Honeycomb Filter Partition Wall Thickness Design
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Solution Overview
Problem
Conventional honeycomb filters experience non-uniform flow of exhaust gas and increased pressure loss due to differences in partition wall thickness, which affects their efficiency in particulate matter filtration.
Innovation Solution
A honeycomb filter design with a pillar-shaped substrate featuring inflow cells with pentagonal or hexagonal shapes and outflow cells with square shapes, where the thickness of the partition wall between inflow cells is smaller than that between inflow and outflow cells, allowing for a larger pore volume and reduced pressure loss while maintaining isostatic strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the partition wall thickness is increased to maintain isostatic strength, then the structural strength is improved, but the pressure loss increases due to reduced pore volume
Solution Approach 1:
The patent applies different partition wall thicknesses to different locations: the first partition wall (between inflow and outflow cells) has thickness T1, while the second partition wall (between inflow cells) has thickness T2 where T2 > T1. This local differentiation allows the thicker second partition wall to provide enhanced isostatic strength while the thinner first partition wall maintains lower pressure loss for exhaust gas flow.
Solution Approach 2:
The partition wall structure is segmented into two distinct types with different thicknesses. The first partition wall separates inflow and outflow cells, while the second partition wall separates adjacent inflow cells. This segmentation allows each partition wall to be optimized for its specific functional requirements.
2Ease of manufacture
If the partition wall thickness is made uniform, then the manufacturing is simplified, but the exhaust gas flow becomes non-uniform causing increased pressure loss
Solution Approach 1:
The patent implements non-uniform partition wall thickness by making the second partition wall (between inflow cells) thicker than the first partition wall (between inflow and outflow cells). This local quality differentiation ensures uniform exhaust gas flow distribution while maintaining manufacturing feasibility through a systematic design approach.
3Loss of energy
If the partition wall between inflow cells is made thinner to reduce pressure loss, then the pressure loss decreases, but the isostatic strength is compromised
Solution Approach 1:
The patent strategically places the thinner first partition wall only where it is needed (between inflow and outflow cells for gas flow), while the thicker second partition wall (between inflow cells) provides the necessary isostatic strength support for the overall structure.
Solution Approach 2:
The partition wall system is segmented into two functional zones: the first partition wall optimized for minimal pressure loss, and the second partition wall optimized for structural strength, allowing both requirements to be satisfied simultaneously.
Data Source
AI summary
Provided is a honeycomb filter, including: a pillar-shaped honeycomb substrate having an inflow end face and an outflow end face and including a porous partition wall surrounding a plurality of cells; and a plugging portion disposed at any one of ends of the cells at the inflow end face and at the outflow end face. In a cross section orthogonal to an extending direction of the cells, inflow cells have a pentagonal or a hexagonal shape, and outflow cells have a square shape. The cells are configured that the inflow cells surround one outflow cell and one side of an inflow cell and one side of an adjacent outflow cell are parallel to each other. The partition wall is configured that thickness of a first partition wall disposed between the inflow cells and the outflow cells is smaller than thickness of a second partition wall disposed between the inflow cells.