Ceramic Honeycomb Peripheral Wall Coating Gap Prevention
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Solution Overview
Problem
Existing methods for producing ceramic honeycomb structures for exhaust gas cleaning suffer from peeling and chipping of the peripheral wall due to heat shock during rapid drying processes, leading to structural instability and unusability.
Innovation Solution
A method involving the application of a coating material to both end surfaces of a ceramic honeycomb body with longitudinal grooves, where the coating material is inserted into peripheral cells, ensuring it remains on the end surfaces, preventing gaps formation during drying and subsequent handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rapid drying by hot-air drying furnace or microwave is used to improve production efficiency, then drying time is reduced, but extreme temperature difference occurs between ceramic honeycomb body and peripheral wall causing gaps and peeling
Solution Approach 1:
The patent applies preliminary action by pre-heating the ceramic honeycomb body before applying the coating material, and then performing gradual drying of the coating material. This preliminary thermal preparation and controlled drying process prevents sudden temperature differences that cause gaps and peeling, while still maintaining reasonable production efficiency.
Solution Approach 2:
The patent changes the drying parameters by using gradual drying at controlled temperatures (first drying at 50-100°C for 1-24 hours, then second drying at 100-200°C for 1-24 hours) instead of rapid high-temperature drying. This parameter change prevents extreme temperature differences between the ceramic body and coating material, eliminating gaps and peeling while maintaining productivity.
2Ease of manufacture
If coating material is applied only to peripheral surface without end surfaces, then application process is simplified, but gaps form at boundaries during drying causing peripheral wall breakage
Solution Approach 1:
The patent applies preliminary action by extending the coating material application to include the peripheral portions of both end surfaces before drying. This preliminary extension of coating coverage prevents gap formation at boundaries during drying, ensuring peripheral wall strength without significantly complicating the manufacturing process.
Solution Approach 2:
The patent applies another dimension by extending the coating material from the peripheral surface into the peripheral cells at the end surfaces. This dimensional extension ensures complete coverage and prevents gaps at the boundaries, strengthening the peripheral wall structure while maintaining ease of manufacture through a systematic coating approach.
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 prevents peeling and chipping of the peripheral wall, maintaining structural integrity during use in metal containers and ensuring efficient exhaust gas cleaning without pressure loss.
Implementation Method 1
drying it to form the peripheral wall 52
Implementation Method 2
By thermal stress (heat shock) generated at this time, gaps are formed in a boundary between the grooves 56 of the ceramic honeycomb body 51 and end portions of the peripheral wall 52
Data Source
Figure 1(a)~2(a)
Figure 2(b)~3(b)
Figure 3(c)~4(b)
AI summary
A method for producing a ceramic honeycomb structure comprising a ceramic honeycomb body having large numbers of longitudinal cells partitioned by porous cell walls, and a peripheral wall formed on a peripheral surface of the ceramic honeycomb structure, comprising the steps of extruding a moldable ceramic material to form a honeycomb-structured ceramic green body; machining a peripheral portion of the green body or a sintered body obtained from the green body to remove part of cell walls in the peripheral portion, thereby obtaining the ceramic honeycomb body having longitudinal grooves on the peripheral surface; applying a coating material to the peripheral surface of the ceramic honeycomb body to form the peripheral wall, as well as to peripheral portions of both end surfaces of the ceramic honeycomb body; and inserting the coating material applied to the peripheral portions of both end surfaces into peripheral cells, with partially remaining on the peripheral portions.