Hexagonal-cell honeycomb structure with tubular skin layer
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Solution Overview
Problem
Hexagonal-cell honeycomb structures face challenges in achieving mechanical strength while maintaining a thin wall thickness of 140 μm or less, as existing techniques that enhance mechanical strength in square-cell structures do not effectively translate to hexagonal-cell structures, leading to concerns about damage resistance and uniformity in the sintering and extrusion processes.
Innovation Solution
A hexagonal-cell honeycomb structure with a tubular skin layer and basic cell walls of 140 μm or less, featuring a relationship between the inscribed circle diameter and cell pitch (Da/P ≥ 0.13), which ensures large mechanical strength and uniformity, and a specific distribution of cell wall thicknesses between the first and second areas to enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the wall thickness of the ceramic honeycomb structure is reduced to 140 μm or less, then the heat capacity is decreased and the structure achieves early activation, but the damage resistance and mechanical strength against outside pressure decrease
Solution Approach 1:
The patent applies local quality by creating a skin layer on the outer surface of the honeycomb structure. This skin layer has different properties from the basic cell walls - it provides enhanced mechanical strength and damage resistance specifically where needed (on the outer surface), while the inner cell walls maintain their thin thickness for heat capacity reduction. This resolves the contradiction by locally enhancing strength without increasing overall wall thickness.
2Ease of manufacture
If the cell wall thickness is made uniform throughout the structure, then the manufacturing process is simplified, but the mechanical strength against outside pressure is insufficient
Solution Approach 1:
The patent implements local quality by introducing a skin layer specifically on the outer surface of the honeycomb structure. This skin layer provides enhanced mechanical strength and damage resistance precisely where the structure needs it most (on the outer surface subjected to outside pressure), while the inner cell walls maintain uniform thin thickness. This allows the structure to achieve both manufacturing simplicity and enhanced strength.
3Strength
If different cell wall thicknesses are used in different areas, then the mechanical strength is improved, but the shrinking amount in sintering process becomes different and accurate dimension and uniformity of end surface are not ensured
Solution Approach 1:
The patent applies local quality by placing the skin layer only on the outer surface of the honeycomb structure, rather than varying the cell wall thickness throughout the entire structure. This approach provides enhanced mechanical strength on the outer surface while maintaining uniform thickness in the inner cell walls, thereby ensuring consistent shrinking behavior during sintering and accurate dimensions after extrusion.
4Strength
If existing square-cell structure techniques are applied to hexagonal-cell structure, then some mechanical strength can be ensured, but the mechanical strength is not fully improved due to structural differences
Solution Approach 1:
The patent adapts the skin layer concept to hexagonal-cell structures by applying it specifically to hexagonal honeycomb structures. This localized approach on the outer surface provides enhanced mechanical strength while accounting for the specific geometric characteristics of hexagonal cells, making the solution adaptable to the particular structural requirements of hexagonal configurations rather than simply copying square-cell approaches.
Data Source
AI summary
A hexagonal-cell honeycomb structure having a plurality of cell walls having a hexagonal shape in cross-section and forming a plurality of hexagonal cell passages, and a tubular skin layer surrounding the cell walls, The thickness of the basic cell walls is 140 μm or less and an inscribed circle diameter Da inscribed at an intersectional portion of the basic cell walls 2 and an cell pitch P having the relationship Da/P≧0.13.