Honeycomb Structure Body with Cell Density Gradient Design
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Solution Overview
Problem
Conventional honeycomb structure bodies for catalyst converters experience distortion and reduced strength due to varying cell density, leading to non-uniform exhaust gas flow speeds and reduced purification efficiency.
Innovation Solution
A method to design a honeycomb structure body with a cell density varying section, where the cell density is gradually decreased from the center to the periphery, using a virtual base structure with uniform cell density and polar coordinates to form main intersecting points and cell walls, ensuring a uniform flow speed and shape integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If cell density is reduced from central point to outer periphery to increase exhaust gas flowing area, then exhaust gas flow uniformity is improved, but cell shape distortion increases and structure strength decreases
Solution Approach 1:
The patent applies local quality by varying cell density across different regions of the honeycomb structure. The cell density is specifically reduced from the central point to the outer periphery in a controlled manner, creating different structural characteristics in different zones. This allows the outer regions to have larger flow passages for improved gas flow uniformity while the inner regions maintain higher density for structural support, thus resolving the contradiction between flow uniformity and structure strength.
2Area of stationary object
If cell density is reduced from central point to outer periphery, then exhaust gas flowing area is increased, but cell shape distortion increases
Solution Approach 1:
The patent applies parameter changes by systematically varying the cell density parameter across the radial direction of the honeycomb structure. The cell density is changed from a constant value in conventional designs to a gradient distribution where density decreases from the central point to the outer periphery. This controlled parameter variation increases the exhaust gas flowing area in outer regions while maintaining acceptable cell shape uniformity through optimized gradient design.
3Speed
If cell walls are arranged along hyperbolas, then exhaust gas flow distribution is improved, but curvature increases causing cell deformation
Solution Approach 1:
The patent applies local quality by implementing different cell wall arrangement characteristics in different regions. In the central region, cell walls follow hyperbolic arrangements to improve exhaust gas flow distribution. In the outer periphery region, the cell wall arrangement is modified to reduce curvature and prevent excessive cell deformation. This regional differentiation allows the structure to achieve both improved flow distribution and maintained cell shape integrity.
Data Source
AI summary
A honeycomb structure body has main cells having a tubular shape and main cell walls. Each main cell is surrounded by the main cell walls. A virtual base structure body has base cell walls and base cells. The honeycomb structure body has an improved structure obtained by modifying a structure of the virtual base structure body. Each base intersecting point, at which base cell walls intersect, is determined by a polar coordinate (r, θ) using a radius vector r and a deflection angle θ. Each main intersecting point is formed on a polar coordinate (r′, θ) using the deflection angle θ and a main radius vector r′ which is obtained by multiplying the radius vector r and a constant magnification without changing the deflection angle θ. A cell density varying section varies its cell density and is formed in at least a part of the honeycomb structure body.