High isostatic strength honeycomb structures and extrusion dies therefor

A honeycomb structure comprising:

• intersecting porous walls extending between an inlet end and an outlet end of the honeycomb structure;
• inlet channels and outlet channels formed by the intersecting porous walls, inlet hydraulic diameters of the inlet channels being greater than outlet hydraulic diameters of the outlet channels, and the inlet channels comprising inlet corners with inlet corner radii Ri in a range from 10 mils (0.25 mm) to 14 mils (0.36 mm), and the outlet channels comprising outlet corners with outlet corner radii Ro in a range from 5 mils (0.13 mm) to 7 mils (0.18 mm);
• a centerpost defined by adjacent opposing inlet corners of two of the inlet channels and adjacent opposing outlet corners of two of the outlet channels;
• a first diagonal length D1 being a shortest distance between the opposing outlet corners of the two outlet channels, D1 being in a range from 25 mils (0.64 mm) to 31 mils (0.79 mm);
• a second diagonal length D2 being a shortest distance between the opposing inlet corners of the two inlet channels, D2 being in a range from 12 mils (0.30 mm) to 18 mils (0.46 mm);
• an aspect ratio of D1:D2 of the centerpost in a range from 1.6 to 2.0;
• and
• a channel density in a range from 250 cpsi to less than 350 cpsi.

A honeycomb structure comprising:

• intersecting porous walls extending between an inlet end and an outlet end of the honeycomb structure;
• inlet channels and outlet channels formed by the intersecting porous walls, inlet hydraulic diameters of the inlet channels being greater than outlet hydraulic diameters of the outlet channels, and the inlet channels comprising inlet corners with inlet corner radii Ri in a range from 16 mils (0.41 mm) to 20 mils (0.51 mm) and the outlet channels comprising outlet corners with outlet corner radii Ro in a range from 4 mils (0.10 mm) to 7 mils (0.18 mm);
• a centerpost defined by adjacent opposing inlet corners of two of the inlet channels and adjacent opposing outlet corners of two of the outlet channels;
• a first diagonal length D1 being a shortest distance between the opposing outlet corners of two of the outlet channels, D1 being in a range from 26 mils (0.66 mm) to 32 mils (0.81 mm);
• a second diagonal length D2 being a shortest distance between the opposing inlet corners of two of the inlet channels, D2 being in a range from 10 mils (0.25 mm) to 16 mils (0.41 mm);
• an aspect ratio D1:D2 of the centerpost in a range from 1.9 to 2.5;
• and
• a channel density in a range from 350 cpsi to 450 cpsi.

A honeycomb body comprising:

• a honeycomb structure comprising:
• intersecting porous walls extending between an inlet end and an outlet end of the honeycomb structure;
• inlet channels and outlet channels formed by the intersecting porous walls, the inlet channels comprising inlet hydraulic diameters HDi and the outlet channels comprising outlet hydraulic diameters HDo, the inlet channels comprising inlet corners with inlet corner radii Ri, and the outlet channels comprising outlet corners with outlet corner radii Ro;
• a centerpost defined by adjacent opposing inlet corners of two of the inlet channels and adjacent opposing outlet corners of two of the outlet channels;
• wherein the centerpost comprises:
• a first diagonal length D1 being a shortest distance between the adjacent opposing outlet corners;
• a second diagonal length D2 being a shortest distance between the adjacent opposing inlet corners;
• an aspect ratio D1:D2 being less than 2.7 when a hydraulic diameter ratio HDi:HDo is in a range from 1.4 to 1.6, and a channel density is in a range from 350 cpsi to 450 cpsi;
• and
• the aspect ratio D1:D2 being less than 2.0 and the outlet corner radii Ro being less than 7 mils when the hydraulic diameter ratio HDi:HDo is in a range from 1.2 to less than 1.4, and the channel density is in a range from 250 cpsi to less than 350 cpsi.