Honeycomb Structure Electrode Formation via Releasing Sheet
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Solution Overview
Problem
Existing methods face challenges in forming electrodes with uniform thickness on the curved surface of tubular honeycomb structures, particularly in achieving even film thickness and accommodating shape irregularities such as middle warps or trumpet-like shapes.
Innovation Solution
A manufacturing method involving the use of releasing sheets coated with electrode paste, which are attached to the curved surface of the honeycomb structure and then fired to form electrodes, ensuring uniform thickness and adherence to the surface while allowing for the removal of the sheets to produce a honeycomb structure with evenly distributed electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrode material is poured into a form and the form is elastically deformed to adhere electrode material on the side surface of the honeycomb structure, then electrodes can be formed on the curved surface, but it is difficult to achieve uniform film thickness and accommodate shape irregularities such as middle warps or trumpet-like shapes
Solution Approach 1:
The invention changes the physical state of the releasing sheet from rigid to flexible by selecting materials with appropriate elasticity modulus, allowing the sheet to conform to shape irregularities while maintaining uniform electrode thickness through controlled deformation
Solution Approach 2:
The releasing sheet acts as an intermediary carrier between the electrode material and the honeycomb structure, enabling uniform electrode deposition on irregular surfaces by absorbing shape variations through its flexibility
2Manufacturing precision
If electrode material is applied to form uniform thickness on the curved surface, then manufacturing precision is improved, but the process complexity increases due to difficulty in accommodating shape irregularities
Solution Approach 1:
By adjusting the elasticity modulus parameter of the releasing sheet material, the invention simplifies the manufacturing process while achieving uniform electrode thickness, eliminating the need for complex deformation control procedures
3Power
If the honeycomb structure is used as a heater with electrodes on the side surface, then heat generation capability is improved, but electrode thickness uniformity and adherence become difficult to control
Solution Approach 1:
The invention controls the elasticity modulus parameter of the releasing sheet to ensure uniform electrode thickness deposition, which directly improves the electrical resistance uniformity and consequently the heat generation capability of the honeycomb structure heater
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 method enables the easy formation of electrodes with uniform thickness on curved surfaces, enhancing heat generation and durability by controlling electrode thickness and resistivity, while preventing peel defects and air bubbles.
Implementation Method 1
firing the formed honeycomb body with the pastes for the electrodes, to obtain a honeycomb structure having the side surface provided with the electrodes
Data Source
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AI summary
There is disclosed a manufacturing method of a honeycomb structure in which electrodes can easily be formed on a side surface of a tubular honeycomb structure which is the curved surface. The manufacturing method of the honeycomb structure includes a step of coating a surface of each of releasing sheets with a paste for an electrode, to prepare electrode forming sheets 23 in which the releasing sheets are provided with electrode paste films; a formed honeycomb body with the electrode forming sheets forming step of attaching the electrode forming sheets 23 to a side surface of a tubular formed ceramic honeycomb body which is the curved surface, the formed ceramic honeycomb body having partition walls with which a plurality of cells are formed and an outer peripheral wall, to prepare a formed honeycomb body 110 with the electrode forming sheets; and a honeycomb structure forming step of firing the formed honeycomb body 110 with the electrode forming sheets, or removing releasing sheets 22 from the formed honeycomb body 110 with the electrode forming sheets to form the formed honeycomb body with the pastes for the electrodes, and then firing the formed honeycomb body with the pastes for the electrodes, to obtain a honeycomb structure having a side surface provided with the electrodes.