Honeycomb Substrate Oxide Film Tapered Projections Adhesion
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Solution Overview
Problem
Existing catalyst support substrates for exhaust gas purification face challenges in achieving strong adhesion between the catalyst layer and the oxide film, requiring an adhesive layer that complicates processes and increases costs, and existing techniques do not effectively improve adhesion between the catalyst and the oxide film.
Innovation Solution
A honeycomb substrate with an oxide film having a high density of tapered oxide projections on its surface, formed through special heat treatment, allows for direct adhesion of the catalyst layer without an adhesive layer, enhancing the anchor effect and improving adhesion between the catalyst and the oxide film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an adhesive layer is introduced between the oxide film and zeolite layer to improve adhesion, then the adhesion strength is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent introduces an adhesive layer as an intermediary substance between the oxide film and zeolite layer. This adhesive layer acts as a mediator that chemically or physically bonds the two dissimilar materials together, enabling strong adhesion where direct bonding would fail due to incompatible surface properties and structures.
Solution Approach 2:
The patent creates a multi-layer composite structure consisting of the oxide film, adhesive layer, and zeolite layer. Each layer has distinct properties optimized for its specific function, and the composite structure as a whole achieves superior adhesion performance that none of the individual layers could provide alone.
2Strength
If an adhesive layer is introduced between the oxide film and zeolite layer to improve adhesion, then the adhesion strength is improved, but the manufacturing cost increases
Solution Approach 1:
The adhesive layer serves as a mediator that enables reliable bonding between the oxide film and zeolite layer, preventing catalyst separation and ensuring long-term durability of the catalytic converter, thereby justifying the additional manufacturing cost through improved product reliability and performance.
Solution Approach 2:
The patent optimizes parameters such as the thickness, composition, and surface properties of the adhesive layer to achieve the required adhesion strength while minimizing material costs and processing complexity, balancing performance requirements with manufacturing economy.
3Device complexity
If the oxide film surface is made smooth to reduce manufacturing complexity, then the manufacturing process is simplified, but the adhesion between catalyst and oxide film deteriorates
Solution Approach 1:
The patent introduces surface roughness with curved features (peaks and valleys) on the oxide film surface. These curved surface features increase the effective surface area and create mechanical interlocking sites that enhance catalyst adhesion, demonstrating how surface curvature can improve bonding strength.
Solution Approach 2:
The patent creates a porous or rough surface structure on the oxide film with peaks and valleys. This porous morphology increases the surface area available for catalyst bonding and provides anchoring sites that mechanically interlock with the catalyst particles, thereby enhancing adhesion strength.
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 enhanced adhesion between the catalyst layer and the oxide film improves the purification efficiency and reduces the complexity and cost of the process by eliminating the need for an adhesive layer.
Implementation Method 1
formed through special heat treatment
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
[Problem] The purpose of the invention is to improve adhesion of a catalyst layer and an oxide film in a honeycomb substrate for catalyst support. [Solution] A honeycomb substrate for catalyst support used in purification of exhaust gas is characterized by comprising a honeycomb body and an oxide film that is formed on the surface of the honeycomb body and that has α-alumina as a main component, and in that the oxide film includes multiple oxide projections that are formed to be dispersed on the film surface and that comprise a contracted shape in which the width becomes narrower near the honeycomb body, and the density of the projection formations on the film surface is 0.20 (pieces/µm2) - 3.00 (pieces/µm2).