Honeycomb Structure Manufacturing via Segmented Bonding
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Solution Overview
Problem
The manufacturing of large honeycomb structures with silicon carbide, which are prone to thermal shock and deformation, results in low raw material yield and increased manufacturing time due to the need for auxiliary members and complex assembly processes, leading to inefficiencies and higher costs.
Innovation Solution
A method involving the extrusion of quadrangular prismatic honeycomb segments, cutting them to form triangular segments, and combining these with quadrangular segments using a pressurizing jig to form a bonded body without auxiliary members, ensuring stable shape and consistent bonding layer width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If auxiliary members are used to assemble triangular segments in corners, then shape stability is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent removes the auxiliary members (such as triangular prismatic auxiliary members or blocking members) from the assembly process. By extracting these intermediate components, the manufacturing process becomes simpler while still achieving the goal of stabilizing the shape of the bonded body through direct bonding of quadrangular and triangular segments.
Solution Approach 2:
The bonding material itself serves the dual function of joining segments and providing structural support. The quadrangular and triangular segments are designed to interlock and stabilize each other through their geometric shapes, eliminating the need for separate auxiliary members to maintain shape stability during assembly.
2Stability of the object's composition
If auxiliary members are used in assembly, then shape stability is improved, but manufacturing time increases
Solution Approach 1:
The patent eliminates the time-consuming steps of adding and removing auxiliary members by extracting them from the assembly process entirely. The segments are bonded directly without intermediate auxiliary components, significantly reducing manufacturing time while maintaining shape stability through the inherent geometric interlocking of the segments.
Solution Approach 2:
The geometric design of the quadrangular and triangular segments allows them to self-stabilize during assembly without requiring auxiliary members. The interlocking shapes provide inherent structural support, eliminating the need for additional time to install and remove supporting components.
3Manufacturing precision
If circumferential grinding is performed on bonded body, then shape precision is improved, but raw material yield decreases
Solution Approach 1:
The patent divides the honeycomb structure into modular quadrangular and triangular segments that are pre-formed with precise dimensions. This segmentation allows for easier assembly and reduces the need for extensive circumferential grinding of the entire bonded body, as each segment can be individually controlled during manufacturing.
Solution Approach 2:
The segments are pre-formed and pre-cut with precise dimensions before assembly. By performing the cutting and shaping operations during the segment formation stage rather than after assembly, the patent minimizes the need for post-assembly grinding, thereby reducing raw material loss while maintaining shape precision.
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 method enhances shape stability and raw material yield while reducing manufacturing time and costs by eliminating the need for auxiliary members and simplifying the assembly process.
Implementation Method 1
pressurizing the triangular segment from a circumferential direction of the temporary assembly toward a central direction
Implementation Method 2
drying the obtained honeycomb bonded body
Data Source
AI summary
A manufacturing method of a honeycomb structure including:a formed body forming step of extruding a forming raw material, to form a plurality of quadrangular prismatic columnar honeycomb formed bodies;a firing step of firing the honeycomb formed bodies, to form a plurality of quadrangular prismatic-columnar quadrangular segments;a triangular segment forming step to form a triangular prismatic-columnar triangular segment;a bonded body forming step to form a honeycomb bonded body; anda circumference grinding step to manufacture the honeycomb structure,wherein the bonded body forming step further includes:a pressurizing step of pressurizing the triangular segment from a circumferential direction of the temporary assembly toward a central direction thereof, by use of a pressurizing jig comprising a pressurizer.