Single-Fire Honeycomb Structure Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing ceramic honeycomb structures, used as particulate traps and heat exchangers, are time-intensive and costly due to multiple firing steps, and previous plugging techniques result in weak interfaces and durability issues.
Innovation Solution
A method involving an aqueous ceramic solution mixed with a batch cross-link agent, allowing for a single drying step that makes the honeycomb structure water-resistant and enabling plugging with a second aqueous solution, reducing the need for multiple firing steps and improving structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple firing steps are used to manufacture honeycomb structures, then structural integrity is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent combines multiple separate firing steps into a single integrated firing process. The honeycomb structure and plugs are fired together in one cycle at temperatures between 900-1100°C, eliminating the need for separate firing operations while maintaining the structural integrity of both components and their bond interface.
Solution Approach 2:
The plugs are inserted into the honeycomb structure before the final firing step, allowing them to be positioned and secured in advance. This preliminary placement enables the plugs and honeycomb walls to bond simultaneously during the single firing process, reducing overall manufacturing time while ensuring strong structural attachment.
2Strength
If multiple firing steps are used for plugging honeycomb structures, then plug-honeycomb bond strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the plug bonding process with the honeycomb structure firing into a single operational step. Both the honeycomb walls and plugs undergo sintering simultaneously in one firing cycle, creating strong bonds without requiring separate firing operations, thereby simplifying the manufacturing process while maintaining bond strength.
Solution Approach 2:
The patent optimizes firing parameters including temperature (900-1100°C), atmosphere (oxidizing or neutral), and duration to achieve optimal bond strength between plugs and honeycomb structure in a single firing step. These controlled parameter changes ensure strong bonding while eliminating the need for multiple firing cycles.
3Reliability
If conventional plugging methods are used, then cell channels are sealed, but interface strength between plugs and honeycomb structure is weak
Solution Approach 1:
The patent uses plugs made from ceramic materials with composition similar to the honeycomb structure walls, creating a composite system where both components sinter together during firing. This material compatibility ensures strong chemical and mechanical bonding at the interface while effectively sealing the cell channels.
Solution Approach 2:
The patent controls firing temperature (900-1100°C) and atmosphere to optimize the bonding process. These parameter changes enable the plug material and honeycomb wall material to fuse together during a single firing cycle, creating strong interfaces that maintain both sealing and structural integrity.
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 time and costs while enhancing the structural integrity of the honeycomb filters, allowing for efficient production within existing systems.
Implementation Method 1
aqueous ceramic solutions that include ceramic or batch cross-link agents therein that promote cross-linking of the materials used to construct the honeycomb structure
Implementation Method 2
drying the honeycomb structure via a single drying step, such that the honeycomb structure is substantially water resistant
Data Source
AI summary
A method for manufacturing a honeycomb structure comprises providing an aqueous ceramic solution, providing a batch cross-link agent, mixing the agent with the solution, extruding the aqueous ceramic solution containing the cross-link agent into a honeycomb structure, and drying the honeycomb structure via a single drying step thereby forming a hardened, substantially water resistant, honeycomb structure. The method may further comprise addition of a ceramic surfactant to the aqueous ceramic solution, as well as plugging channels within the honeycomb structure with a plugging material comprising an aqueous ceramic solution that includes batch cross-link agents and ceramic surfactants therein. Also disclosed is a green body honeycomb article having a green honeycomb matrix containing a first ceramic batch compound of inorganic constituents, a first batch cross-link agent, and an aqueous vehicle wherein the matrix includes interconnected walls forming open-ended channels and a plugging material located in at least one of the open-ended channels.