Shear-Thinning Bonding Material for Honeycomb Structure Manufacturing
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Solution Overview
Problem
The manufacturing method of honeycomb structures using silicon carbide segments is inefficient due to the need for spacers, undercoat treatments, mask treatments, and manual removal of surplus bonding material, which increases manufacturing time and complexity.
Innovation Solution
A method involving the use of a shear-thinning bonding material that coats and bonds honeycomb fired bodies without spacers or undercoat treatments, allowing for efficient lamination and grinding to form a honeycomb structure, where the bonding material's viscosity and thixotropic index are controlled to prevent adhesion to end faces and facilitate easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spacers are disposed in spaces between honeycomb segments to control bonding material thickness, then bonding precision is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The invention removes spacers from the bonding process entirely. Instead of using physical spacers to control thickness, the bonding material itself is formulated with specific viscosity characteristics (1500-5000 poise) that enable it to maintain uniform thickness without external spacing components, thereby simplifying the manufacturing process while preserving bonding precision
Solution Approach 2:
The invention changes the rheological parameters of the bonding material by controlling its viscosity within a specific range (1500-5000 poise). This parameter optimization allows the material to flow adequately during application while maintaining sufficient body to prevent excessive spreading, eliminating the need for spacers to control thickness
2Reliability
If undercoat treatment is performed to prevent water absorption and bonding material peeling, then bonding reliability is improved, but manufacturing time increases
Solution Approach 1:
The invention incorporates preliminary protective measures directly into the bonding material formulation rather than requiring a separate undercoat step. The bonding material is designed with water resistance properties and adhesion promoters built-in, allowing it to perform both bonding and protection functions simultaneously, thus eliminating the need for preliminary undercoat treatment
Solution Approach 2:
The invention merges the functions of undercoat treatment and bonding material application into a single step. The bonding material is formulated to simultaneously provide adhesion, water resistance, and defect prevention that were previously achieved through separate undercoat and bonding steps, thereby reducing manufacturing time while maintaining reliability
3Manufacturing precision
If mask treatment is performed to prevent bonding material from closing cell openings, then cell openness is preserved, but manufacturing complexity increases
Solution Approach 1:
The invention removes mask films from the manufacturing process. Instead of applying masks to protect cell openings, the bonding material is formulated with controlled viscosity and application parameters that prevent it from flowing into and closing the cell openings, thereby simplifying the process while maintaining cell openness
Solution Approach 2:
The invention optimizes the viscosity parameters of the bonding material (1500-5000 poise) to control its flow behavior during application. This parameter control ensures the material stays in the intended bonding zones and does not migrate into cell openings, eliminating the need for mask treatment while preserving cell clarity
4Manufacturing precision
If manual removal of surplus bonding material is performed, then end face cleanliness is improved, but productivity decreases
Solution Approach 1:
The invention enables the bonding material to be self-managing regarding surplus removal. The material is formulated with specific rheological properties that allow excess material to be easily removed during the pressing operation itself, without requiring subsequent manual cleaning steps, thus maintaining end face cleanliness while improving productivity
Solution Approach 2:
The invention skips the manual cleaning step by designing the bonding process so that surplus material removal is integrated into the pressing operation. The controlled viscosity and flow characteristics allow excess material to be readily eliminated during pressing, enabling the process to move quickly through to completion without time-consuming manual intervention
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 reduces manufacturing steps, prevents end face contamination, and enhances efficiency by allowing simultaneous removal of excess bonding material during grinding, resulting in a stable and cost-effective honeycomb structure production.
Implementation Method 1
the bonding material has a shear thinning property
Data Source
AI summary
A manufacturing method of a honeycomb structure includes a forming step of forming a quadrangular pillar-shaped honeycomb formed body, a firing step of firing the honeycomb formed body and forming a quadrangular pillar-shaped honeycomb fired body, a coating step of coating at least a part of side surfaces of the honeycomb fired body with a paste-like bonding material, a honeycomb block body preparing step of bonding the plurality of honeycomb fired bodies while performing pressurizing, to prepare a honeycomb block body, and a circumference grinding step of grinding a circumferential surface of the honeycomb block body and obtaining the honeycomb structure, and in the honeycomb block body preparing step, the bonding is performed without interposing any member other than the bonding material between the honeycomb fired bodies, and the bonding material has a shear thinning property.