Bonding Material Composition for Diesel Particulate Filters
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Solution Overview
Problem
Conventional bonding material compositions for honeycomb structures, used in diesel particulate filters, face challenges with high thermal stress resistance and the generation of defects like cracks and voids due to the use of oriented inorganic fibers, which also increase costs and pose safety risks.
Innovation Solution
A bonding material composition comprising flat particles, non-flat particles, smectite-based clay, and an inorganic adhesive, with specific mass ratios and properties, is used to relax thermal stress and improve bonding strength, reducing the risk of defects and costs associated with fiber-based materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If orientated inorganic fibers are used in the bonding material composition, then thermal stress resistance is improved, but high tensile Young's modulus generates high thermal stress and low compressive Young's modulus reduces bonding strength
Solution Approach 1:
The patent changes the physical form parameter of the filler from fibrous to plate-like particles, which fundamentally alters the mechanical properties of the bonding material. Plate-like particles provide different stress distribution characteristics compared to fibers, enabling improved bonding strength while maintaining thermal stress resistance through controlled compressive Young's modulus
Solution Approach 2:
The patent creates a composite bonding material composition combining plate-like particles (such as mica, talc, or glass flakes) with inorganic binders and additives. This composite approach allows optimization of both thermal stress resistance and bonding strength by selecting appropriate plate-like particle materials and their proportions in the composition
2Reliability
If inorganic fibers are used as filler in the bonding material composition, then thermal stress relaxation is achieved, but defects such as cracks and voids are generated during drying or thermal treatment
Solution Approach 1:
The patent changes the geometric parameter of the filler from one-dimensional fibers to two-dimensional plate-like particles. This dimensional change eliminates the orientation-related differential expansion and contraction problems that cause cracks and voids during drying and thermal treatment, while still providing effective thermal stress relaxation through the plate structure
Solution Approach 2:
The patent replaces expensive and problematic inorganic fibers with readily available plate-like particles such as mica, talc, or glass flakes. These materials are more cost-effective and do not pose the same safety risks or processing problems as fibers, while achieving the desired thermal stress relaxation function
3Reliability
If inorganic fibers are used in the bonding material composition, then thermal stress resistance is improved, but cost increases due to fiber control requirements
Solution Approach 1:
The patent replaces expensive inorganic fibers with inexpensive plate-like particles such as mica, talc, or glass flakes. These materials are readily available, do not require special handling or control measures, and significantly reduce manufacturing costs while maintaining or improving thermal stress resistance
Solution Approach 2:
The patent extracts the problematic fibrous component from the bonding material composition and replaces it with plate-like particles. This extraction eliminates the need for fiber diameter and length control, removing the associated cost burden while preserving the essential thermal stress resistance function
4Reliability
If inorganic fibers are used in the bonding material composition, then thermal stress resistance is improved, but safety risks to human body are introduced
Solution Approach 1:
The patent replaces inorganic fibers with plate-like particles such as mica, talc, or glass flakes that do not pose inhalation or skin irritation risks. These alternative materials are safe for handling and processing, eliminating the occupational safety concerns associated with fiber use while maintaining thermal stress resistance
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 composition provides enhanced thermal shock resistance and reduced defect generation, while being safer and more cost-effective, suitable for use in diesel exhaust gas purification filters.
Implementation Method 1
the compressive Young's modulus in the thickness direction of the bonding material layer is 3 GPa or less, preferably 0.1 to 2 GPa, from the viewpoint of relaxing thermal stress generating in a joined body
Implementation Method 2
a bonding material composition for obtaining a joined body by unitarily joining two or more members to be joined by means of a bonding material layer
Data Source
AI summary
There is provided a bonding material composition for obtaining a joined body by unitarily joining two or more members to be joined by means of a bonding material layer, wherein the bonding material composition contains flat particles, non-flat particles, smectite-based clay, and an inorganic adhesive as main components. The bonding material composition costs little, can relax thermal stress generated in the joined body without using fibers which may do harm to a human body, and can reduce defects such as a crack and a void upon drying or a thermal treatment.