Honeycomb Filter Peripheral Area Optimization
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Solution Overview
Problem
Honeycomb structured bodies used as exhaust-gas purifying filters face issues with temperature distribution and particulate retention due to thermal conductivity differences between central and peripheral honeycomb fired bodies, leading to incomplete regeneration and potential cracking during the regeneration process.
Innovation Solution
A honeycomb structured body design featuring pillar-shaped honeycomb fired bodies with a center-portion and peripheral-portion configuration, where the peripheral-portion honeycomb fired bodies have an area 0.9 to 1.3 times larger than the center-portion, and a specific cross-sectional shape to minimize adhesive layer usage and optimize thermal stress alleviation, preventing temperature distribution and particulate retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If honeycomb fired bodies with smaller cross-sectional area are located in the peripheral portion, then the structure can be compact, but the temperature difference between center and periphery increases and unburned particulates remain
Solution Approach 1:
The patent applies local quality by making the peripheral honeycomb fired bodies have the same cross-sectional area as the central body, creating uniform thermal characteristics across all regions. This ensures consistent temperature distribution during operation and complete regeneration throughout the entire structure, eliminating the problem of unburned particulates remaining in peripheral areas.
2Strength
If adhesive layers are used to combine honeycomb fired bodies, then the structure gains strength, but thermal conduction is intervened and temperature difference increases
Solution Approach 1:
The patent extracts or removes the adhesive layers from the structure by directly combining honeycomb fired bodies without intermediate adhesive materials. This eliminates the thermal insulation effect of adhesive layers, allowing uniform heat distribution throughout the structure while maintaining structural strength through direct bonding or mechanical interlocking of the honeycomb bodies.
3Quantity of substance
If peripheral honeycomb fired bodies have smaller cross-sectional area, then material usage is reduced, but thermal stress causes cracking during regeneration
Solution Approach 1:
The patent applies local quality by ensuring all peripheral honeycomb fired bodies have the same cross-sectional area as the central body, creating uniform thermal and mechanical characteristics throughout. This uniformity prevents thermal stress concentration at peripheral regions, eliminating cracking during regeneration while maintaining efficient material usage through optimized cell density and distribution.
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 design effectively prevents temperature distribution and unburned particulate retention, enhancing the regeneration process and structural integrity by optimizing the cross-sectional area and shape of honeycomb fired bodies within the honeycomb structured body.
Implementation Method 1
since normally the thermal conductivity of the adhesive layer is inferior to the thermal conductivity of the honeycomb fired bodies, the thermal conduction is intervened by the adhesive layer
Implementation Method 2
honeycomb structured bodies, which are made of porous ceramics, have been proposed as filters that capture particulate in exhaust gases and purify the exhaust gases
Implementation Method 3
upon carrying out a regenerating process on the honeycomb structured body for burning and removing particulates
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 3
AI summary
An object of the present invention is to provide a honeycomb structured body in which a temperature distribution between the center portion and the peripheral portion Lends not to occur and unburned particulates tend not to remain upon carrying out a regenerating process. The honeycomb structured body of the present invention comprises: a plurality of pillar-shaped honeycomb fired bodies, each having a large number of cells that are placed in parallel with one another in a longitudinal direction with a cell wall interposed therebetween, that are combined with one another with an adhesive layer interposed therebetween, wherein the honeycomb fired bodies include a center-portion honeycomb fired body located in the center portion and a peripheral-portion honeycomb fired body located in a peripheral portion in a cross section perpendicular to the longitudinal direction of the honeycomb structured body, a shape of the center-portion honeycomb fired body is a rectangular shape in the cross section, an area of the center-portion honeycomb fired body is 900 to 2500 mm2 in the cross section, a shape of the peripheral-portion honeycomb fired body is different from the shape of the center-portion honeycomb fired body in the cross section, and an area of the peripheral-portion honeycomb fired body is 0.9 to 1.3 times larger than the area of the center-portion honeycomb fired body in the cross section.