously.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If a single screen with uniform opening ratio is used, then manufacturing is simplified, but bent or broken cells occur in ceramic moldings

Engineering Contradiction:

Improvescreen manufacturing simplicityVSAvoidmolding cell integrity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The screen is divided into multiple sections with different opening ratios to prevent bent or broken cells in ceramic moldings, while maintaining relatively simple manufacturing processes for each section.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The screen has varying opening ratios at different locations to ensure uniform molding quality and prevent cell deformation, achieving precise control over the extrusion process.

Inventive Principle:

Principle #3Local quality

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 solution effectively removes foreign matter and prevents screen deformation, resulting in ceramic moldings with improved strength and reduced breakage and bending, especially when using foaming or foamed resin as a pore-forming material, enhancing the quality and productivity of honeycomb structures.

Implementation Method 1

a screen for removing foreign matter, etc. in the molding material

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

fix a screen between porous plates in the material-flowing path, with varying opening ratios and orientations, to effectively remove foreign matter and prevent screen deformation

Methodology Applied

Scientific EffectMechanical support and stress distribution:

Implementation Method 3

extrusion-molding a molding material charged into a material-flowing path from a molding die

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS8834783B2Method and apparatus for producing ceramic molding

Publication Date: 2014.09.16 MIRAI CASTING AMERICA INC

AI summary

A molding apparatus for producing a ceramic molding comprising a material-flowing path, a molding die disposed at one end of the material-flowing path, and a pressurizing means for extrusion-molding the molding material; the material-flowing path comprising pluralities of porous plates for passing the molding material and a screen fixed therebetween, and a method for producing a ceramic molding using this apparatus.