Chamfered Stepped Peripheral Wall Honeycomb Structure
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Solution Overview
Problem
Conventional honeycomb structures face issues with defective sealing and manufacturing efficiency due to incomplete cell formation and structural defects in the peripheral walls, leading to reduced filtering efficiency and increased pressure loss.
Innovation Solution
A honeycomb structure with a stepped peripheral wall featuring projected and recessed portions, where at least one of these portions is chamfered by a curve line or straight line in the cross section, improves sealing efficiency and reduces defects such as chipping and cracking, enhancing the capturing efficiency of particulates and pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a conventional honeycomb fired body is used with cells having different cross-sectional shapes at the periphery, then the cells can be formed to fit the peripheral contour, but the cells at the outermost periphery are more prone to defective sealing and incomplete formation
Solution Approach 1:
The invention applies different cross-sectional shapes to cells at different locations within the honeycomb fired body. Specifically, cells at the outermost periphery are given a first cross-sectional shape (e.g., triangular or trapezoidal) that conforms to the peripheral contour, while cells at internal positions are given a second cross-sectional shape (e.g., rectangular or square). This local differentiation ensures that peripheral cells fit the outer contour for structural integrity while maintaining reliable sealing through appropriate geometric design.
Solution Approach 2:
The invention employs asymmetric cell configurations where the cross-sectional shape of peripheral cells differs from that of internal cells. The peripheral cells may have triangular or trapezoidal cross-sections with one side formed along the curved peripheral surface, while internal cells have rectangular or square cross-sections. This asymmetry allows the honeycomb structure to adapt to the peripheral contour while maintaining uniform sealing quality across all cells.
2Shape
If the cross-sectional shape of peripheral cells is made different from internal cells to fit the contour, then the peripheral contour can be formed, but the manufacturing complexity and difficulty of ensuring uniform cell formation increase
Solution Approach 1:
The invention implements local quality by assigning different cross-sectional shapes to cells based on their position within the honeycomb fired body. Peripheral cells are designed with first cross-sectional shapes (triangular or trapezoidal) that conform to the outer contour, while internal cells use second cross-sectional shapes (rectangular or square). This position-based differentiation simplifies the molding process by providing clear geometric rules for cell formation while achieving the desired peripheral contour.
3Reliability
If plug material paste is used to seal cells, then particulates can be collected, but defective filling occurs more frequently when cells have varying cross-sectional shapes
Solution Approach 1:
The invention applies local quality by designing different cross-sectional shapes for cells at different positions to optimize sealing performance. Peripheral cells with triangular or trapezoidal cross-sections are configured to fit the peripheral contour, while internal cells with rectangular or square cross-sections provide uniform sealing. This geometric differentiation ensures that plug material paste can effectively fill and seal all cells without defective filling, as each cell shape is optimized for its specific location.
4Ease of manufacture
If a honeycomb structure with uniform cell cross-sectional shapes is used, then manufacturing is simpler, but the peripheral cells cannot properly conform to the curved peripheral surface
Solution Approach 1:
The invention implements local quality by differentiating cell cross-sectional shapes based on position within the honeycomb fired body. Peripheral cells are designed with first cross-sectional shapes (triangular or trapezoidal) that conform to the curved peripheral surface, while internal cells use second cross-sectional shapes (rectangular or square). This position-based geometric differentiation maintains manufacturing simplicity through systematic design while achieving proper peripheral conformity.
Data Source
AI summary
A honeycomb structure includes a ceramic block including at least one honeycomb fired body. The at least one honeycomb fired body has cell walls and a peripheral wall. The peripheral wall is formed around the at least one honeycomb fired body. The peripheral wall of the at least one honeycomb fired body, which forms a periphery of the ceramic block, is a stepped peripheral wall provided with a level difference. The level difference includes a projected portion and a recessed portion in a cross section perpendicular to a longitudinal direction of the at least one honeycomb fired body. At least one of the projected portion and the recessed portion is formed by at least one of a curve line and a straight line in the cross section perpendicular to the longitudinal direction of the at least one honeycomb fired body by being subjected to chamfering.