Segment-Joined Honeycomb Structure Manufacturing via Rib Destruction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing honeycomb structures, particularly those using silicon carbide, face challenges such as thermal shock defects and low raw material yield due to the need for extensive processing and grinding to achieve the desired shape and size, which reduces production efficiency and increases material waste.
Innovation Solution
A method involving extrusion forming to create a segment-joined honeycomb structure with a belt-like joining rib that is later destroyed, allowing for the filling of a bonding material in the gaps between segments, thereby eliminating the need for rough processing and grinding, and enhancing the thermal expansion coefficient to prevent thermal shock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extensive rough processing and grinding are performed to achieve desired shape and size, then manufacturing precision is improved, but productivity deteriorates and raw material yield deteriorates
Solution Approach 1:
The honeycomb formed article is pre-formed with the desired cylindrical shape and dimensions during the extrusion forming process, before firing. This preliminary shaping eliminates the need for subsequent rough processing and grinding operations, directly resolving the contradiction by achieving both high precision and high productivity through advance preparation
Solution Approach 2:
The invention extracts and removes the time-consuming rough processing and grinding steps from the manufacturing process. By achieving the desired shape directly during forming, these extraction steps are eliminated entirely, improving productivity while maintaining precision
2Manufacturing precision
If extensive rough processing and grinding are performed to achieve desired shape and size, then manufacturing precision is improved, but raw material yield deteriorates
Solution Approach 1:
The honeycomb formed article is pre-formed with the desired cylindrical shape and dimensions during the extrusion forming process, before firing. This preliminary shaping eliminates the need for subsequent rough processing and grinding operations that would remove material, directly resolving the contradiction by achieving both high precision and high raw material yield through advance preparation
Solution Approach 2:
The invention extracts and removes the material-removing rough processing and grinding steps from the manufacturing process. By achieving the desired shape directly during forming, these extraction steps are eliminated entirely, improving raw material yield while maintaining precision
3Temperature
If a large honeycomb structure is formed using silicon carbide, then thermal resistance is improved, but reliability deteriorates due to thermal shock defects
Solution Approach 1:
The invention changes the physical and chemical parameters of the honeycomb structure by forming a glass phase during firing that fills the pores and boundaries of silicon carbide particles. This parameter change creates a composite structure with reduced thermal expansion coefficient and improved thermal shock resistance, resolving the contradiction between thermal resistance and thermal shock resistance
Solution Approach 2:
The invention creates a composite material structure where glass phase is formed within and around silicon carbide particles during firing. This composite structure combines the high thermal resistance of silicon carbide with the thermal shock resistance of the glass matrix, resolving the contradiction between thermal resistance and reliability under thermal shock
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 improves production efficiency and significantly increases raw material yield by eliminating the need for extensive processing and grinding, while providing high thermal shock resistance and maintaining the structural integrity of the honeycomb structure.
Implementation Method 1
subjecting a forming raw material to extrusion forming to obtain a segment-joined type honeycomb formed article
Implementation Method 2
firing the honeycomb formed article to form a honeycomb fired article
Data Source
Figure 1
Figure 2~3A
Figure 3B~4B
AI summary
A method for manufacturing a honeycomb structure 130 includes: subjecting a forming raw material to extrusion forming to obtain a segment-joined type honeycomb formed article 100 provided with honeycomb segments 1 and an outer peripheral portion 2 surrounding a whole outermost periphery of the honeycomb segments, wherein a slit-shaped gap 8 extending from one end face 11 to the other end face 12 is formed between adjacent segments, the adjacent honeycomb segments are joined by a belt-like joining rib 4 extending from the face 11 to the face 12 and having a thickness of 0.1 to 1.5 mm, and the honeycomb segments 1 have partition walls separating and forming cells; firing the honeycomb formed article 100 to form a honeycomb fired article 110; destroying the joining rib 4 in the honeycomb fired article 110; and forming a buffer portion 7 by filling a bonding material in the gap 3.