Honeycomb Block Manufacturing via Joining Material Segmentation
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Solution Overview
Problem
The existing method for manufacturing honeycomb structured bodies is inefficient, as it requires multiple manufacturing steps and does not significantly increase the number of units produced per unit time, especially when producing shorter-length bodies, leading to prolonged manufacturing times.
Innovation Solution
The method involves joining end faces of honeycomb fired bodies to create a longer honeycomb joined body, which is then bonded with an adhesive paste to form an aggregated body, allowing for the simultaneous manufacturing of multiple honeycomb structured bodies in one bonding process, utilizing a joining material like double-faced tape and a cavity-holding member to secure and separate the blocks efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If side faces of honeycomb fired bodies are bonded to manufacture aggregated bodies, then honeycomb structured bodies can be manufactured, but the manufacturing time increases and productivity cannot be increased regardless of the length of honeycomb structured bodies
Solution Approach 1:
The manufacturing process is segmented into two independent stages: (1) joining end faces of honeycomb fired bodies to create honeycomb joined bodies, and (2) bonding side faces of these joined bodies to create aggregated bodies. This segmentation allows parallel processing where multiple honeycomb fired bodies are joined simultaneously in stage 1, and then multiple joined bodies are bonded in stage 2, significantly increasing the number of units that can be manufactured per bonding cycle.
Solution Approach 2:
Honeycomb joined bodies are prepared in advance by joining end faces of multiple honeycomb fired bodies before the bonding process. This preliminary action allows the joined bodies to be ready for aggregation bonding, enabling batch processing and reducing the total manufacturing time by overlapping preparation and bonding operations.
2Productivity
If multiple honeycomb fired bodies are joined to create honeycomb joined bodies, then productivity increases, but the device complexity increases due to additional joining materials and processes
Solution Approach 1:
A joining material is introduced as an intermediary between the end faces of honeycomb fired bodies to facilitate joining. This intermediary material simplifies the joining process by providing a standardized bonding interface, making it easier to join multiple bodies together while maintaining structural integrity, thus enabling increased productivity without excessive complexity.
3Productivity
If honeycomb joined bodies are used for bonding, then multiple aggregated bodies can be manufactured in one bonding process, but the difficulty of separating the blocks increases
Solution Approach 1:
The joining material is strategically positioned at the end faces of honeycomb fired bodies, and the separation is performed by removing or cutting through this joining material layer. This extraction approach allows clean separation of the honeycomb blocks after bonding, maintaining ease of manufacture despite producing multiple aggregated bodies in one process.
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 approach increases the efficiency of honeycomb structured body production by enabling the manufacture of multiple units per unit time, while maintaining the same quality and characteristics as conventional methods, with the ability to easily separate and coat the blocks, reducing manufacturing time and improving productivity.
Implementation Method 1
bonding side faces of a plurality of honeycomb joined bodies to one another with an adhesive paste interposed therebetween
Implementation Method 2
joining end faces of at least two honeycomb fired bodies to each other with a joining material interposed therebetween
Data Source
Figure 1(a)~1(e)
Figure 2
Figure 3(a)~3(b)
AI summary
The present invention has its object to provide a method for manufacturing a honeycomb structured body with efficiency. A method for manufacturing a honeycomb structured body includes: molding a ceramic raw material to manufacture a pillar-shaped honeycomb molded body having a plurality of cells placed longitudinally in parallel with one another with a cell wall interposed therebetween; firing the honeycomb molded body to manufacture a honeycomb fired body; and manufacturing a honeycomb block including the plurality of honeycomb fired bodies, wherein the manufacturing of the honeycomb block includes: joining end faces of at least two honeycomb fired bodies to each other with a joining material interposed therebetween to manufacture a honeycomb joined body whose length is larger than a length of the one honeycomb fired body; bonding side faces of a plurality of honeycomb joined bodies to one another with an adhesive paste interposed therebetween to manufacture an aggregated body of the honeycomb joined bodies; drying and solidifying the adhesive paste to manufacture a honeycomb block including the aggregated body of the honeycomb joined bodies; and separating the honeycomb block including the aggregated body of the honeycomb joined bodies at a position of the joining material to give at least two honeycomb blocks in which side faces of the plurality of honeycomb fired bodies are bonded to one another.