Exhaust Gas Purification Catalyst Wall Flow Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing exhaust gas purification catalysts with a wall flow structure have limited opportunities for contact between exhaust gas and the catalyst layer, leading to suboptimal utilization of catalyst capacity and insufficient reduction of harmful components beyond regulatory limits.
Innovation Solution
The catalyst layer is strategically placed in the interior of the partition wall at sections A and C, and also on the surfaces of the partition wall at section B, increasing contact opportunities and enhancing purification efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the catalyst layer is provided only in the interior of the partition wall, then the structure is simple and manufacturing is easier, but the contact opportunities between exhaust gas and catalyst layer are limited, reducing purification efficiency
Solution Approach 1:
The partition wall is divided into multiple sections (first section, second section, third section) along the exhaust gas flow direction, with the catalyst layer selectively provided in different locations for each section. This segmentation allows optimization of purification efficiency in different zones while managing structural complexity
Solution Approach 2:
The catalyst layer is provided in different locations (interior vs. surface) depending on the specific section of the partition wall. In the first and third sections, it is provided in the interior, while in the second section, it is provided on the surface, creating local quality variations that maximize contact opportunities with exhaust gas
2Productivity
If the catalyst layer is provided only in the interior of the partition wall, then pressure loss is reduced, but the utilization of catalyst capacity is insufficient
Solution Approach 1:
The catalyst layer configuration transitions from a single-dimensional interior placement to a multi-dimensional arrangement that includes both interior and surface placements across different sections. This dimensional expansion increases catalyst capacity utilization without proportionally increasing pressure loss
3Productivity
If the catalyst layer is provided on the surface of the partition wall, then contact opportunities with exhaust gas increase, but manufacturing precision requirements increase
Solution Approach 1:
The partition wall is segmented into three sections, with the catalyst layer provided on the surface only in the second section. This segmentation isolates the manufacturing precision requirements to a specific zone, making the overall manufacturing process more manageable
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 utilizes the catalyst layer to achieve superior exhaust gas purification performance, improved warm-up properties, and reduced pressure loss, particularly at low to medium loads and high loads.
Implementation Method 1
the catalyst layer is provided in the interior of the partition wall, at the A section and the C section, while at the B section, the catalyst layer is provided not only in the interior of the partition wall, but also on the surfaces of the partition wall
Data Source
AI summary
The present invention provides an exhaust gas purification catalyst 10 having a substrate 11 having a wall flow structure, and a catalyst layer 20. The catalyst layer 20 has: an A section 20a provided in the interior of the partition wall 16, along an extension direction X of the partition wall 16, from an exhaust gas inflow end section 13; a C section 20c provided in the interior of the partition wall 16, along the extension direction X of the partition wall 16, from an exhaust gas outflow end section 15; and a B section 20b disposed between the A section 20a and the C section 20c in the extension direction X of the partition wall 16, and provided over the surface of the partition wall 16 on the side in contact with the inlet cell 12, the interior of the partition wall 16, and the surface of the partition wall 16 on the side in contact with the outlet cell 14.