Honeycomb Filter Sealing Structure to Prevent Masking Film Peeling
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Solution Overview
Problem
Conventional honeycomb structures experience peeling of sealing portions during the removal of masking films, leading to defective products and increased repair time.
Innovation Solution
A honeycomb structure with sealing portions composed of a specific ceramic composition (MgO: 9.0 to 13.4% by mass, Al2O3: 29.0 to 35.5% by mass, SiO2: 50.0 to 58.0% by mass) and controlled surface roughness (arithmetic average height Sa of 18.0 μm or less) to prevent peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a masking film is attached to the end surface to distinguish cells for sealing portions, then the sealing portions can be formed at predetermined positions, but peeling of the sealing portions occurs locally when the film is peeled off
Solution Approach 1:
The invention changes the surface roughness parameter of the sealing portions to 18.0 μm or less (arithmetic average height Sa), which fundamentally alters the interaction between the masking film and sealing portion surface. This parameter change prevents peeling during film removal while maintaining precise positioning capability.
2Ease of manufacture
If the sealing portions are formed with conventional materials and surface properties, then the filter can be manufactured, but peeling occurs during film removal requiring repair time
Solution Approach 1:
By controlling the surface roughness parameter (Sa ≤ 18.0 μm) and specifying the ceramic composition ranges, the invention eliminates peeling defects during masking film removal. This prevents defective products and eliminates the need for time-consuming repairs, directly addressing both manufacturability and time loss.
3Strength
If the sealing portions have high surface roughness, then the film adhesion may be improved, but peeling occurs locally when the film is peeled off
Solution Approach 1:
The invention identifies an optimal surface roughness parameter range (Sa ≤ 18.0 μm) that balances film adhesion with peeling resistance. This parameter change ensures the masking film can be properly applied and removed without causing local peeling of the sealing portions.
Solution Approach 2:
The sealing portions are composed of a specific ceramic composite material with controlled composition ranges (MgO: 9.0 to 13.4% by mass, Al2O3: 29.0 to 35.5% by mass, SiO2: 50.0 to 58.0% by mass). This composite material structure provides both adequate film adhesion and resistance to peeling during removal.
Data Source
AI summary
A honeycomb structure includes an outer peripheral side wall; a plurality of first cells having an opening on the first end surface and having a sealing portion on the second end surface; and a plurality of second cells having the sealing portion on the first end surface and having the opening on the second end surface, wherein the first cells and the second cells are arranged adjacent to each other with a partition wall interposed therebetween; wherein the sealing portion is composed of a ceramic containing MgO:9.0 to 13.4% by mass, Al2O3: 29.0 to 35.5% by mass, and SiO2: 50.0 to 58.0% by mass, and wherein an arithmetic average height Sa of the sealing portions on the first end surface and the second end surface is 18.0 μm or less, respectively.