Plugged Honeycomb Structure with Reinforced Outflow Cells
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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 measures often reducing filtration capacity and increasing mass, leading to impaired purification performance and fuel consumption.
Innovation Solution
A plugged honeycomb structure with reinforced outflow cells in specific corner portions and unreinforced inflow cells, where the reinforcing portions are strategically placed to minimize pressure loss while enhancing mechanical strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing portions are formed in corner portions of all cells to improve durability, then strength is improved, but the capacity of passages is remarkably reduced and pressure loss increases
Solution Approach 1:
The patent applies local quality by forming reinforcing portions only in corner portions of outflow cells, not in inflow cells. This localized reinforcement strategy provides structural strength where thermal stress is most severe (outflow side) while preserving passage capacity in inflow cells, thereby resolving the contradiction between durability and pressure loss.
2Strength
If reinforcing portions are formed in inflow cells to improve strength, then durability is improved, but the capacity of passages on the fluid inflow side is reduced and pressure loss increases
Solution Approach 1:
The patent implements local quality by differentiating the treatment of inflow cells and outflow cells. Inflow cells are left without reinforcing portions to maintain maximum passage capacity and filtration area, while outflow cells receive reinforcement where structural integrity is most critical due to thermal stress concentration.
3Strength
If the mass of the plugged honeycomb structure is increased by forming reinforcing portions, then strength is improved, but the time to reach necessary temperature for purification increases and fuel consumption is deteriorated
Solution Approach 1:
The patent applies local quality by forming reinforcing portions only in specific corner portions of outflow cells rather than throughout the entire structure. This selective reinforcement minimizes the added mass while still providing necessary strength, thereby reducing the energy required to heat the structure and lowering fuel consumption.
4Strength
If arc-shaped R portions are formed in corner portions of all cells to inhibit breakage, then durability is improved, but the capacity of passages is remarkably reduced
Solution Approach 1:
The patent implements local quality by forming arc-shaped R portions only in corner portions of outflow cells, not in inflow cells. This localized approach provides breakage resistance where thermal stress is most severe while preserving passage capacity in the remaining cells, resolving the contradiction between durability and passage volume.
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 configuration effectively inhibits the increase in pressure loss, improves durability, and maintains purification performance, allowing for efficient exhaust gas heating and reduced fuel consumption, thus resolving the paradoxical improvement of strength and pressure loss in honeycomb structures.
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, and purified gas from which the particulate matter is removed flows out from the outflow cells
Data Source
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AI summary
There is provided a plugged honeycomb structure 100 having: a honeycomb structure 4 having plural columnar honeycomb segments 8 having porous partition walls 1 separating and forming plurality of cells 2, outflow side plugging portions 5b, and inflow side plugging portions. At least the honeycomb segment 8 present at the centroid 0 of a cross section perpendicular to the cell extension direction of the honeycomb structure 4 is a reinforced segment 8x having a reinforcing portion 6 in at least one corner portion 21 where the partition walls 1 intersect one another in a cross section perpendicular to the cell 2 extension direction of the outflow cell 2b present in the intersection portion U of the diagonal lines P1, P2 in a cross section of the honeycomb segment 8.