Honeycomb Structure Defect Mending with Color Contrast
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Solution Overview
Problem
Existing honeycomb structures used in exhaust gas treating apparatuses face challenges in identifying and tracking defective portions, such as holes or scratches, formed during manufacturing or usage, due to the difficulty in distinguishing these defects from the same material used for the structure.
Innovation Solution
A honeycomb structure with defective portions mended using a mending material of a different color, allowing for identification and tracking of the defect stage, including during manufacturing, catalyst application, or assembly processes, with the mending material being made of the same material as the coating or peripheral wall for compatibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the defective portion is sealed with ceramic material of the same material as the honeycomb structure, then the structural integrity and material compatibility are maintained, but the defective portion cannot be identified or tracked
Solution Approach 1:
The patent applies color changes by using a mending material with a different color from the peripheral wall material. This allows defective portions to be easily identified and tracked while maintaining the same base material composition for structural integrity. The color difference serves as a visual indicator without compromising the material compatibility.
2Difficulty of detecting and measuring
If the defective portion is sealed with a different material, then the defective portion can be identified, but the structural integrity and material compatibility are compromised
Solution Approach 1:
The patent applies local quality by maintaining the same base material composition for both the peripheral wall and mending material, ensuring structural integrity and material compatibility. The only difference introduced is the color property at the localized defective portion, which enables identification without compromising the overall material consistency or structural strength.
3Manufacturing precision
If the honeycomb structure is manufactured with high precision to avoid defects, then the quality is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent applies preliminary action by providing a method to identify and mend defective portions after they are formed during manufacturing. Instead of attempting to prevent all defects through extremely complex manufacturing processes, the invention enables post-manufacturing detection and repair, simplifying the overall manufacturing approach while maintaining product quality.
Data Source
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AI summary
A honeycomb structure is disclosed that includes plural cells with holes arranged in a longitudinal direction, a peripheral wall, and a defective portion formed on the peripheral wall that is mended with a mending material that is in a color different from the color- of the peripheral wail Also, a method is disclosed for manufacturing a honeycomb structure including plural cells with holes arranged in a longitudinal direction and a peripheral wall which method involves mending a defective portion formed on the peripheral wall of the honeycomb structure with a mending material in a color different from the color of the peripheral wall.