Honeycomb Structure Adhesive Layer Particle Control
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Solution Overview
Problem
Honeycomb structures used as catalyst carriers for exhaust gas conversion from vehicles are prone to damage due to cracks in adhesive layers caused by vibrations, leading to detachment of honeycomb fired bodies and reduced conversion performance.
Innovation Solution
A honeycomb structure is designed with pillar-shaped honeycomb fired bodies bonded using adhesive layers containing ceramic particles with a controlled particle diameter distribution, where the number of particles larger than the average pore diameter is limited to 30% or less, and optionally includes inorganic fibers or whiskers to enhance bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If adhesive layers are used to combine honeycomb fired bodies, then large-size honeycomb structure can be achieved, but cracks occur in adhesive layers due to repeated vibrations causing detachment and damage
Solution Approach 1:
The patent changes the particle size parameter of ceramic particles in the adhesive layer, specifically controlling that particles larger than the average pore diameter of honeycomb fired bodies constitute 30% or less of total particles. This parameter optimization prevents crack formation while maintaining bonding strength, resolving the contradiction between achieving large structure size and ensuring adhesive layer reliability under vibration conditions
Solution Approach 2:
The patent uses composite adhesive layers containing ceramic particles (such as alumina, silica, zirconia) combined with binder materials. This composite structure provides both bonding capability and crack resistance, allowing large honeycomb structures to be assembled reliably without the adhesive layers cracking under repeated vibrations
2Strength
If ceramic particles with controlled size distribution are used in adhesive layers, then adhesive strength increases preventing detachment, but manufacturing precision requirements increase
Solution Approach 1:
The patent establishes a specific parameter range for ceramic particle sizes, defining that particles larger than the average pore diameter should constitute 30% or less of the total. This quantified parameter control provides clear manufacturing guidelines while achieving the desired adhesive strength, balancing strength improvement with manufacturability
Solution Approach 2:
The patent applies different particle size requirements to different portions of the adhesive layer composition. Rather than uniform particle sizing, it specifies that only 30% or less of particles exceeding the pore diameter threshold are needed, allowing a distribution that optimizes both strength and manufacturing feasibility through localized quality variation in the particle size spectrum
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 configuration increases the adhesive strength between honeycomb fired bodies, preventing detachment and damage, while maintaining high conversion performance by ensuring effective contact between exhaust gases and catalysts.
Implementation Method 1
a plurality of pillar-shaped honeycomb fired bodies are combined with one another by interposing adhesive layers containing at least ceramic particles
Data Source
AI summary
A honeycomb structure includes a plurality of pillar-shaped honeycomb fired bodies, each having a large number of cells longitudinally placed in parallel with one another with a cell wall therebetween. The honeycomb fired bodies are combined with one another by interposing adhesive layers containing at least ceramic particles. In the ceramic particles contained in the adhesive layers, the number of those particles having a particle diameter larger than an average pore diameter of the honeycomb fired body is set to 30% or less of the total number of the ceramic particles.