Honeycomb Structure Sensor Insertion Hole Design
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Solution Overview
Problem
Conventional honeycomb structures used in exhaust gas purification systems face challenges in direct measurement of temperature and pressure, leading to inaccurate defect detection and potential damage during sensor insertion, along with issues like soot leakage and manufacturing complexities.
Innovation Solution
A honeycomb structure with a sensor insertion hole formed in the end face, equipped with a breakage prevention means such as a wall reinforcing member or sleeve, allowing for direct measurement of temperature and oxygen concentration, and enabling easy attachment of sensors without damaging the structure, while preventing soot leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a hole is formed in the honeycomb side face to insert a sensor, then temperature measurement becomes possible, but the honeycomb structure is damaged and characteristics are impaired
Solution Approach 1:
The invention changes the dimension of sensor insertion from the side face (radial direction) to the end face (axial direction) of the honeycomb structure. This dimensional change allows sensor insertion without compromising the thin partition walls that define the cells, thereby maintaining structural integrity while enabling temperature measurement.
Solution Approach 2:
The invention forms the sensor insertion hole in the end face during the honeycomb manufacturing process itself, before the honeycomb is assembled into the exhaust system. This preliminary action prevents damage that would occur during later installation and ensures the hole is properly positioned without compromising structural strength.
2Measurement precision
If a hole is formed in the honeycomb side face for sensor insertion, then temperature sensing is enabled, but soot leakage occurs from the space between sensor and filter case
Solution Approach 1:
By moving the sensor insertion location from the side face to the end face of the honeycomb, the invention eliminates the gap between the sensor and filter case that causes soot leakage. The end face insertion allows the sensor to be positioned within the exhaust flow path without creating external gaps where soot could escape.
3Ease of operation
If the honeycomb structure is used without plugging at the ends, then direct measurement is proposed by forming a hole in the side face, but this applies damage to the cell partition wall
Solution Approach 1:
The invention resolves the contradiction by changing the insertion dimension from side face to end face. This allows direct measurement capability while avoiding damage to the thin partition walls, as the end face provides sufficient structural support for hole formation without compromising cell integrity.
4Ease of manufacture
If sensors are attached to piping in front or rear of the honeycomb filter, then pressure drop and temperature can be indirectly measured, but accurate defect detection is difficult
Solution Approach 1:
The invention extracts the sensor from the external piping system and integrates it directly into the honeycomb structure by forming an insertion hole in the end face. This allows the sensor to measure parameters directly within the exhaust flow path, providing accurate defect detection while maintaining ease of manufacture through integrated hole formation.
Data Source
AI summary
Provided is a honeycomb structure that is divided by a porous partition wall 3, as well as that is formed of a plurality of cells 5 acting as a through channel of a fluid. An insertion hole 9 in which a sensor can be inserted is formed in an end face of the honeycomb structure, and a breakage prevention means 17 is provided on an inner circumference or in the proximity of the insertion hole. According to this honeycomb structure, it is possible to provide a honeycomb structure or a honeycomb filter in which a temperature, an oxygen concentration and the like of the honeycomb structure can be directly measured; a temperature control of the honeycomb structure, being a base member can be easily made, and various sensors in accordance with applications of OBD measurement, measurement of an oxygen concentration, an NOx concentration and the like can be attached; and further, canning is easy to be conducted, and the durability of various attached sensors can be improved. Especially in the case of the use in a DPF, the present invention can be preferably used without soot leakage.