Honeycomb Structure with Communicating Incomplete Cells
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Solution Overview
Problem
Conventional honeycomb structures with multiple cell structures separated by boundary walls suffer from poor thermal shock resistance due to stress concentration at the boundary walls, leading to potential breakage.
Innovation Solution
A honeycomb structure design featuring a pillar-shaped body with a porous partition wall and a circumferential wall, where the center and circumferential cell structures have incomplete cells that communicate with each other, reducing stress concentration by adjusting the percentage of communicating cells between 5% and 50%, and differing in shape and cell density, with a continuous partition wall and inclined cell arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a honeycomb structure has two or more cell structures separated by a boundary wall, then exhaust gas purification efficiency is improved, but thermal shock resistance deteriorates due to stress concentration at the boundary wall
Solution Approach 1:
The invention applies different cell structure configurations in different regions of the honeycomb structure. Specifically, the circumferential portion has a different cell arrangement compared to the central portion, creating local variations in stress distribution. This local quality differentiation allows the structure to maintain high purification efficiency while reducing stress concentration at the boundary wall, thereby improving thermal shock resistance
Solution Approach 2:
The honeycomb structure is divided into multiple cell structures separated by boundary walls, with each region (central and circumferential) having distinct cell configurations. This segmentation enables independent optimization of each region's properties, allowing the central portion to focus on purification efficiency while the circumferential portion addresses stress distribution and thermal shock resistance
2Ease of manufacture
If the inscribed circle of a boundary cell has a diameter of 0.5 mm or more, then manufacturing is simplified, but stress concentration occurs at the boundary wall leading to poor thermal shock resistance
Solution Approach 1:
The invention implements different cell size specifications in different regions. The circumferential cells have an inscribed circle diameter of 0.5 mm or more for ease of manufacture, while the central cells have a smaller inscribed circle diameter to reduce stress concentration. This local differentiation resolves the contradiction by allowing each region to have optimal cell dimensions for its specific functional requirements
Data Source
AI summary
The honeycomb structure is equipped with a pillar-shaped honeycomb structure body having a porous partition wall that defines a plurality of cells extending from an inflow end face to an outflow end face and serving as a through channel of a fluid and a circumferential wall placed to surround the circumference of the partition wall. The honeycomb structure body has, in a face orthogonal to an extending direction of the cells of the honeycomb structure body, a circumferential cell structure, a center cell structure, and a boundary wall placed at a boundary between the circumferential cell structure and the center cell structure and incomplete cells of 5% or more to 50% or less of the total number of the incomplete cells of the center cell structure is communicated with incomplete cells of the circumferential cell structure with each other.