Honeycomb Structure Bonding Strength and Clogging
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Solution Overview
Problem
Honeycomb structures face issues with clogging due to trapped particulate matter and detachment of segments from the bonding member during repeated combustion and regeneration, especially when using silicon carbide as the framework, which also complicates the manufacturing process with multiple steps and materials.
Innovation Solution
A honeycomb structure design featuring protruding and depressed portions on the outer peripheral walls of segments, connected by filler layers and plate-shaped connecting members, allowing for increased bonding strength and preventing detachment, while also optimizing cell sizes to reduce clogging on the inflow side.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If honeycomb segments are bonded together at side faces using a bonding material, then a large-sized honeycomb structure can be obtained, but detachment of segments from the bonding member occurs during repeated heating and cooling
Solution Approach 1:
The invention applies bonding material to the entire outer peripheral surface of honeycomb segments before assembly, ensuring complete coverage and pre-establishing strong bonding zones at potential detachment points (corner portions and intermediate portions), which prevents segment detachment during subsequent thermal cycling
Solution Approach 2:
The invention transitions from bonding only at linear side face interfaces to bonding across the entire two-dimensional outer peripheral surface, including corner portions and intermediate portions, thereby creating multiple bonding zones that collectively prevent segment detachment
2Stability of the object's composition
If multiple small honeycomb segments are manufactured and bonded together, then thermal shock resistance is improved, but the manufacturing process becomes complex with many steps
Solution Approach 1:
The invention combines multiple small honeycomb segments into a single large-sized structure with integrated outer peripheral surfaces, maintaining thermal shock resistance while simplifying the manufacturing process by enabling formation, drying, and firing as unitary operations
3Object-generated harmful factors
If cells on the inflow side are used for trapping particulate matter, then filtration is achieved, but clogging of these cells occurs
Solution Approach 1:
The invention inverts the conventional arrangement by plugging cells at the exhaust gas inflow end instead of the outflow end, allowing trapped particulate matter to be contained within the honeycomb structure and preventing clogging of the inflow side cells
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
There is provided a honeycomb structure 100 comprising a plurality of honeycomb segments 4 where second cells 1b plugged only in the end portion 13 on one side and first cells 1a each plugged only in the other end portion on the other side are alternately disposed, with the first cells 1a having a cross-sectional area larger than that of the second cells 1b; the honeycomb segments 4 are disposed with a gap between side faces 5 facing each other, two or more plate-shaped connecting members 7 for connecting the side faces 5 facing each other are provided for each pair of side faces 5 facing each other, and a filler layer 11 disposed in the gap is provided; and an outer peripheral wall 3 constituting a side face 5 in contact with the filler layer 11 in the honeycomb segment 4 has protruding portions along an external shape of the first cells 1a and depressed portions along an external shape of the second cells 1b.