Honeycomb Structure Manufacturing for Micrometer-Level Accuracy
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Solution Overview
Problem
Existing methods for manufacturing honeycomb structures lack sufficient accuracy in external dimensions, leading to variations that can exceed several hundred micrometers.
Innovation Solution
A method involving a storage step to stabilize temperature and humidity conditions, followed by outer surface processing and impregnation with molten metal, and fitting into a heated metal tube to enhance dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the honeycomb molded body is directly inserted into the metal tube without storage, then the manufacturing process is simpler and faster, but the external dimension accuracy deteriorates with variations exceeding several hundred micrometers
Solution Approach 1:
The honeycomb molded body is stored in a controlled environment with specific temperature (20±5°C) and humidity (60±10% RH) conditions for a predetermined period before insertion into the metal tube. This preliminary storage action stabilizes the dimensional state of the molded body, ensuring external dimension accuracy within tens of micrometers when subsequently fitted into the metal tube.
2Manufacturing precision
If the honeycomb molded body is stored under adjusted temperature and humidity, then external dimension accuracy improves to within tens of micrometers, but the manufacturing time increases
Solution Approach 1:
The storage conditions are optimized with specific parameters: temperature maintained at 20±5°C and humidity at 60±10% RH. These controlled parameter changes create optimal conditions for stabilizing the honeycomb molded body's dimensions without requiring excessive storage time, achieving accuracy within tens of micrometers efficiently.
3Manufacturing precision
If outer surface processing is performed before insertion, then the fit quality improves, but the manufacturing complexity increases
Solution Approach 1:
Outer surface processing is performed on the honeycomb molded body before insertion into the metal tube. This preliminary surface treatment ensures optimal fit quality between the molded body and the metal tube by preparing the surface in advance, allowing for better dimensional compatibility and connection quality.
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
The method achieves external dimension accuracy within tens of micrometers, improving the consistency and precision of the honeycomb structure.
Implementation Method 1
it is considered that the honeycomb molded body absorbs moisture from the outside according to the storage environment, and hence the state of the honeycomb molded body changes
Implementation Method 2
a fitting step of inserting the honeycomb molded body after the completion of the storage step into a heated metal tube and then cooling the metal tube
Data Source
AI summary
Provided is a method of manufacturing a honeycomb structure capable of manufacturing a honeycomb structure excellent in external dimension accuracy. A method of manufacturing a honeycomb structure includes: a preparation step of preparing a honeycomb molded body; a storage step of storing the honeycomb molded body under a state in which temperature and humidity are adjusted; and a fitting step of inserting the honeycomb molded body after the completion of the storage step into a heated metal tube and then cooling the metal tube.