Honeycomb Catalyst Body with Localized Pore Segmentation
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Solution Overview
Problem
Honeycomb catalyst bodies face challenges in achieving high mechanical strength and effective exhaust gas purification while minimizing pressure loss, as increased porosity for catalyst loading compromises mechanical strength and particulate matter collection efficiency.
Innovation Solution
A honeycomb catalyst body with partition walls having a porosity of 25-55% and catalyst layers covering only 5% or less of the pore surfaces, ensuring high mechanical strength and efficient exhaust gas purification with reduced pressure loss by alternating cell configurations and controlled catalyst layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the porosity of partition walls is increased to load catalyst onto pore surfaces, then exhaust gas purification performance is improved, but mechanical strength of honeycomb structure deteriorates
Solution Approach 1:
The patent applies local quality by differentiating between two types of pores in the partition walls: through-pores (providing mechanical strength) and blind pores (providing catalyst loading area). This local differentiation allows the partition wall to simultaneously achieve high mechanical strength through the through-pore structure and effective catalyst loading through the blind pore structure, resolving the contradiction between strength and purification performance
Solution Approach 2:
The partition wall is segmented into functionally distinct pore types: through-pores that extend completely through the wall for structural integrity, and blind pores that terminate within the wall for catalyst loading. This segmentation allows each pore type to fulfill its specific function without compromising the other, enabling both high mechanical strength and effective catalyst deployment
2Reliability
If the porosity of partition walls is excessively increased, then catalyst loading area is improved, but pressure loss increases and mechanical strength deteriorates
Solution Approach 1:
The patent uses local quality by assigning different pore types to different functions: through-pores maintain structural integrity and control pressure loss, while blind pores provide catalyst loading area. This localized functional differentiation allows the system to achieve high catalyst loading without excessively increasing overall porosity, thereby avoiding excessive pressure loss
3Reliability
If catalyst is loaded onto surfaces of pores in partition walls, then exhaust gas purification is improved, but mechanical strength of honeycomb structure deteriorates
Solution Approach 1:
The patent applies local quality by restricting catalyst loading primarily to blind pore surfaces rather than through-pore surfaces. This localized catalyst deployment ensures that catalyst is positioned where it can effectively contact exhaust gas (in blind pores) while maintaining the structural integrity of through-pores that contribute to mechanical strength
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 provides a honeycomb catalyst body with enhanced mechanical strength, effective NOx purification, and reduced pressure loss, meeting regulated emission standards while maintaining efficient particulate matter collection.
Implementation Method 1
a porosity of partition walls needs to be increased so as to satisfy both of loading a catalyst onto the surfaces of pores of the partition walls, and avoiding the increase of a pressure loss
Implementation Method 2
a catalyst such as zeolite is loaded onto the surfaces of partition walls with which cells of the honeycomb structure are defined and formed, and the surfaces of pores formed in the partition walls
Data Source
Figure 1~2
Figure 3
AI summary
There is disclosed a honeycomb catalyst body having a high mechanical strength, an excellent exhaust gas purification performance, and less pressure loss. The honeycomb catalyst body includes a honeycomb structure 10 having porous partition walls 1 with which a plurality of cells 2 are defined and formed, outflow side plugged portions 8a, inflow side plugged portions 8b, and catalyst layers 5 formed on the surfaces of the partition walls 1 on the side of the outflow cells, the cells 2 of the honeycomb structure 10 are formed so that an open area of each outflow cell in a cross section of the outflow cell which is vertical to a cell extending direction is larger than an open area of each inflow cell in the cross section of the outflow cell which is vertical to the cell extending direction, a porosity of the partition walls 1 of the honeycomb structure 10 is from 25 to 55%, and in a cross section parallel to the extending direction of the cells 2, a total area of the catalyst layers 5 formed on the surfaces of the pores in the partition walls 1 is 5% or less of a total area of the pores in the partition walls 1.