Honeycomb Structure Cell Wall Thickness Optimization
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Solution Overview
Problem
Honeycomb structures used in exhaust gas filtration face challenges in maintaining high particulate collection efficiency while minimizing pressure loss and heat capacity, particularly when porosity and cell wall thickness are increased or reduced, leading to inefficient particulate capture and increased pressure loss.
Innovation Solution
A honeycomb structure with cell walls of specific thickness and surface area per unit volume, characterized by the relationship 11/6−10/3×A≦B, where A is the thickness and B is the surface area, ensuring efficient particulate collection and low pressure loss, regardless of cell wall thickness, by optimizing the travel distance and difficulty of particulates through the cell walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If porosity of the honeycomb structure is increased or cell walls are thinned to reduce heat capacity, then heat capacity is reduced, but particulates will pass the cell walls easily so that the efficiency in collecting the particulates deteriorates
Solution Approach 1:
The invention changes the critical parameters of cell wall thickness and specific surface area to satisfy a specific mathematical relationship (11/6−10/3×A≦B). This parameter optimization allows the cell walls to be thin enough to reduce heat capacity while maintaining sufficient surface area to prevent particulate passage, thereby resolving the contradiction between heat capacity reduction and particulate collection efficiency
Solution Approach 2:
The invention applies local quality by optimizing the specific surface area of particles forming the cell walls independently from the overall cell wall thickness. By controlling the micro-structure (particle surface area) rather than just the macro-structure (wall thickness), the invention achieves both low heat capacity and high particulate collection efficiency in different spatial scales
2Stress or pressure
If cell wall thickness is reduced to lower pressure loss, then pressure loss is reduced, but it becomes difficult to ensure sufficient strength and particulate collection efficiency
Solution Approach 1:
The invention optimizes the parameter combination of cell wall thickness and specific surface area according to the relationship (11/6−10/3×A≦B), allowing thinner cell walls that reduce pressure loss while maintaining sufficient structural strength through increased surface area of the particles forming the walls
3Stress or pressure
If cell wall thickness is reduced to lower pressure loss, then pressure loss is reduced, but efficiency in collecting particulates may deteriorate
Solution Approach 1:
The invention simultaneously optimizes two parameters - reducing cell wall thickness to lower pressure loss while increasing specific surface area of particles to maintain particulate collection efficiency, with both parameters satisfying the relationship (11/6−10/3×A≦B)
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 proposed honeycomb structure achieves high efficiency in collecting particulates (not lower than 80%) while maintaining low pressure loss and sufficient strength, enabling effective exhaust gas purification even at early engine stages.
Implementation Method 1
a plurality of cells are defined by cell walls, and fluid including particulates is purified by the cell walls
Data Source
AI summary
A honeycomb structure including a plurality of cells arranged in parallel while being separated by cell walls, and extending in a longitudinal direction of the honeycomb structure. Each cell is sealed at one of end portions thereof. In the honeycomb structure, the relation expressed by an expression (1) is satisfied:11/6−10/3×A≦B (1)where A (mm) designates thickness of the cell walls, and B (m2/cm3) designates a surface area per unit volume of the cell walls.