Ceramic Block Peripheral Sealing Jig Design
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Solution Overview
Problem
Existing methods for forming a peripheral sealing material layer on honeycomb structured bodies used in exhaust gas filtration face challenges in achieving uniform thickness and preventing thin or missing sections, leading to inefficiencies in gas purification and environmental contamination.
Innovation Solution
An application jig with a tapered and straight opening section design is used to spread a sealing material paste evenly over the ceramic block, ensuring a consistent and thick peripheral sealing material layer is formed, utilizing a rigid material and specific dimensions to prevent warping and adhesion issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a ring-shaped scraper is used to spread sealing material paste, then the paste can be distributed over the peripheral surface, but the thickness becomes non-uniform with thin or missing sections
Solution Approach 1:
The opening section of the application jig is divided into two distinct parts: a first opening section with gradually decreasing diameter and a second opening section with substantially constant diameter. This segmentation allows the sealing material paste to be applied and then uniformly scraped to achieve consistent thickness without thin or missing sections.
Solution Approach 2:
Different sections of the application jig have different geometric properties tailored to specific functions: the first opening section has a tapered geometry for initial paste distribution, while the second opening section has a constant diameter for uniform scraping and thickness control. This local differentiation resolves the contradiction between coverage and uniformity.
2Stability of the object's composition
If the application jig uses a rigid material, then warping is prevented ensuring consistent dimensions, but adhesion of sealing material paste becomes problematic
Solution Approach 1:
The application jig is made of rigid material for overall dimensional stability, but the surface of the opening section is locally modified with a non-sticking coating. This allows the rigid structure to maintain consistent dimensions while the coated surface prevents paste adhesion issues.
Solution Approach 2:
A non-sticking coating is introduced as an intermediary layer between the rigid application jig surface and the sealing material paste. This coating mediates the interaction, preventing direct adhesion between the paste and the rigid jig surface while allowing the jig to maintain its dimensional stability.
3Manufacturing precision
If the second opening section has substantially constant diameter, then uniform scraping is achieved, but the transition from tapered to constant section creates a boundary line that may affect paste flow
Solution Approach 1:
The opening section is segmented into two parts with a clearly defined boundary line. The first opening section has gradually decreasing diameter for paste distribution, and the second opening section has substantially constant diameter for uniform scraping. This segmentation achieves uniform sealing material layer while managing geometric complexity through functional division.
Data Source
AI summary
A method of manufacturing a honeycomb structured body, includes providing an application jig. A sealing material paste is put on a peripheral surface of a pillar-shaped ceramic block. The application jig is set in such a manner that a first principal surface of the application jig faces upward and a second principal surface of the application jig faces downward. The ceramic block is placed inside a second opening section of the application jig. The ceramic block is passed through an opening section of the application jig so that a face defining the second opening section spreads an entire peripheral surface of the ceramic block with the sealing material paste to manufacture a honeycomb structured body with a peripheral sealing material layer formed on the peripheral surface of the ceramic block.