Honeycomb Structure Partition Wall Thickness Design
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Solution Overview
Problem
Honeycomb structures with high open area ratios face challenges in maintaining structural strength and preventing cell deformation, especially during the extrusion process, which affects their efficiency and productivity.
Innovation Solution
A honeycomb structure design featuring a first region with an open area ratio of 83% or more, where the partition walls have a thickness of 0.11 mm or less and a partition wall strength index of 4.0 or more, combined with a second region having thicker walls and rounded intersecting portions, to enhance structural integrity and prevent cell deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the thickness of partition walls is decreased to obtain a high open area ratio, then the heat capacity is lowered and pressure loss decreases, but the structural strength of the honeycomb structure weakens
Solution Approach 1:
The patent applies local quality by differentiating partition wall thickness across different regions of the honeycomb structure. The first region (outer peripheral portion) has thinner partition walls (0.11 mm or less) to maximize open area ratio and reduce heat capacity, while the second region (inner portion) has thicker partition walls to maintain structural strength. This spatial variation in wall thickness allows simultaneous optimization of thermal performance and mechanical integrity.
Solution Approach 2:
The patent segments the honeycomb structure into two distinct regions based on functional requirements. The first region occupies the outer peripheral portion where thermal performance is prioritized, while the second region occupies the inner portion where structural support is critical. This segmentation enables each region to be optimized independently for its specific function.
2Loss of energy
If the open area ratio is increased to 80% or more, then the heat capacity is lowered, but the structural strength deteriorates causing cell deformation
Solution Approach 1:
The patent uses local quality to maintain cell shape stability in the inner portion while allowing maximum openness in the outer portion. The second region (inner portion) has thicker partition walls that prevent cell deformation and maintain structural integrity, while the first region (outer peripheral portion) can achieve high open area ratio without compromising overall cell shape stability.
Solution Approach 2:
The patent applies beforehand cushioning by designing the second region with thicker partition walls to compensate for and prevent potential cell deformation before it occurs. This preemptive structural reinforcement in the inner portion counteracts the weakening effect of thin walls in the outer region, ensuring overall cell shape stability is maintained even at high open area ratios.
3Productivity
If the amount of material to be extruded per unit time is increased to enhance productivity, then the extrusion speed is increased, but the flow speed distribution becomes uneven and cell deformation occurs
Solution Approach 1:
The patent applies local quality to manage extrusion flow distribution by creating regions with different wall thicknesses. The first region (outer peripheral portion) with thinner walls allows faster material flow and higher productivity, while the second region (inner portion) with thicker walls provides structural support that prevents cell deformation, thus maintaining manufacturing precision despite increased extrusion rate.
Data Source
AI summary
A honeycomb structure includes a honeycomb structure body constituted of a first region which is an inside region and a second region which is an outside region surrounding a periphery of the first region. An open area ratio in the first region is 83% or more and a porosity of partition walls is from 20 to 60%. A thickness t1 of the partition walls constituting the first region is 0.11 mm or less, a thickness t2 of the partition walls constituting the second region is larger than the thickness t1 of the partition walls, a ratio (t3/t1) between a thickness t3 of the partition walls forming first complete cells from the outermost periphery of the honeycomb structure body toward a center thereof in the second region and the thickness t1 of the partition walls is from 1.2 to 1.4, and a partition wall strength index A is 4.0 or more.