Catalyst Block Outer Frame Segmentation to Prevent Thermal Deformation
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Solution Overview
Problem
Conventional catalyst blocks for exhaust gas purification face issues with thermal deformation during high-temperature baking, leading to shape distortion and reduced denitration performance, and require complex and costly installation methods, with catalysts often being applied to non-purification areas and difficult to maintain.
Innovation Solution
A catalyst block design featuring a rigid honeycomb core with fixed first and second plates, housed within an outer frame that prevents thermal deformation, allows for easy catalyst application and maintenance, and facilitates the exchange of honeycomb cores, using ferrite-based stainless plates for enhanced transport and magnetic handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the block for a catalyst is baked at high temperature to integrate the honeycomb core and outer frame, then the integration is achieved, but the outer frame may be thermally deformed to distort the shape of the block
Solution Approach 1:
The catalyst block is divided into two separate components: the honeycomb core and the outer frame. These components are assembled after individual preparation rather than being baked together as a single integrated unit. This segmentation allows each component to be treated independently, preventing thermal deformation of the outer frame while still achieving functional integration through post-baking assembly.
Solution Approach 2:
The honeycomb core is prepared and its shape is fixed before the outer frame is assembled around it. By performing preliminary preparation of the core and then assembling the frame separately, the design avoids subjecting the outer frame to high-temperature baking that would cause thermal deformation, while still achieving the necessary integration for catalyst support.
2Stability of the object's composition
If a rib is formed in the outer frame to enhance rigidity, then thermal deformation is suppressed, but the molding complexity and cost increase
Solution Approach 1:
Instead of modifying the outer frame with complex ribs to enhance rigidity, the design segments the structure into a separate honeycomb core that provides the necessary rigidity and structural support. The outer frame can then remain simple in design, serving only as a housing, thereby avoiding molding complexity while still achieving the required stability.
3Ease of manufacture
If the honeycomb core is immersed in catalyst bath before housing, then catalyst is applied, but the fragile honeycomb core may be distorted during transport
Solution Approach 1:
The honeycomb core is prepared and its shape is stabilized before catalyst application. The core is then assembled into the outer frame in a protected state, and only after this protective housing is in place is the catalyst applied through immersion. This sequence prevents distortion during transport while still enabling catalyst application.
Solution Approach 2:
The outer frame serves as a protective housing that cushions and protects the fragile honeycomb core before catalyst application. By providing this protective structure in advance, the core is shielded from mechanical stresses during transport and handling, preventing distortion while maintaining the ability to apply catalyst subsequently.
4Loss of substance
If drain holes are formed in the outer frame to remove catalyst, then catalyst attached to the frame is removed, but catalyst is unnecessarily used on non-exhaust gas passage areas
Solution Approach 1:
The design extracts or removes the outer frame from the catalyst application process entirely. By configuring the outer frame with smooth inner surfaces and avoiding protrusions, the frame becomes catalyst-free, eliminating the need for drain holes and catalyst removal operations. This prevents unnecessary catalyst usage on non-functional areas while simplifying the manufacturing process.
Solution Approach 2:
The catalyst application is localized exclusively to the honeycomb core where exhaust gas passages exist, while the outer frame is designed with properties (smooth surfaces, no protrusions) that prevent catalyst adhesion. This local differentiation ensures catalyst is applied only where needed for purification, eliminating waste without requiring complex removal mechanisms.
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 solution minimizes thermal deformation, reduces unnecessary catalyst usage, and lowers maintenance costs by preventing catalyst application on non-purification areas and enabling straightforward core exchange, thereby enhancing denitration performance and operational efficiency.
Implementation Method 1
using ferrite-based stainless plates for enhanced transport and magnetic handling
Data Source
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AI summary
[Problem] The purpose of the present invention is to provide a catalyst block having little distortion in the outside surface. [Solution] Provided is a catalyst block for cleaning exhaust gas characterized by having: a square-shaped honeycomb core provided with first - fourth outside surfaces; a first plate attached to the first outside surface; a second plate attached to the second outside surface; and an exterior frame disposed along the outer periphery of the firm and solid honeycomb core formed from the honeycomb core, the first plate and the second plate, said exterior frame being provided with a recessed part that at least encases the first plate, the second plate, the third outside surface and the fourth outside surface. The catalyst block is also characterized in that a catalyst is supported in the honeycomb core, the first plate and the second plate, and the catalyst is not supported in the exterior frame.