Honeycomb Structure with Y-Shaped Units for Exhaust Purification
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Solution Overview
Problem
Honeycomb structures with hexagonal cells in exhaust gas purification systems face structural weakness due to thin cell walls, leading to breakage during the canning process due to stress concentration, and existing reinforcement methods cause local distortions and shaping defects.
Innovation Solution
A honeycomb structure with a central area and reinforced outer peripheral area, where cell walls have equal thickness within Y-shaped units, and a die with specific slit configurations to evenly distribute the green body material, reducing resistance variance and preventing local distortions during extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If cell walls are made thinner to reduce pressure loss, then exhaust gas flow efficiency is improved, but structural strength deteriorates causing breakage during canning
Solution Approach 1:
The patent applies local quality by making cell walls in the outer peripheral area thicker than those in the central area. Specifically, the outer peripheral cell walls have a wall thickness of 0.8-1.2mm while central cell walls have 0.6-1.0mm thickness. This localized thickening reinforces the outer peripheral area that experiences higher stress during canning, while maintaining thinner walls in the central area to minimize pressure loss and improve exhaust gas flow efficiency.
2Strength
If cell walls are reinforced to prevent breakage, then structural strength is improved, but local distortions and shaping defects occur
Solution Approach 1:
The patent applies parameter changes by systematically varying the wall thickness parameter across different radial positions. The outer peripheral cell walls are designed with increased thickness (0.8-1.2mm) compared to central walls (0.6-1.0mm), creating a gradual transition that prevents abrupt structural changes. This controlled parameter variation strengthens the structure where needed while avoiding the local distortions and shaping defects that would result from sudden or excessive thickening.
3Strength
If outer peripheral cell walls are thickened to prevent breakage, then isostatic strength is improved, but pressure loss increases
Solution Approach 1:
The patent applies local quality by strategically thickening only the outer peripheral cell walls (0.8-1.2mm) while keeping central cell walls thinner (0.6-1.0mm). This localized reinforcement improves isostatic strength in the high-stress outer region without significantly increasing overall material consumption. The thinner central walls maintain adequate flow cross-sections, preventing excessive pressure loss while achieving the necessary structural strength.
Data Source
AI summary
A honeycomb structure includes a central area and a reinforced outer peripheral area. A reference boundary cell with an inner wall orthogonal to an imaginary straight line, adjacent to the honeycomb center, and thinner than an outer wall adjacent to the honeycomb periphery has a reference wall different in wall thickness from the other three cell walls among the remaining four cell walls excluding the inner wall and the outer wall. The honeycomb structure includes a reference Y-shaped unit having the reference wall, the outer wall, and a cell wall. The honeycomb structure includes a plurality of Y-shaped units extending in the same directions as the reference Y-shaped unit. For every Y-shaped unit in the central area and the reinforced outer peripheral area of the honeycomb structure, the cell walls of each Y-shaped unit has an equal wall thickness.