Honeycomb Structure Uniform Coat Layer via Vent Drying
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Solution Overview
Problem
Conventional methods for manufacturing honeycomb structures with integrated adhesive and coat layers suffer from interface separation issues when exposed to temperature fluctuations, leading to potential breakage and reduced durability, particularly in applications like exhaust gas-purifying filters.
Innovation Solution
A method involving extrusion-molding honeycomb molded bodies, firing them to form pillar-shaped honeycomb fired bodies, and using a molding frame with a vent portion for the sealing material paste to ensure even drying and integration of inorganic particles and fibers, preventing interface separation by maintaining uniform distribution and strength across the coat layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the adhesive layer and coat layer are formed in separate steps, then the manufacturing process is simple and easy to control, but an interface is formed between the two layers causing separation and breakage under thermal stress
Solution Approach 1:
The patent combines the formation of the adhesive layer and coat layer into a single integrated process. The sealing material paste is applied to both the gaps between honeycomb fired bodies (forming adhesive layer) and the outer periphery (forming coat layer) simultaneously, then dried and solidified in one operation, eliminating the interface between the two layers that causes separation under thermal stress.
Solution Approach 2:
The patent applies the sealing material paste to both the adhesive and coat layer positions before the drying and solidification process. This preliminary application ensures that both layers are formed from the same material state, creating a unified structure without interfaces that would otherwise form during separate manufacturing steps.
2Manufacturing precision
If the sealing material paste is dried uniformly, then the coat layer has uniform strength and prevents interface separation, but the drying process becomes more complex requiring vent portions
Solution Approach 1:
The patent introduces vent portions with porous structures into the molding frame. These vent portions allow controlled air permeability during the drying process, enabling uniform evaporation of moisture from the sealing material paste throughout the entire structure, including the coat layer, thereby achieving uniform strength without excessive complexity.
Solution Approach 2:
The vent portions act as intermediaries between the external environment and the sealing material paste during drying. They facilitate controlled moisture removal by allowing air to pass through, ensuring uniform drying throughout the thick coat layer without requiring complex heating or pressure systems.
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 results in a honeycomb structure with a coat layer having uniform strength and high surface strength, reducing the likelihood of separation and enhancing durability even under thermal stress, such as in exhaust gas-purifying applications.
Implementation Method 1
The sealing material paste is dried to solidify the sealing material paste and to form an adhesive layer between the honeycomb fired bodies and a coat layer on a periphery of a ceramic block
Implementation Method 2
A molding frame optionally having a vent portion with air permeability is provided
Data Source
AI summary
A method for manufacturing a honeycomb structure includes extrusion-molding honeycomb molded bodies. The honeycomb molded bodies are fired to form honeycomb fired bodies. A molding frame optionally having a vent portion with air permeability is provided. The honeycomb fired bodies are fixed in the molding frame. A member having an other vent portion with air permeability is optionally disposed on an inner face side of the molding frame. A gap between the honeycomb fired bodies and a gap between the molding frame and the honeycomb fired bodies are filled with a sealing material paste. The sealing material paste includes inorganic particles and/or inorganic fibers. The sealing material paste is dried to solidify the sealing material paste and to form an adhesive layer and a coat layer. The sealing material paste is in contact with at least a part of the vent portion during the drying.