Corrugated Metal Particle Separator for Exhaust Gas Filtration
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Solution Overview
Problem
Existing particle separators for internal combustion engine exhaust gases face challenges in maintaining permeability with low pressure loss and stability, especially when dealing with larger particles like ceramic and metallic chips, which can accumulate and cause performance issues and increased load over time.
Innovation Solution
A particle separator with a metallic layer having corrugations that span the housing cross-section, designed to retain only particles significantly larger than soot, featuring a robust and dimensionally stable structure with a corrugated surface that promotes particle displacement and abrasion, ensuring low pressure loss and improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a particle separator is designed to retain larger particles like ceramic and metallic chips, then particle retention capability is improved, but pressure loss increases due to particle accumulation over time
Solution Approach 1:
The particle separator is divided into multiple sections with different mesh sizes arranged in sequence. Coarse particles are retained by larger mesh openings first, then finer particles are captured by subsequent smaller mesh openings. This segmentation allows the system to retain various particle sizes while maintaining lower pressure loss compared to using a single fine mesh throughout.
Solution Approach 2:
The patent applies partial action by using larger mesh openings in certain sections rather than uniformly applying fine mesh filtration across the entire separator. This allows the system to focus retention efforts where needed while maintaining higher flow capacity in other areas, reducing overall pressure loss while still achieving effective particle retention.
2Reliability
If a particle separator uses a fine mesh structure to retain particles, then particle retention is improved, but structural stability and permeability deteriorate due to clogging and increased load
Solution Approach 1:
The separator structure is segmented into multiple zones with progressively different mesh sizes. The coarse sections handle large particle retention with minimal clogging, while finer sections handle smaller particles. This segmentation prevents uniform clogging across the entire structure, maintaining structural stability and permeability over time.
Solution Approach 2:
Different sections of the particle separator are assigned different mesh sizes based on local requirements. Areas with higher particle loads use larger openings to prevent clogging, while areas with lower loads can use finer mesh for better retention. This local differentiation optimizes both retention capability and structural stability throughout the separator.
3Reliability
If a particle separator retains particles over extended operation periods, then particle retention performance is improved, but load on the separator increases leading to reduced stability
Solution Approach 1:
The separator is segmented into multiple retention stages with progressively finer mesh sizes. As particles accumulate in upstream sections, the segmented structure allows continued operation without overwhelming the entire separator. Each segment handles a portion of the retention load, distributing mechanical stress and maintaining overall structural stability during extended operation.
Solution Approach 2:
The separator uses partial action by implementing multiple retention stages rather than a single high-capacity retention layer. This distributes the retention load across several sections, preventing any single area from becoming overloaded. The system achieves sustained particle retention performance while maintaining structural integrity through this distributed approach.
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 solution effectively retains larger particles while maintaining low pressure loss and enhancing the stability and durability of the particle separator, preventing damage to downstream components and ensuring efficient exhaust gas flow.
Implementation Method 1
a particle separator with a metallic layer having corrugations that span the housing cross-section, designed to retain only particles significantly larger than soot
Implementation Method 2
featuring a robust and dimensionally stable structure with a corrugated surface that promotes particle displacement and abrasion
Data Source
Figure 1~2
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Figure 5~6
AI summary
The invention relates to a particle separator (1) for treating the exhaust gases of an internal combustion engine (2), at least one metal layer (3) through which exhaust gas can flow being located in a housing (4) that comprises an inlet opening (5), an outlet opening (6), a cross-section (25) and a central axis (7). The at least one metal layer (3) has a corrugation (9) that spans the cross-section (25) of the housing (4). A particle separator of this type has a large surface for providing the lowest possible flow resistance and a low risk of clogging.