WO2024118391A1 - Pentagonal cell based honeycomb bodies - Google Patents

Abstract

Honeycomb bodies comprising honeycomb structures of intersecting walls, such as ceramic walls, configured to include pentagonal cells defining pentagonal channels. Porous filter bodies comprised of pentagon unit cell based honeycomb bodies.

Description

PENTAGONAL CELL BASED HONEYCOMB BODIES

Cross Reference to Related Application

[0001] This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Serial No. 63/428626, filed on November 29, 2022, the content of which is relied upon and incorporated herein by reference in its entirety.

BACKGROUND

Field

[0002] The present specification relates to honeycomb bodies comprising honeycomb structures of intersecting walls, such as ceramic walls, configured to include pentagonal cells defining pentagonal channels.

Technical Background

[0003] Engine exhaust gaseous emission abatement for both gasoline and diesel engines has been successfully managed using ceramic monolithic components in the exhaust system. The ceramic product can act as a carrier for a catalyst material, for example for a noble metal catalyst material, in converting polluting to non-polluting gases in the exhaust. Ceramic products have included catalytic converters and particulate filters used in the exhaust treatment strategy. Common monolithic ceramics contain square shaped cell geometry of certain cell density and wall thickness. A cellular structure with a cell geometry with alternating large and small channel configuration has been used for filter products to improve the ash storage capacity in inlet cells and to reduce the ash and soot loaded pressure drop for those particulate filter products.

SUMMARY

[0004] Aspects of the disclosure pertain to porous filter bodies comprised of pentagon unit cell based honeycomb bodies and methods for their manufacture and use.

[0005] In one aspect, honeycomb bodies are disclosed herein comprising a honeycomb structure comprised of a matrix of a plurality of cell walls extending in an axial direction from a first end to a second end, wherein at least some of the walls intersect with each other in a cellular configuration defining a plurality of axial channels extending from the first end to the second end, wherein the cellular configuration comprises: rows of octagon cell structures (“octagon rows”), each octagon row being comprised of a series of abutting octagon cell structures, preferably whose centers are aligned in a straight line, each abutting octagon cell structure sharing a common cell wall with another abutting octagon cell structure; and rows of pentagonal cells (“pentagon rows”), each pentagon row being comprised of a series of abutting pentagonal cells, wherein each abutting pentagonal cell shares a common pentagon cell wall with another abutting pentagonal cell; wherein each octagon row is spaced away from another octagon row by a respective pentagon row disposed between pairs of octagon rows, and wherein each abutting pentagonal cell shares a common cell wall with at least one abutting octagon cell structure.

[0006] In embodiments, the octagon rows are separated from each other by pentagon rows.

[0007] In embodiments, the cellular configuration comprises a plurality of abutting octagon cell structures.

[0008] In embodiments, each of the octagon rows comprises at least two abutting octagon cell structures.

[0009] In embodiments, each of the octagon rows comprises at least three abutting octagon cell structures.

[0010] In embodiments, the octagon cell structures are comprised of outer cell walls, and the common cell wall shared between an abutting octagon cell structure and another abutting octagon cell structure is an outer cell wall of the octagon cell structures. In embodiments, a plurality of the octagon cell structures further comprises inner walls surrounded by the outer walls; in embodiments, the octagon cell structures further comprise respective inner pentagonal cells inside respective octagon cell structures, each inner pentagonal cell being comprised of the inner walls and the outer cell walls of its respective octagon cell structure; in embodiments, the inner cell walls are thinner than the outer cell walls; in embodiments, the inner cell walls intersect with the outer cell walls at substantially right angles; in embodiments, the inner cell walls intersect at a geometric center of its respective octagon cell structure; in embodiments, the inner walls comprise one or more inwardly extending fin walls inside one or more respective octagon cell structures. [0011] In embodiments, each channel defined by an octagon cell structure has a transverse area greater than a transverse area of each channel defined by a pentagonal cell.

[0012] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0013] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 4% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0014] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 10% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0015] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 25% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0016] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 50% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0017] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 100% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0018] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 150% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0019] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 200% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0020] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 250% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells. [0021] In embodiments, a ratio of an aggregate transverse area of the channels defined by the octagon cell structures divided by aggregate transverse area of the channels of the outlet cells is greater than 1.

[0022] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 2.

[0023] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 3.

[0024] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 4.

[0025] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 5.

[0026] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 6.

[0027] In embodiments, the honeycomb body further comprises a first set of sealing plugs disposed in the channels of the octagon cell structures proximate one end of the honeycomb body, and a second set of sealing plugs disposed in the channels of the pentagonal cell structures proximate an opposite end of the honeycomb body.

[0028] In embodiments, the honeycomb body further comprises sealing plugs disposed in the channels of the octagon cell structures.

[0029] In embodiments, the honeycomb body further comprises sealing plugs disposed in the channels of the octagon cell structures proximate the first end of the honeycomb body.

[0030] In embodiments, the honeycomb body further comprises sealing plugs disposed in the channels of the pentagonal cell structures.

[0031] In embodiments, the honeycomb body further comprises sealing plugs disposed in the channels of the pentagonal cell structures proximate the second end of the honeycomb body.

[0032] In another aspect, honeycomb bodies are disclosed herein comprising a honeycomb structure comprised of: a matrix of a plurality of cell walls extending in an axial direction from a first end to a second end, wherein at least some of the walls intersect with each other in a cellular configuration defining a plurality of axial channels extending from the first end to the second end, wherein the cellular configuration comprises: rows of octagon cell structures (“octagon rows”), each octagon row being comprised of a series of abutting octagon cell structures, each abutting octagon cell structure sharing a common cell wall with another abutting octagon cell structure; and rows of pentagonal cells (“pentagon rows”), each pentagon row being comprised of a series of abutting pentagonal cells, wherein each abutting pentagonal cell shares a common pentagon cell wall with another abutting pentagonal cell; wherein each octagon row is spaced away from another octagon row by a respective pentagon row disposed between pairs of octagon rows, wherein each abutting pentagonal cell shares a common cell wall with at least one abutting octagon cell structure.

[0033] In embodiments, the geometric centers of the octagon cell structures are aligned in a straight line in their respective rows.

[0034] In embodiments, the octagon rows are separated from each other by pentagon rows.

[0035] In embodiments, the cellular configuration comprises a plurality of abutting octagon cell structures.

[0036] In embodiments, each of the octagon rows comprises at least two abutting octagon cell structures.

[0037] In embodiments, each of the octagon rows comprises at least three abutting octagon cell structures.

[0038] In embodiments, the octagon cell structures are comprised of outer cell walls, and the common cell wall shared between an abutting octagon cell structure and another abutting octagon cell structure is an outer cell wall of the octagon cell structures. In some of these embodiments, a plurality of the octagon cell structures further comprises inner walls surrounded by the outer walls. In some embodiments, the octagon cell structures further comprise respective inner pentagonal cells inside respective octagon cell structures , each inner pentagonal cell being comprised of the inner walls and the outer cell walls of its respective octagon cell structure; in some embodiments, the inner cell walls are thinner than the outer cell walls; in some embodiments, the inner cell walls intersect with the outer cell walls at substantially right angles; in some embodiments, the inner cell walls intersect at a geometric center of its respective octagon cell structure; in some embodiments, the inner walls comprise one or more inwardly extending fin walls inside one or more respective octagon cell structures. [0039] In embodiments, each channel defined by an octagon cell structure has a transverse area greater than a transverse area of each channel defined by a pentagonal cell.

[0040] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0041] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 4% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0042] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 10% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0043] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 25% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0044] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 50% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0045] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 100% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0046] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 150% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0047] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 200% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells. [0048] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 250% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0049] In embodiments, a ratio of an aggregate transverse area of the channels defined by the octagon cell structures divided by aggregate transverse area of the channels of the outlet cells is greater than 1.

[0050] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 2.

[0051] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 3.

[0052] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 4.

[0053] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 5.

[0054] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 6.

[0055] In embodiments, the honeycomb body further comprises a first set of sealing plugs disposed in the channels of the octagon cell structures proximate one end of the honeycomb body, and a second set of sealing plugs disposed in the channels of the pentagonal cell structures proximate an opposite end of the honeycomb body.

[0056] In embodiments, the honeycomb body further comprises sealing plugs disposed in the channels of the octagon cell structures.

[0057] In embodiments, the honeycomb body further comprises sealing plugs disposed in the channels of the octagon cell structures proximate the first end of the honeycomb body.

[0058] In embodiments, the honeycomb body further comprises sealing plugs disposed in the channels of the pentagonal cell structures.

[0059] In embodiments, the honeycomb body further comprises sealing plugs disposed in the channels of the pentagonal cell structures proximate the second end of the honeycomb body. [0060] In another aspect, honeycomb bodies are disclosed herein comprising a honeycomb structure comprised of: a matrix of a plurality of cell walls extending in an axial direction from a first end to a second end, wherein at least some of the walls intersect with each other in a cellular configuration defining a plurality of axial channels extending from the first end to the second end, wherein the cellular configuration comprises: a plurality of rectangle cell structures, and a plurality of octagon cell structures, wherein each octagon cell structure shares four common cell walls with four other abutting octagon cells, wherein each rectangle cell structure shares four common cell walls with four abutting octagon cell structures, and wherein the octagon cell structures further comprise inner walls disposed inside the octagon cell structures and configured to form inner pentagonal cells.

[0061] In embodiments, the rectangle cell structures further comprise inner walls which are disposed inside the rectangle cell structures and which are configured to form inner rectangular cells. In some embodiments, the inner walls intersect with other walls of the rectangle cell structure at substantially right angles. In some embodiments, the inner cell walls intersect at a geometric center of its respective rectangle cell structure.

[0062] In embodiments, each channel defined by an octagon cell structure has a transverse area greater than a transverse area of each channel defined by a pentagonal cell.

[0063] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0064] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 4% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0065] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 10% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0066] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 25% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells. [0067] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 50% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0068] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 100% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0069] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 150% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0070] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 200% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0071] In embodiments, the channels defined by the octagon cell structures have an aggregate transverse area which is 250% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

[0072] In embodiments, a ratio of an aggregate transverse area of the channels defined by the octagon cell structures divided by aggregate transverse area of the channels of the outlet cells is greater than 1.

[0073] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 2.

[0074] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 3.

[0075] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 4.

[0076] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 5.

[0077] In embodiments, a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 6.

[0078] Additional features and advantages will be set forth in the detailed description, which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments described herein, comprising the detailed description, which follows, the claims, as well as the appended drawings.

[0079] It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein, and together with the description serve to explain the principles and operations of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0080] FIG. 1 schematically illustrates a transverse cross-sectional view, and a closeup portion view, of an embodiment of a honeycomb body disclosed herein comprising a honeycomb structure comprising a pentagon unit cells and octagon cell structures.

[0081] FIG. 2 schematically illustrates a transverse cross-sectional view, and a closeup portion view, of an embodiment of a honeycomb body disclosed herein comprising a honeycomb structure comprising a honeycomb structure comprising a pentagon unit cells and octagon cell structures similar to that shown in FIG. 1 but comprising relatively thicker cell walls and nested relatively thinner cell walls.

[0082] FIG. 3 schematically illustrates a transverse cross-sectional view, and a closeup portion view, of an embodiment of a honeycomb body disclosed herein comprising a honeycomb structure comprised of octagon cell structure and pentagon unit cell geometry, wherein the octagon cell structures are free of pentagon unit cells.

[0083] FIG. 4 schematically illustrates a transverse cross-sectional close-up portion view of three examples of a honeycomb body with square cells and filleted comers wherein the honeycomb structure of the honeycomb filter body has cells of alternating size such that an alternating checkerboard-type plug pattern of smaller size cells plugged at an inlet end and larger size cells plugged at an opposite outlet end (also known as an “ACT” type wall flow filter): (i) cells of all the same size such that an alternating checkerboard-type plug pattern at one end and an opposite end for a honeycomb filter body provides an outlet/inlet area ratio of 1.0; (ii) cells of alternating size such that an alternating checkerboard-type plug pattern of smaller size cells plugged at an inlet end and larger size cells plugged at an opposite outlet end for a honeycomb filter body provides an outlet/inlet area ratio of 1.3; and (iii) cells of alternating size such that an alternating checkerboard-type plug pattern of smaller size cells plugged at an inlet end and larger size cells plugged at an opposite outlet end for a honeycomb filter body provides an outlet/inlet area ratio of 1.5.

[0084] FIG. 5A schematically illustrates a transverse cross-sectional close-up portion view of an embodiment of a honeycomb body disclosed herein comprised of octagon cell structures and pentagon cells, wherein the ratio of the transverse open area of the octagon cell structure to the transverse open area of the pentagon cell is 2.7.

[0085] FIG. 5B schematically illustrates a transverse cross-sectional close-up portion view of an embodiment of a honeycomb body disclosed herein comprised of octagon cell structures and pentagon cells, wherein the ratio of the transverse open area of the octagon cell structure to the transverse open area of the pentagon cell is 4.

[0086] FIG. 5C schematically illustrates a transverse cross-sectional close-up portion view of an embodiment of a honeycomb body disclosed herein comprised of octagon cell structures and pentagon cells, wherein the ratio of the transverse open area of the octagon cell structure to the transverse open area of the pentagon cell is 6.7.

[0087] FIG. 6 schematically illustrates a transverse cross-sectional close-up portion view of an embodiment of a honeycomb body disclosed herein comprised of octagon cell structures and pentagon cells, similar to the embodiment shown in FIG. 3 but further comprising inwardly extending fins extending into the interior channel of octagon cell structures.

[0088] FIG. 7 schematically illustrates an exemplary unit cell corresponding to FIG. 3 for the pentagon+octagon cell structure considered for pressure drop flow modeling, as presented in FIG. 8.

[0089] FIG. 8 graphically illustrates modeled pressure drop performance for examples which used as a baseline a 350/7 (350 cpsi/ 7 mils thick walls) geometry and 2 inch square cells, for various inlet velocities (meters/second). [0090] FIG. 9 schematically illustrates a transverse cross-sectional close-up portion view of an embodiment of a honeycomb body disclosed herein comprised of octagon cell structures and rectangle cell structures, wherein the octagon cell structures are comprised of pentagon cells

DETAILED DESCRIPTION

[0091] Reference will now be made in detail to embodiments of articles for emissions treatment, for example, filtration articles, comprising a plugged honeycomb filter body comprising inorganic deposits disposed on walls defining inlet channels of the plugged honeycomb filter body, the inorganic deposits comprising fumed silica particles, embodiments of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

[0092] Embodiments disclosed herein comprise cellular structures, or cell geometries, based on a pentagon (or pentagonal) unit cell (or pentagon cell). Such cellular structures may be implemented to increase a ratio of channel volume to surface area for the honeycomb bodies. Embodiments comprising the pentagon unit cell may be configured in various arrangements and/or in multiple combinations which can provide a wide range of ratio of inlet area to outlet area of the honeycomb body, and can provide a wider range than known all square channel geometry (large inlet square channels and small outlet square channels) as well as large octagonal inlet channels and small square outlet channels, as well as hexagonal cells. Embodiments herein utilizing pentagonal unit cells are also expected to improve catalyst material utilization as compared to the aforementioned known geometries. Optionally, in embodiments a fin feature may be added onto channel walls such as to gain further performance advantages in emission treatment technology. Furthermore, embodiments incorporating nested cell designs, wherein some of cell walls are thicker, such as to provide improved ISO strength performance, can further strengthen the mechanical integrity of the honeycomb body. We have found that the cellular structure designs can be very flexibly incorporated to reduce or eliminate some of the limitations experienced in either square only or hexagon only cell geometry honeycomb bodies, for example, face plugging issues (wherein soot accumulates and blocks parts or whole inlet cells) which have been observed in square channel substrates, and such cellular structure designs disclosed herein can avoid difficulties associated with the production of extrusion dies with the large square cell - small square cell (ACT) design, or large octagonal cell - small square cell design, or with a hexagon cell geometry.

EXAMPLES

[0093] Embodiments will be further understood by the following non-limiting examples.

[0094] FIG. 1 schematically illustrates a transverse cross-sectional view, and a closeup portion view, of an embodiment of a honeycomb body disclosed herein comprising a honeycomb structure with a pentagon unit cell geometry for substrates and filter application use in diesel and gasoline exhaust aftertreatment system. The pentagonal cells of the pentagon unit cell geometry have five cell walls, or five edges, and two angles greater than 90 degrees, which define pentagonal channels. In embodiments such as illustrated, the wall thickness (average wall thickness of the straight portions of the walls) has constant thickness. For example in some embodiments the honeycomb structure comprises cell walls with straight portions of uniform thickness, such as 7 mils.

[0095] FIG. 2 schematically illustrates a transverse cross-sectional view, and a closeup portion view, of an embodiment of a honeycomb body disclosed herein comprising a honeycomb structure with a pentagon unit cell geometry similar to that shown in FIG. 1 but comprising relatively thicker cell walls and nested relatively thinner cell walls. FIG. 2 illustrates octagonal cells of relatively thicker walls surrounding intersecting relatively thinner walls which intersect with each other, and which intersect with the relatively thicker surrounding walls. We have found that by incorporating thinner walls, such as the embodiment illustrated in FIG. 2, improves pressure drop performance of the honeycomb body, and can improve the coating of the honeycomb structure such as with catalytic material coating (“catalytic coating”).

[0096] FIG. 3 schematically illustrates a transverse cross-sectional view, and a closeup portion view, of an embodiment of a honeycomb body disclosed herein comprising a honeycomb structure comprised of octagon cell structure and pentagon unit cell geometry, wherein the octagon cell structures are free of pentagon unit cells. [0097] FIG. 4 schematically illustrates a transverse cross-sectional close-up portion view of three examples of a honeycomb body with square cells and filleted comers: (i) cells of all the same size such that an alternating plug pattern at one end and an opposite end for a honeycomb filter body provides an outlet/inlet area ratio of 1.0; (ii) cells of alternating size such that an alternating checkerboard-type plug pattern of smaller size cells plugged at an inlet end and larger size cells plugged at an opposite outlet end for a honeycomb filter body provides an outlet/inlet area ratio of 1.3; and (iii) cells of alternating size such that an alternating checkerboard-type plug pattern of smaller size cells plugged at an inlet end and larger size cells plugged at an opposite outlet end for a honeycomb filter body provides an outlet/inlet area ratio of 1.5. As seen in the three examples, for a given geometry (cells per square inch, cpsi; wall thickness), with increasing outlet/inlet area ratio, the size of the outlet channel increases relative to the size of the inlet channel, and eventually reaches a practical limit of a smallest distance separating the diagonally opposite outlet channels (as most clearly illustrated among the examples by the third example with outlet/inlet area ratio of 1.5).

[0098] FIG. 5A schematically illustrates a transverse cross-sectional close-up portion view of an embodiment of a honeycomb body disclosed herein comprised of octagon cell structures and pentagon cells, wherein the ratio of the transverse open area of the octagon cell structure to the transverse open area of the pentagon cell is 2.7.

[0099] FIG. 5B schematically illustrates a transverse cross-sectional close-up portion view of an embodiment of a honeycomb body disclosed herein comprised of octagon cell structures and pentagon cells, wherein the ratio of the transverse open area of the octagon cell structure to the transverse open area of the pentagon cell is 4.

[00100] FIG. 5C schematically illustrates a transverse cross-sectional close-up portion view of an embodiment of a honeycomb body disclosed herein comprised of octagon cell structures and pentagon cells, wherein the ratio of the transverse open area of the octagon cell structure to the transverse open area of the pentagon cell is 6.7.

[00101] FIG. 6 schematically illustrates a transverse cross-sectional close-up portion view of an embodiment of a honeycomb body disclosed herein comprised of octagon cell structures and pentagon cells, similar to the embodiment shown in FIG. 3 but further comprising inwardly extending fins extending into the interior channel of octagon cell structures.

[00102] FIG. 7 schematically illustrates an exemplary unit cell corresponding to FIG. 3 for the pentagon+octagon cell structure considered for pressure drop flow modeling, as described below and as shown in FIG. 8.

[00103] FIG. 8 graphically illustrates modeled pressure drop performance for examples which used as a baseline a 350/7 (350 cpsi/ 7 mils thick walls) geometry and 2 inch square cells, for various inlet velocities (meters/second). The highest to lowest pressure drop performance was: 350/7 square; all pentagon cells; nested pentagon cells; cross-section pentagon cells; octagon cell structure + pentagon cells. FIG. 8 illustrates the substantial drop in backpressure that can be achieved with embodiments disclosed herein. While the pentagon cell shape by itself offers a slight advantage over the square shape, as it is closer to circular, and results in a slightly higher hydraulic diameter and open frontal area compared to the square cell. Without being held to theory, we believe that this feature can lead to more uniform washcoat deposition in the cell for more efficient catalyst utilization. Also, the thinner internal walls of the nested design further reduce the backpressure, and the larger channels of the cross section and ACT designs result in even lower backpressure.

[00104] Table 1 show geometric differences between the substrates of FIG. 8 and the resulting difference in pressure drop. The standard pentagon is nearly the same as the 350/7 square design in terms of open frontal area OF A, hydraulic diameter Dh, and backpressure. The nested design increases the OF A which reduces the pressure drop further. For filter applications, the hydraulic diameter of the inlet channels becomes important as it determines how much the backpressure will increase as soot accumulates in the inlet channels. Both the ACT and cross section pentagon designs show a much larger hydraulic diameter of the inlet channels allowing for ACT ratios of 2.5 and 2.11, respectively. This represents a significant advantage over what is possible with square cell honeycomb structures (including square cell ACT honeycomb structures). Even when used as substrates (as opposed to a filter body with plugged substrate), the honeycomb structures with higher ACT give a much lower pressure drop across the channels than the square cell honeycomb structures. [00105] Table 1 - Performance characteristics of pentagon honeycomb structures compared to 350/7 square substrate.

[00106] FIG. 9 schematically illustrates a transverse cross-sectional close-up portion view of an embodiment of a honeycomb body disclosed herein comprised of octagon cell structures and rectangle cell structures, wherein the octagon cell structures are comprised of pentagon cells which are arranged to provide additional cross section walls which are capable of enhancing isometric strength (ISO) performance and capable of enhancing flow mixing (such as inducing turbulent flow) of exhaust gases, for example to provide improved catalyst contact between the exhaust stream and catalyst material that may be disposed on the cell walls of the honeycomb body. The rectangle cell structures may also be provided with intersecting interior walls, such as to produce additional such benefits.

[00107] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Thus, it is intended that the specification cover the modifications and variations of the various embodiments described herein provided such modification and variations come within the scope of the appended claims and their equivalents.

Claims

What is claimed is:

1. A honeycomb body comprising a honeycomb structure comprised of: a matrix of a plurality of cell walls extending in an axial direction from a first end to a second end, wherein at least some of the walls intersect with each other in a cellular configuration defining a plurality of axial channels extending from the first end to the second end, wherein the cellular configuration comprises: rows of octagon cell structures (“octagon rows”), each octagon row being comprised of a series of abutting octagon cell structures, each abutting octagon cell structure sharing a common cell wall with another abutting octagon cell structure; and rows of pentagonal cells (“pentagon rows”), each pentagon row being comprised of a series of abutting pentagonal cells, wherein each abutting pentagonal cell shares a common pentagon cell wall with another abutting pentagonal cell; wherein each octagon row is spaced away from another octagon row by a respective pentagon row disposed between pairs of octagon rows, and wherein each abutting pentagonal cell shares a common cell wall with at least one abutting octagon cell structure.

2. The honeycomb body of claim 1 each of the octagon rows comprises at least two abutting octagon cell structures.

3. The honeycomb body of claim 1 each of the octagon rows comprises at least three abutting octagon cell structures.

4. The honeycomb body of claim 1 the octagon cell structures are comprised of outer cell walls, and the common cell wall shared between an abutting octagon cell structure and another abutting octagon cell structure is an outer cell wall of the octagon cell structures.

5. The honeycomb body of claim 4 wherein a plurality of the octagon cell structures further comprises inner walls surrounded by the outer walls.

6. The honeycomb body of claim 5 wherein the octagon cell structures further comprise respective inner pentagonal cells inside respective octagon cell structures, each inner pentagonal cell being comprised of the inner walls and the outer cell walls of its respective octagon cell structure.

7. The honeycomb body of claim 5 wherein the inner cell walls are thinner than the outer cell walls.

8. The honeycomb body of claim 5 wherein the inner cell walls intersect with the outer cell walls at substantially right angles.

9. The honeycomb body of claim 5 wherein the inner cell walls intersect at a geometric center of its respective octagon cell structure.

10. The honeycomb body of claim 5 wherein the inner walls comprise one or more inwardly extending fin walls inside one or more respective octagon cell structures.

11. The honeycomb body of claim 1 wherein each channel defined by an octagon cell structure has a transverse area greater than a transverse area of each channel defined by a pentagonal cell.

12. The honeycomb body of claim 1 wherein the channels defined by the octagon cell structures have an aggregate transverse area greater than an aggregate transverse area of the channels defined by the pentagonal cells.

13. The honeycomb body of claim 1 wherein the channels defined by the octagon cell structures have an aggregate transverse area which is 4% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

14. The honeycomb body of claim 1 wherein the channels defined by the octagon cell structures have an aggregate transverse area which is 10% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

15. The honeycomb body of claim 1 wherein the channels defined by the octagon cell structures have an aggregate transverse area which is 25% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

16. The honeycomb body of claim 1 wherein the channels defined by the octagon cell structures have an aggregate transverse area which is 50% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

17. The honeycomb body of claim 1 wherein the channels defined by the octagon cell structures have an aggregate transverse area which is 100% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

18. The honeycomb body of claim 1 wherein the channels defined by the octagon cell structures have an aggregate transverse area which is 150% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

19. The honeycomb body of claim 1 wherein the channels defined by the octagon cell structures have an aggregate transverse area which is 200% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

20. The honeycomb body of claim 1 wherein the channels defined by the octagon cell structures have an aggregate transverse area which is 250% or more greater than an aggregate transverse area of the channels defined by the pentagonal cells.

21. The honeycomb body of claim 1 wherein a ratio of an aggregate transverse area of the channels defined by the octagon cell structures divided by aggregate transverse area of the channels of the outlet cells is greater than 1.

22. The honeycomb body of claim 1 wherein a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 2.

23. The honeycomb body of claim 1 wherein a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 3.

24. The honeycomb body of claim 1 wherein a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 4.

25. The honeycomb body of claim 1 wherein a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 5.

26. The honeycomb body of claim 1 wherein a ratio of aggregate transverse area of the channels of the inlet cells divided by aggregate transverse area of the channels of the outlet cells is greater than 6.

27. The honeycomb body of claim 1 further comprising a first set of sealing plugs disposed in the channels of the octagon cell structures proximate one end of the honeycomb body, and a second set of sealing plugs disposed in the channels of the pentagonal cell structures proximate an opposite end of the honeycomb body.

28. The honeycomb body of claim 1 further comprising sealing plugs disposed in the channels of the octagon cell structures.

29. The honeycomb body of claim 1 further comprising sealing plugs disposed in the channels of the octagon cell structures proximate the first end of the honeycomb body.

30. The honeycomb body of claim 1 further comprising sealing plugs disposed in the channels of the pentagonal cell structures.

31. The honeycomb body of claim 1 further comprising sealing plugs disposed in the channels of the pentagonal cell structures proximate the second end of the honeycomb body.