Plugged Honeycomb Structure Erosion Resistance
Solution Overview
Problem
Conventional plugged honeycomb structures used in exhaust gas purification systems face issues with erosion, durability, and space constraints, leading to decreased purification performance and increased pressure loss, which are not adequately addressed by existing solutions such as wire meshes or foreign substance-trapping pockets.
Innovation Solution
A plugged honeycomb structure with a cutout portion in the fluid passage end portion and strategically designed bonding material layers to inhibit erosion and enhance durability, allowing for effective space utilization and improved purification performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire mesh or shield plate is arranged in the flow passage to inhibit erosion, then durability is improved, but device complexity and pressure loss increase
Solution Approach 1:
The honeycomb structure is divided into multiple segments with different functions: erosion-resistant segments at the inflow end and filtration segments at the outflow end. This segmentation allows each part to perform its specific function optimally without requiring additional protective components throughout the entire structure.
Solution Approach 2:
Instead of adding protective layers over the entire honeycomb structure, the invention inverts the approach by making only the inflow end portions erosion-resistant while keeping the outflow end portions as standard filtration structures. This selective application reduces complexity while maintaining durability where it is most needed.
2Reliability
If foreign substance-trapping pockets are arranged in the flow passage, then erosion is inhibited, but the apparatus size increases
Solution Approach 1:
The erosion-resistant function is merged into the honeycomb structure itself by forming erosion-resistant portions directly as part of the segments. This eliminates the need for separate foreign substance-trapping pockets, as the structure provides both erosion resistance and filtration in a unified design.
Solution Approach 2:
The erosion-resistant segments serve multiple functions: they protect against erosion from foreign substances and also function as part of the overall filtration system. This multi-functionality eliminates the need for dedicated erosion-protection components, reducing apparatus size.
3Reliability
If the flow passage diameter is increased to arrange pockets, then erosion resistance is improved, but vehicle height must be increased
Solution Approach 1:
The structure is segmented into erosion-resistant portions at the inflow end and standard filtration portions at the outflow end. This allows the erosion-resistant segments to be positioned strategically without requiring an overall increase in passage diameter, maintaining compact vehicle installation height.
4Reliability
If cutout portion is formed in the honeycomb structure, then erosion resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The cutout portions are formed during the segment manufacturing process itself, before the segments are assembled into the final honeycomb structure. This preliminary action integrates the erosion-resistant feature formation into the base manufacturing process, avoiding complex post-assembly operations.
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5C
AI summary
There is provided a plugged honeycomb structure 20 for a diesel particulate filter, the plugged honeycomb structure 20 having a plurality of cells 5 functioning as fluid passages separated by partition wall 6 and plugging portions in such a manner that each of adjacent cells 5 is plugged in one end portion on the mutually opposite side; wherein the plugged honeycomb structure has a cutout portion 2 in a part of a fluid passage end portion, and each of predetermined cells 5 constituting the cutout portion 2 is plugged as well in a passage end portion; and a method for manufacturing the plugged honeycomb structure. The plugged honeycomb structure can have a desired end portion shape according to the purpose and application and inhibit deterioration in purification performance and strength due to shape processing and is excellent in raw material yield and costs.