Honeycomb Structure with Boundary Wall and Thick Intersection Parts
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Solution Overview
Problem
Conventional honeycomb structures with thinner partition walls and higher cell density face challenges in maintaining mechanical strength and preventing catalyst clogging when loaded with catalyst, as they compromise thermal shock resistance and pressure loss efficiency.
Innovation Solution
A honeycomb structure design featuring a boundary wall separating two or more cell structures, with strategically thicker intersection parts at specific distances from the boundary wall, optimizing the thickness and distribution of intersection parts to enhance mechanical strength while preventing catalyst clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the partition wall is made thinner and cell density is increased to improve purifying performance, then the mechanical strength and thermal shock resistance deteriorate
Solution Approach 1:
The partition wall is designed with non-uniform thickness, featuring thicker portions at specific locations (such as at the corners of cells or at the inlet/outlet ends) and thinner portions at other locations. This local variation in thickness allows the partition wall to maintain adequate mechanical strength at critical locations while reducing overall material usage and improving heat dissipation, thereby resolving the contradiction between purifying performance and mechanical strength.
2Productivity
If the partition wall is made thinner to increase cell density, then catalyst clogging occurs more frequently
Solution Approach 1:
The partition wall incorporates thicker portions at specific locations where catalyst loading occurs, providing sufficient space and structural support to prevent catalyst clogging. The thinner portions are strategically placed where clogging is less likely to occur, allowing increased cell density in those regions while maintaining reliability where needed.
3Strength
If the reinforced partition wall thickness is increased to improve mechanical strength, then the open ends of cells become very small causing catalyst clogging
Solution Approach 1:
The partition wall is designed with thicker portions only at specific critical locations (such as corners or ends) rather than uniformly throughout. This localized reinforcement provides the necessary mechanical strength while leaving the cell open ends sufficiently large for effective catalyst loading, resolving the contradiction between strength and catalyst loading efficiency.
4Reliability
If the partition wall thickness is uniformly increased to prevent catalyst clogging, then the cell density decreases and pressure loss increases
Solution Approach 1:
The partition wall features non-uniform thickness with thicker portions only at specific locations where clogging prevention is critical, while maintaining thinner portions in other areas. This localized approach prevents catalyst clogging at critical points without uniformly reducing cell density or increasing pressure loss, thereby resolving the contradiction between reliability and productivity.
Data Source
AI summary
A honeycomb structure includes a pillar-shaped honeycomb structure body having a porous partition wall defining a plurality of cells serving as fluid through channel extending from an inflow end face to an outflow end face; and a circumferential wall surrounding the partition wall, wherein in a plane orthogonal to cell extending direction, the honeycomb structure body has a circumferential cell structure, a center cell structure having a cell structure different from the circumferential cell structure, and a boundary wall, the honeycomb structure body has intersection parts of the partition wall, including basic intersection parts and thick intersection parts having a thickness larger than that of the basic intersection parts, the thick intersection parts include at least one of: first thick intersection parts and second thick intersection parts, and in the circumferential cell structure, the intersection parts at least include the circumferential basic intersection parts.