SiC Honeycomb Joining Material Powder Utilization
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Solution Overview
Problem
The challenge in producing silicon carbide-based honeycomb structures is the difficulty in effectively utilizing processed powder generated during production, as increasing joining strength leads to higher Young's modulus, making it hard to relieve thermal stress and ensure durability.
Innovation Solution
A joining material containing 0.1 to 50% by mass of processed powder with an average particle diameter D50 of 0.5 to 60 μm is used, balancing joining strength and Young's modulus, allowing for effective utilization of the processed powder and improved thermal stress relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the joining strength of the joining layer is increased, then the joining strength is improved, but the Young's modulus of the joining layer is also increased, making it difficult to relieve thermal stress
Solution Approach 1:
The patent applies parameter changes by precisely controlling the particle size distribution (D50 between 0.5 to 60 μm) and chemical composition (specific ratios of SiO2, Al2O3, and processed powder) of the joining material. This optimization allows the joining layer to achieve high joining strength while maintaining low Young's modulus, resolving the contradiction between strength and thermal stress relief capability
Solution Approach 2:
The patent uses composite materials by formulating the joining layer with multiple components including processed powder (30-70 mass%), SiO2 powder (10-40 mass%), Al2O3 powder (5-20 mass%), and inorganic fibers (1-15 mass%). This composite structure enables the joining layer to simultaneously achieve high strength and low Young's modulus, effectively resolving the technical contradiction
2Ease of manufacture
If processed powder is reused in the production of silicon carbide-based honeycomb segments, then production costs are reduced, but the utilization in other applications such as joining material is not progressing very much
Solution Approach 1:
The patent converts the previously underutilized processed powder (a byproduct of segment production) into a valuable component of the joining material. By specifying that the joining material contains 30-70 mass% processed powder, the invention transforms waste material into a functional ingredient that contributes to both cost reduction and performance enhancement
Solution Approach 2:
The patent applies universality by enabling the processed powder to serve multiple functions: it acts as a filler material, a bonding agent, and a cost-reducing component in the joining layer. This multi-functional use of processed powder across different applications (segment production and joining material) increases overall utilization efficiency
Data Source
AI summary
A joining material used for joining side surfaces of a plurality of silicon carbide-based honeycomb segments to each other to produce a silicon carbide-based honeycomb structure. The joining material contains from 0.1 to 50% by mass of processed powder generated in the production of the silicon carbide-based honeycomb segments and/or the silicon carbide-based honeycomb structure. The joining material has an average particle diameter D50 of from 0.5 to 60 μm.