Honeycomb Structure Manufacturing via Particle Pre-Saturation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional honeycomb structures for exhaust gas treatment face challenges in size stability due to uneven moisture and molding aid distribution within inorganic particles, leading to inconsistent viscosity and material distribution, which affects the strength and performance of the final honeycomb structure.
Innovation Solution
A method of manufacturing a honeycomb structure where inorganic particles are pre-saturated with water to control moisture and molding aid entry, ensuring consistent viscosity and improved size stability through controlled water content and humidity conditions during the preparation of the raw material paste, followed by extrusion molding and firing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If inorganic particles with multiple micropores are used to increase specific surface area, then catalytic performance is improved, but size stability of molded bodies deteriorates due to uneven moisture and molding aid distribution
Solution Approach 1:
The inorganic particles are pre-saturated with water before being mixed with the molding aid and other components to form the raw material paste. This preliminary action ensures that the micropores are filled with water, preventing uneven absorption of molding aid and ensuring consistent viscosity and size stability during extrusion molding
Solution Approach 2:
The water content of the inorganic particles is controlled at 10 wt% or more through pre-saturation, which changes the physical state and moisture distribution parameters of the raw material paste, leading to improved viscosity control and size stability
2Ease of operation
If raw material paste has reduced viscosity due to poor dispersibility, then ease of mixing is improved, but honeycomb structure strength deteriorates due to uneven material distribution
Solution Approach 1:
The inorganic particles are pre-saturated with water before mixing, which ensures uniform distribution of moisture and molding aid throughout the raw material paste, preventing uneven material distribution in the final honeycomb structure while maintaining good mixing characteristics
Solution Approach 2:
The pre-saturation of inorganic particles with water creates a more homogeneous raw material paste by ensuring uniform moisture distribution, which prevents localized variations in material properties and ensures consistent strength throughout the honeycomb structure
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 results in honeycomb structures with enhanced size stability and uniform material distribution, improving the structural integrity and performance of the honeycomb units in treating exhaust gases.
Implementation Method 1
causing the inorganic particles to contain water in advance before preparation of a raw material paste
Implementation Method 2
obtain the honeycomb unit by firing the honeycomb molded body
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A method of manufacturing a honeycomb structure including a honeycomb unit, the honeycomb unit containing inorganic particles and having a plurality of cells extending from a first end face to a second end face of the honeycomb unit along a longitudinal direction thereof and separated by a plurality of cell walls, is characterized by the steps of (a) causing the inorganic particles to contain water; (b) preparing raw material paste for the honeycomb unit, the raw material paste containing at least the inorganic particles containing the water, a molding aid, and water; (c) molding the raw material paste into a honeycomb molded body; and (d) obtaining the honeycomb unit by firing the honeycomb molded body. The inorganic particles have a specific surface area of 50 m2/g or more.