Honeycomb Filter Adhesive Strength Distribution
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Solution Overview
Problem
Honeycomb structured bodies with large cross-sectional dimensions tend to experience adhesive layer cracks and honeycomb fired bodies slipping due to pressure differences and heat generation from PM deposition, leading to structural instability and reduced performance as filters or catalyst carriers.
Innovation Solution
A honeycomb structured body with a ceramic block design featuring two types of adhesive layers with different strengths, where the center-portion honeycomb fired bodies are bonded with a higher adhesive strength to prevent slipping and cracking, and a method for manufacturing this structure by molding, firing, and bonding honeycomb fired bodies with specific adhesive layers to achieve enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a honeycomb structured body with large cross-sectional dimensions is used, then the filtering capacity and catalyst carrier performance are improved, but adhesive layer cracks and honeycomb fired bodies slipping occur due to pressure differences and heat generation
Solution Approach 1:
The patent applies different adhesive strengths at different locations within the honeycomb structured body. Specifically, the adhesive layer has a first adhesive strength in regions where PM deposition is significant and a second adhesive strength (higher than the first) in other regions. This local differentiation allows the structure to withstand pressure differences and thermal stress in high-deposition areas while maintaining overall structural integrity, thereby resolving the contradiction between large cross-sectional area and structural stability.
2Ease of manufacture
If a single adhesive strength is used throughout the honeycomb structured body, then the manufacturing process is simplified, but adhesive layer cracks occur in regions with high PM deposition and heat generation
Solution Approach 1:
The patent specifies that the adhesive layer should have a first adhesive strength in regions where PM deposition is significant and a second adhesive strength (higher than the first) in other regions. This local differentiation ensures that areas subjected to higher thermal and mechanical stress have enhanced adhesive properties, preventing cracks while maintaining manufacturing feasibility through defined strength zones.
Solution Approach 2:
The patent changes the adhesive strength parameter of the adhesive layer based on location within the honeycomb structured body. By adjusting the adhesive strength parameter to be higher in regions远离PM deposition zones and lower in zones with significant PM deposition, the patent optimizes both reliability and manufacturability, resolving the contradiction between manufacturing simplicity and adhesive layer integrity.
3Reliability
If honeycomb fired bodies are bonded with high adhesive strength throughout, then structural stability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies high adhesive strength (second adhesive strength) only in specific regions where needed, rather than uniformly throughout the entire honeycomb structured body. This localized approach to adhesive strength enhancement maintains structural stability in critical areas while avoiding the increased complexity and cost associated with uniformly high adhesive strength throughout, thus resolving the contradiction between reliability and device complexity.
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 prevents honeycomb fired bodies from slipping and reduces adhesive layer cracking, ensuring the honeycomb structured body maintains structural integrity and performance even under high pressure and heat conditions, particularly for cross-sections of 200 mm or more.
Implementation Method 1
an adhesive layer interposed therebetween... an adhesive strength α between center-portion honeycomb fired bodies... and an adhesive strength β between honeycomb fired bodies
Data Source
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AI summary
An object of the present invention is to provide a honeycomb structured body having a structure which hardly allows honeycomb fired bodies near a center of an end face of the honeycomb structured body to slip out of the honeycomb structured body, when used as a honeycomb filter or a catalyst supporting carrier. The honeycomb structured body of the present invention comprises: a ceramic block in which a plurality of pillar-shaped honeycomb fired bodies are combined with one another with an adhesive layer interposed therebetween, the honeycomb fired body having a large number of cells that are longitudinally placed in parallel with one another with a cell wall interposed therebetween, wherein the adhesive layer includes at least two kinds of adhesive layers each of which bonds honeycomb fired bodies on both sides of the adhesive layer with a different adhesive strength from each other, center-portion honeycomb fired bodies out of the honeycomb fired bodies are bonded to one another with one adhesive layer interposed therebetween, the center-portion honeycomb fired bodies being located in a center portion of a cross-section taken perpendicularly to the longitudinal direction of the ceramic block, and an adhesive strength α between the center-portion honeycomb fired bodies is higher than an adhesive strength β between honeycomb fired bodies bonded to one another with an other adhesive layer interposed therebetween.