Honeycomb Scraper Sealing Method for Uniform Thickness
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Solution Overview
Problem
Conventional methods for manufacturing honeycomb structural bodies with sealing material layers face issues such as dispersion in the external dimensions, uneven thickness, and irregularities due to high viscosity sealing materials and the use of plate-shaped scrapers, leading to poor assembly properties and increased pressure loss when used in exhaust gas purification systems.
Innovation Solution
A manufacturing method using a ring-shaped scraper to apply and spread a paste-like sealing material with a viscosity range of 15 to 45 Pa·s, containing an inorganic filler and binder, to form a thin, even sealing material layer on the peripheral portion of pillar-shaped porous honeycomb members, preventing protruding separation traces and ensuring uniform thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plate-shaped scraper is used to form a sealing material paste layer, then the sealing material can be spread over the circumferential face, but protruding separation traces are formed and the thickness becomes uneven due to high viscosity of the paste-like sealing material
Solution Approach 1:
The invention replaces the conventional plate-shaped scraper with a ring-shaped scraper that has a curved surface conforming to the circumferential face of the pillar-shaped porous honeycomb member. This curved scraping surface allows the scraper to maintain consistent contact along the entire circumferential face, eliminating protruding separation traces and ensuring uniform sealing material layer thickness even when processing high viscosity materials.
2Reliability
If the sealing material layer thickness is increased to prevent exhaust gas leakage, then sealing performance improves, but the external dimensions disperse and assembly properties deteriorate
Solution Approach 1:
The invention changes the geometric parameters of the scraping tool from a plate-shaped configuration to a ring-shaped configuration with specific dimensional relationships. The ring-shaped scraper's inner diameter is designed to be slightly larger than the outer diameter of the honeycomb member, allowing it to gently press and spread the sealing material uniformly without causing excessive thickness variation, thus maintaining both sealing performance and dimensional consistency.
3Ease of manufacture
If a paste-like sealing material with high viscosity is used, then the material can be applied to the circumferential face, but it is difficult to expand and spread uniformly over the entire face
Solution Approach 1:
The ring-shaped scraper's curved scraping surface conforms to the circumferential face geometry, allowing the scraper to apply gentle, distributed pressure that facilitates the spreading of high viscosity sealing material. The curved geometry prevents material accumulation and ensures uniform expansion across the entire circumferential face, making the process easier to operate despite the material's high viscosity.
4Loss of energy
If the sealing material layer is made thinner to reduce pressure loss, then fluid flow improves, but the sealing effectiveness may be compromised
Solution Approach 1:
The ring-shaped scraper is designed with controlled pressure application parameters that enable the formation of thin yet uniform sealing material layers. The scraper's geometry and pressing force are optimized to achieve minimum necessary thickness for effective sealing while minimizing pressure loss, creating a balance between sealing effectiveness and fluid flow efficiency.
Data Source
AI summary
An object of the present invention is to provide a manufacturing method of a honeycomb structural body which makes the profile of a cross section perpendicular to the length direction thereof less likely to generate dispersion, and also makes the thickness of its sealing material layer thinner, and a sealing material that is suitably used in the manufacturing method of the honeycomb structural body. According to the present invention, the manufacturing method of a honeycomb structural body with a sealing material layer formed on the peripheral portion of a pillar-shaped porous honeycomb member includes a sealing material applying step of applying a paste-like sealing material, which is a raw material of the sealing material layer, onto a circumferential face of the pillar-shaped porous honeycomb member, and a scraping step of fitting a ring-shaped scraper, which can be brought into contact with the circumferential face of the pillar-shaped porous honeycomb member so as to slide thereon, to the pillar-shaped porous honeycomb member and moving said ring-shaped scraper in the length direction, thereby expanding the paste-like sealing material applied onto the circumferential face of the pillar-shaped porous honeycomb member so as to spread over the entire circumferential face of the pillar-shaped porous honeycomb member.