Plugged Honeycomb Structure with Local Reinforcement
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Solution Overview
Problem
Conventional honeycomb structures used in diesel particulate filters face challenges in balancing durability and pressure loss, with reinforcement methods either compromising filtration capacity or increasing mass, leading to impaired purification performance and fuel consumption.
Innovation Solution
A plugged honeycomb structure design where only outflow cells with maximum thermal stress are reinforced, maintaining filtration capacity and reducing mass, while alternately disposing inflow and outflow cells to inhibit pressure loss and end face cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing portions are formed in all cells to improve strength, then durability is improved, but passage capacity is reduced and pressure loss increases
Solution Approach 1:
The patent applies local quality by forming reinforcing portions only in specific outflow cells (those containing diagonal lines in the cross-section) rather than uniformly in all cells. This localized reinforcement approach maintains structural strength where thermal stress is highest while preserving passage capacity in other cells, thereby reducing overall pressure loss.
2Strength
If reinforcing portions are formed in inflow cells to improve strength, then durability is improved, but filtration area is reduced
Solution Approach 1:
The patent applies local quality by restricting reinforcing portions to specific outflow cells only, completely avoiding inflow cells. This ensures that the filtration area in inflow cells remains maximized while still providing reinforcement in outflow cells where thermal stress during regeneration causes the most damage.
3Strength
If mass of honeycomb structure is increased to improve strength, then durability is improved, but purification performance is impaired
Solution Approach 1:
The patent applies local quality by forming reinforcing portions only in specific outflow cells rather than uniformly throughout the entire structure. This localized approach minimizes the total mass increase while still providing necessary strength where thermal stress is highest, thereby maintaining purification performance.
4Strength
If arc-shaped R portions are formed in all corner portions to improve strength, then durability is improved, but passage capacity is reduced
Solution Approach 1:
The patent applies local quality by forming arc-shaped R portions only in corner portions of specific outflow cells (those containing diagonal lines) rather than in all cells. This selective reinforcement preserves passage capacity in unreinforced cells while providing strength where needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances mechanical strength, reduces pressure loss, and maintains purification performance without increasing fuel consumption, effectively addressing the paradox of improving durability and inhibiting pressure loss simultaneously.
Implementation Method 1
when exhaust gas is allowed to flow in from the inflow cells, particulate matter in the exhaust gas is trapped by the partition walls when the exhaust gas passes through the partition walls
Implementation Method 2
in order to inhibit breakage due to excessive thermal shock or mechanical shock caused in the intersection of the partition walls of the honeycomb structure
Implementation Method 3
in order to inhibit breakage due to excessive thermal shock or mechanical shock caused in the intersection of the partition walls
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
There is provided a plugged honeycomb structure having: a honeycomb structure 4 having porous partition walls 1 separating and forming inflow cells 2a and outflow cells 2b extending from an inflow side end face to the outflow side end face 12, outflow side plugging portions 5b, and inflow side plugging portions. At least one outflow cell 2b contained in an included angle of ±15° with at least one diagonal line drawn in the centroid cell present at the position having the shortest distance from the centroid O of the cross section as the center in the cross section perpendicular to the cell extension direction of the honeycomb structure 4 has a reinforcing portion in at least one corner portion where the partition walls intersect one another in the cross section perpendicular to the cell 2 extension direction.