Honeycomb Segment Bonding Drying Method
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Solution Overview
Problem
The existing methods for bonding honeycomb segments result in non-uniform drying and hardening of bonding material layers, leading to fluctuations in texture and strength characteristics, particularly when multiple segments are integrated, causing issues with thermal shock resistance.
Innovation Solution
The method involves heating the end faces of honeycomb segments until at least 1% of the water content has evaporated, using plate-like particles in the bonding material, and immobilizing the segments during drying to ensure homogeneous contraction and hardening, thereby reducing non-uniformity in bonding layer formation and characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the whole layered article is dried after bonding, then the bonding material is solidified, but non-uniform drying occurs depending on bonded portions leading to texture fluctuations and cracking
Solution Approach 1:
The end faces of the bonded article are dried before the whole article is dried. This preliminary action prevents non-uniform drying by addressing the most critical areas first, where the bonding material is most vulnerable to cracking during thermal shock tests.
Solution Approach 2:
The drying process is divided into two stages: first drying the end faces of the bonded article, then drying the whole article. This segmentation allows controlled, uniform drying that prevents texture fluctuations and cracking while maintaining bonding strength.
2Quantity of substance
If 12 or more honeycomb segments are bonded together, then the filter capacity is increased, but fluctuations in bonding material characteristics are generated due to non-uniform drying
Solution Approach 1:
The end faces are dried before the whole article is dried. This preliminary action is particularly important when 12 or more segments are bonded together, as it prevents non-uniform drying that would otherwise occur in large assemblies, ensuring consistent bonding material characteristics throughout the entire structure.
Solution Approach 2:
Different drying conditions are applied to different parts of the bonded article at different stages. The end faces receive preliminary drying treatment, while the interior is dried subsequently. This local quality approach ensures uniform drying characteristics even in large assemblies with many segments.
3Ease of manufacture
If the bonding material is dried without end face heating, then the process is simpler, but the honeycomb segments move non-homogeneously causing texture fluctuations
Solution Approach 1:
The end faces are heated and dried before the whole article is dried. This preliminary action controls the drying process to prevent non-homogeneous movement of honeycomb segments, ensuring uniform bonding layer texture while adding only minimal process complexity.
Solution Approach 2:
The drying process uses controlled temperature and time parameters, particularly for the end face drying stage. By adjusting these parameters, uniform drying is achieved without excessive complexity, preventing segment movement fluctuations while maintaining process feasibility.
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 effectively suppresses the movement of honeycomb segments during drying, minimizing fluctuations in bonding layer formation and characteristics, thereby enhancing thermal shock resistance and uniformity across bonded portions.
Implementation Method 1
heating the end faces of honeycomb segments until at least 1% of the water content has evaporated
Implementation Method 2
the movement of the honeycomb segments accompanying the drying contraction and hardening of the bonding material can be homogenized
Implementation Method 3
the movement of the honeycomb segments accompanying the drying contraction and hardening of the bonding material
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Disclosed is a drying method of a honeycomb segment bonded body, in which fluctuations of characteristics attributed to fluctuations of a bonding texture of a plurality of honeycomb segments integrally bonded together by bonding material layers can be decreased. The method includes integrally bonding together honeycomb segments 10 each having a plurality of cells which are partitioned by partition walls and which extend through the segment in an axial direction, at a plurality of mutual bonding faces by use of a bonding material, simultaneously heating and drying both end faces 8 of an integrated honeycomb segment bonded body 1 before the bonding material hardens, and then heating and drying the whole body. Both the end faces 8 of the honeycomb segment bonded body 1 may be dried until 1% or more of the water content of the whole body flies.