Honeycomb Structure Partition Wall Thickness Optimization
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Solution Overview
Problem
The challenge is to reduce pressure loss in honeycomb structures when a large amount of catalyst is loaded, as thicker catalyst layers increase resistance to exhaust gas flow.
Innovation Solution
A honeycomb structure design with intersecting partition walls where the thickness of the walls at intersecting portions is optimized, with a ratio of 0.1 to 0.8 compared to the maximum thickness, and complete cells are defined in a substantially polygonal shape, particularly hexagonal, to maintain low pressure loss and structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large amount of catalyst is loaded on the partition walls, then exhaust gas purification effect is improved, but pressure loss is increased
Solution Approach 1:
The partition wall thickness is made non-uniform, with thinner sections at intersecting portions and thicker sections at non-intersecting portions. This local variation in thickness allows the catalyst layer to be thinner at intersection areas (reducing pressure loss) while maintaining sufficient catalyst amount at non-intersection areas (maintaining purification effect).
Solution Approach 2:
The patent changes the geometric parameter of partition wall thickness from uniform to non-uniform, specifically controlling the ratio X2/X1 to be 0.1 to 0.8. This parameter change optimizes the balance between catalyst loading capacity and flow resistance, resolving the contradiction between purification effect and pressure loss.
2Loss of energy
If partition wall thickness is reduced at intersecting portions, then pressure loss is reduced, but structural strength may be compromised
Solution Approach 1:
The partition wall thickness is locally optimized: thinner at intersecting portions (where catalyst coverage is already high from multiple walls meeting, providing sufficient purification) and thicker at non-intersecting portions (where structural support is critical). This local differentiation resolves the contradiction between pressure loss reduction and strength maintenance.
Solution Approach 2:
By controlling the thickness ratio X2/X1 within 0.1 to 0.8, the patent finds the optimal parameter range that simultaneously achieves acceptable pressure loss and maintains structural integrity. The specific ratio range ensures walls are thin enough to reduce flow resistance but thick enough to prevent collapse.
3Strength
If uniform thick partition walls are used, then structural strength is maintained, but catalyst loading capacity is limited and pressure loss increases
Solution Approach 1:
Instead of uniform thickness, the partition wall employs local quality variation: thicker regions provide structural strength and accommodate full catalyst loading, while thinner regions at intersections reduce overall flow resistance and allow for optimized catalyst distribution. This resolves the contradiction between strength and loading capacity.
Solution Approach 2:
The patent transforms the uniform thickness parameter into a variable parameter with controlled thickness ratio (X2/X1 = 0.1 to 0.8), enabling the structure to achieve both high catalyst loading capacity in non-intersection areas and low pressure loss through thinner intersection areas.
Data Source
AI summary
A honeycomb structure including a honeycomb structure body that includes porous partition walls defining a plurality of cells each to function as a through channel for fluid extending from a first end face to a second end face, in which, in a cross-section perpendicular a direction in which cells of the honeycomb structure body extend, portions at which the partition walls intersect to each other are intersecting portions, and in sets of the intersecting portions corresponding to 10% or more of the total number of sets of two adjacent intersecting portions, a ratio of a thickness X2 of the partition wall in the intersecting portion to a maximum thickness X1 of the partition wall between the two adjacent intersecting portions is 0.1 to 0.8.