Plugged Honeycomb Structure With Repeated Cell Sequence Pattern

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Solution Overview

Problem

Conventional plugged honeycomb structures with unique cell shapes experience increased pressure loss and reduced thermal shock resistance due to irregularities in the sequence of cells among honeycomb segments, which affect their performance as trapping filters in internal combustion engines.

Innovation Solution

A plugged honeycomb structure and segment design featuring prismatic-columnar shaped honeycomb segments with a bonding layer and plugging portions, where cells have a predetermined repeated sequence pattern in cross-section, including partition-wall entirely surrounded cells and circumferential-wall partially surrounded cells, ensuring continuity and optimal arrangement of cells between segments to minimize pressure loss and enhance thermal shock resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If honeycomb segments with unique cell shapes are used to create a plugged honeycomb structure, then filtration performance is improved, but pressure loss increases due to irregularities in cell sequence among segments

Engineering Contradiction:

Improvefiltration performanceVSAvoidpressure loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The plugged honeycomb structure is divided into multiple honeycomb segments that can be manufactured separately and then assembled. Each segment contains cells with unique shapes arranged in a specific sequence, allowing the structure to maintain filtration performance while reducing pressure loss through optimized segment-level cell arrangement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the honeycomb structure have different cell shapes and arrangements. The patent applies local quality by creating segments with specific cell sequences (e.g., alternating between first and second cell shapes) to optimize both filtration performance and pressure loss characteristics in different areas of the structure.

Inventive Principle:

Principle #3Local quality

2Reliability

If honeycomb segments with unique cell shapes are used to create a plugged honeycomb structure, then filtration performance is improved, but thermal shock resistance decreases due to irregularities in cell sequence

Engineering Contradiction:

Improvefiltration performanceVSAvoidthermal shock resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The structure is segmented into multiple honeycomb segments with controlled cell sequences. This segmentation allows for better thermal stress distribution and reduces thermal shock resistance deterioration while maintaining filtration performance through optimized cell arrangement in each segment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements local quality by creating segments with specific cell shape sequences that optimize thermal shock resistance. Different cell arrangements are used in different segments to balance filtration performance with thermal shock resistance, addressing the contradiction locally rather than uniformly throughout the entire structure.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If conventional honeycomb segments are used without considering cell sequence continuity, then manufacturing is simpler, but pressure loss and thermal shock resistance are reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidpressure loss

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent applies preliminary action by pre-determining and optimizing the cell sequence arrangement in each honeycomb segment during the manufacturing stage. This allows for better pressure loss characteristics and thermal shock resistance while maintaining manufacturing simplicity, as the optimized sequences are built into the segments before assembly.

Inventive Principle:

Principle #10Preliminary action

4Ease of operation

If honeycomb segments are assembled without maintaining cell sequence continuity at boundaries, then assembly is easier, but pressure loss increases

Engineering Contradiction:

Improveassembly easeVSAvoidpressure loss

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The patent creates honeycomb segments with universal cell sequence patterns that can be consistently assembled. The segments are designed with standardized interfaces and continuous cell sequences that extend across segment boundaries, allowing for easy assembly while maintaining low pressure loss through the continuous flow path created by the repeated cell sequence pattern.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9987582B2Plugged honeycomb structure and plugged honeycomb segment

Publication Date: 2018.06.05 NGK INSULATORS LTD

AI summary

A plugged honeycomb structure includes: a plurality of honeycomb segments, a bonding layer, and plugging portions to plug open ends of cells of the honeycomb segment. Each honeycomb segment is configured so that the cells having at least two types of different shapes have a predetermined repeated sequence pattern. A circumferential-wall partially surrounded cell in which a partition wall and a segment circumferential wall are disposed so as to surround the cell has an area of open end that has a specific ratio to an area of open end of a partition-wall entirely surrounded cell including the cross-sectional shape of the circumferential-wall partially surrounded cell. The repeated sequence pattern of the cells is kept at a boundary between two of the honeycomb segments bonded with the bonding layer at an inflow end face and an outflow end face.