Honeycomb Structure Partially Clogged Cells Protrusions
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Solution Overview
Problem
Conventional honeycomb structures face challenges in improving NOx purifying performance while maintaining mechanical strength, as increasing catalyst loading or cell density leads to increased pressure loss and reduced strength.
Innovation Solution
A honeycomb structure with partially clogged cells that have protrusions inward from the partition wall, optimizing the ratio of clogged cells and protrusion area to enhance gas diffusion and catalyst contact without compromising mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cell density of the honeycomb structure is increased to improve purifying performance, then the contact ratio of catalyst with exhaust gas increases, but the pressure loss in the honeycomb structure increases
Solution Approach 1:
The invention applies local quality by creating partially clogged cells with protrusions that have different flow resistance characteristics compared to normal cells. This local variation in cell structure allows some cells to provide enhanced catalyst contact while others maintain lower resistance flow paths, resolving the contradiction between purifying performance and pressure loss.
2Quantity of substance
If the porosity of the partition wall is increased to improve catalyst loading amount and suppress pressure loss, then the mechanical strength of the honeycomb structure is reduced
Solution Approach 1:
The invention applies parameter changes by optimizing the porosity of the partition wall to a specific range (30-70%) that balances catalyst loading capacity with mechanical strength. This parameter optimization allows sufficient catalyst loading while maintaining structural integrity, resolving the contradiction between catalyst loading amount and mechanical strength.
3Productivity
If the amount of catalyst is increased to improve purifying performance, then the pressure loss in the honeycomb structure increases
Solution Approach 1:
The invention applies segmentation by dividing the honeycomb structure into normal cells and partially clogged cells. This segmentation allows the catalyst to be distributed across different cell types, with partially clogged cells providing enhanced contact areas. The segmented structure enables sufficient catalyst loading while maintaining lower overall pressure loss through the presence of normal cells with lower resistance.
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 structure effectively improves NOx purifying performance by promoting gas diffusion and increasing catalyst contact while maintaining sufficient mechanical strength, as demonstrated by the specified ranges for clogged cell ratio, protrusion area, and partition wall thickness.
Implementation Method 1
improve the purifying performance by promoting gas diffusion
Data Source
AI summary
A honeycomb structure includes a porous partition wall disposed so as to surround cells extending from a first end face to a second end face. The cells include partially clogged cells which account for 10 to 80% of the total number of the cells, and each of which includes a protrusion that protrudes inward from the surface of the partition wall. The protrusion is partially formed in a direction in which each partially clogged cell extends. In a projected view from the first end face to the second end face, a ratio of area of the protrusion in each partially clogged cell to whole area of the through channel of each partially clogged cell is 5 to 80%, the whole area including the protrusion, and the partition wall surrounding each partially clogged cell has a thickness at a thinnest part of 0.038 mm or more.