Cordierite Honeycomb Filter Pore Structure for Low Pressure Loss
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Solution Overview
Problem
Conventional honeycomb filter manufacturing methods fail to produce filters that meet current exhaust gas regulations, leading to inadequate filtration efficiency and increased pressure loss.
Innovation Solution
A honeycomb filter with a partition wall composed of cordierite, average pore diameter of 20 to 30 μm, and a specific number and size of pores exceeding 3.0 μm, loaded with a catalyst for purifying exhaust gas, enhancing filtration efficiency and suppressing pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing methods with uncontrolled particle size and standard pore formers are used, then manufacturing simplicity is maintained, but filtration efficiency is insufficient and pressure loss increases
Solution Approach 1:
The invention changes the particle size parameter of cordierite raw material to a specific range (D10: 3-10 μm, D50: 15-30 μm, D90: 25-50 μm) and controls pore diameter (20-30 μm) to optimize both filtration efficiency and pressure loss characteristics while maintaining manufacturability
Solution Approach 2:
The invention uses a composite pore former system combining water-swellable particles (crosslinked starch) with foamable resin, creating a dual-mechanism pore formation system that achieves controlled pore size distribution and improved filtration performance
2Loss of energy
If pore size is increased to reduce pressure loss, then pressure loss decreases, but filtration efficiency deteriorates
Solution Approach 1:
The invention creates different pore size distributions in different regions of the partition wall, with larger pores (20-30 μm) providing low pressure loss pathways and smaller pores providing filtration function, achieving both low pressure loss and high filtration efficiency simultaneously
Solution Approach 2:
The invention optimizes the pore structure of cordierite partition walls with specific pore diameter (20-30 μm) and pore density (400 pores/mm² or more), creating a porous material that balances permeability for low pressure loss with sufficient surface area for high filtration efficiency
3Reliability
If catalyst loading is increased to improve purification performance, then purification efficiency improves, but pressure loss increases
Solution Approach 1:
The porous cordierite structure with optimized pore size (20-30 μm) and high pore density (400 pores/mm²) provides extensive surface area for catalyst loading while maintaining high permeability, allowing sufficient catalyst amount for purification without excessive pressure loss
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
The filter achieves improved filtration efficiency and reduced pressure loss by optimizing pore size and distribution, enabling effective catalyst loading and catalytic reactions.
Implementation Method 1
the porous partition wall functions as a filter that traps the particulate matter in an exhaust gas
Implementation Method 2
a catalyst for purifying exhaust gas loaded therein
Data Source
AI summary
A honeycomb filter includes a pillar-shaped honeycomb structure body having a porous partition wall disposed, surrounding a plurality of cells which serve as fluid through channels extending from a first end face to a second end face; and a plugging portion provided at an open end on the first end face side or the second end face side of each of the cells, wherein the partition wall is composed of a material containing cordierite as a main component thereof, an average pore diameter of the partition wall is 20 to 30 μm, an average equivalent circle diameter of pores existing at a surface of the partition wall and having equivalent circle diameters exceeding 3.0 μm is 18 to 30 μm, and a number per unit area of pores existing at a surface of the partition wall and having equivalent circle diameters exceeding 3.0 μm is 400 per mm2 or more.