Honeycomb Structure with Partial Outer Wall for Thermal Management
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Solution Overview
Problem
The existing honeycomb structures used in exhaust gas purifying catalyst carriers and particulate trapping filters have a honeycomb outer wall that increases heat capacity and thermal characteristics, leading to deteriorated temperature rise rates and burning efficiency, and require unnecessary manufacturing steps and raw material costs.
Innovation Solution
A honeycomb structure with a non-outer wall region on its substrate circumferential surface, where the honeycomb outer wall is omitted, reducing heat capacity and simplifying the manufacturing process, while maintaining sufficient strength and thermal properties through a flange portion with latticed flange partition walls and a specific ratio of non-outer wall region to total area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a honeycomb outer wall is formed on the substrate circumferential surface, then the strength of the honeycomb structure is increased and protection against impact is improved, but the heat capacity increases and thermal characteristics deteriorate
Solution Approach 1:
The patent applies local quality by forming the honeycomb outer wall only on specific regions of the substrate circumferential surface rather than uniformly across the entire surface. The outer wall is selectively applied to areas requiring enhanced strength while leaving other areas exposed to maintain optimal thermal characteristics and reduce heat capacity.
2Reliability
If a honeycomb outer wall is formed on the substrate circumferential surface, then protection against impact and defects is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent reduces manufacturing complexity by applying the honeycomb outer wall only to specific regions where protection is needed, rather than requiring complete circumferential coverage. This selective application simplifies the coating process and reduces manufacturing time while maintaining sufficient protection against impact and defects.
3Reliability
If a honeycomb outer wall is formed on the substrate circumferential surface, then the honeycomb structure is protected from defects, but the manufacturing cost increases due to additional materials and steps
Solution Approach 1:
The patent reduces manufacturing cost by applying the honeycomb outer wall material only to specific regions of the substrate circumferential surface where defect protection is most needed. This selective application reduces the quantity of coating material required and simplifies the manufacturing process, thereby lowering overall production costs while maintaining adequate protection against defects.
Data Source
AI summary
A honeycomb structure includes a honeycomb substrate including latticed partition walls which define a plurality of cells extending from one end face to the other end face and forming through channels for fluid and a honeycomb outer wall, and a flange portion attached to a part of the honeycomb outer wall of the honeycomb substrate, and including latticed flange partition walls which define a plurality of flange cells extending from one flange end face to the other flange end face and a flange outer wall, and in the honeycomb substrate, a ratio of a non-outer wall region in which the honeycomb outer wall is not disposed is in a range of 10 to 90% to a total area of a substrate circumferential surface.