Honeycomb Catalyst Body Peripheral Cell Design
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Solution Overview
Problem
Existing honeycomb catalyst systems for gasoline engines face challenges in efficiently removing fine particles while minimizing pressure loss and preventing crack formation due to soot accumulation, which affects the structural integrity and efficiency of the catalyst body.
Innovation Solution
A honeycomb catalyst body with a specific design featuring porous partition walls, a catalyst loaded on the partition walls, and strategically placed plugged portions to optimize cell diameter and porosity, reducing pressure loss and preventing soot accumulation, thereby enhancing the removal of CO, HC, and NOx from exhaust gases without causing cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a plugged honeycomb structure is used to remove particulate matter, then PM removal efficiency is improved, but pressure loss increases
Solution Approach 1:
The patent applies local quality by providing plugged portions only at specific locations (outer peripheral cells) rather than uniformly plugging all cells. This localized plugging approach targets the specific problem of soot accumulation in low-temperature peripheral regions while maintaining through-cells in the central region for efficient exhaust flow, thereby balancing PM removal efficiency with acceptable pressure loss characteristics.
2Reliability
If plugged portions are provided in the peripheral portion to prevent crack generation, then structural reliability is improved, but PM removal efficiency decreases
Solution Approach 1:
The patent implements local quality by differentiating the cell structure between peripheral and central regions. Outer peripheral cells are plugged to prevent soot accumulation and crack generation in low-temperature zones, while inner cells remain as through-cells for effective PM removal. This spatial differentiation allows simultaneous achievement of structural reliability and PM removal efficiency.
Solution Approach 2:
The patent segments the honeycomb structure into distinct functional zones: peripheral plugged cells for structural protection and central through-cells for pollution control. This segmentation allows each region to perform its specific function optimally without compromising the overall system performance.
3Loss of energy
If through-cells are provided in the peripheral portion to maintain low pressure loss, then pressure loss is reduced, but soot accumulation occurs causing crack generation
Solution Approach 1:
The patent applies local quality by assigning different functions to peripheral and central cells. Peripheral cells are plugged to address the specific issue of soot accumulation and crack prevention in low-temperature regions, while central cells maintain through-structure for low pressure loss. This localized functional differentiation resolves the contradiction between pressure loss and crack prevention.
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 effectively removes fine particles from direct injection gasoline engines with minimal pressure loss and prevents crack formation, ensuring efficient purification of CO, HC, and NOx while maintaining structural integrity.
Implementation Method 1
the PM contained in the exhaust gas is captured by partition walls
Implementation Method 2
a catalyst loaded on the partition walls of honeycomb base body
Implementation Method 3
honeycomb base body having porous partition walls forming a plurality of divided cells which extend from one end face of honeycomb base body to its other end face and which function as a fluid passage
Implementation Method 4
which can eliminate the CO, HC and NOx contained in the exhaust gas
Data Source
AI summary
There is provided a honeycomb catalyst body comprising a honeycomb base body having porous partition walls forming a plurality of divided cells which extend from one end face of honeycomb base body to its other end face and which function as a fluid passage, and an outer wall present at the outermost peripheral portion of honeycomb base body, plugged portions provided so as to plug part of the plurality of divided cells, and a catalyst loaded on the partition walls of honeycomb base body. The plurality of divided cells include outermost peripheral cells formed by the partition walls and the outer wall, and of the outermost peripheral cells, those cells whose hydraulic diameter is 5 to 75% of the hydraulic diameter of a cell other than the outermost peripheral cells, are through-cells having no plugged portion.