Corrugated Substrate with Partially Open Channels for Exhaust Gas Treatment
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Solution Overview
Problem
Existing substrates with closed channels for treating exhaust gases from combustion engines face clogging issues, leading to increased pressure loss and reduced efficiency, while open channels are less effective in removing impurity particles, achieving only 10-15% reduction.
Innovation Solution
A substrate comprising corrugated sheets with depressions connected to flat wire mesh sheets, featuring partially open channels that allow exhaust gas flow, reducing particle and gas impurity retention through irregular surfaces and mixed gas flow, minimizing clogging and maintaining high efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If closed channels are used for exhaust gas treatment, then particle reduction is improved (70-99%), but channel clogging occurs and pressure loss increases
Solution Approach 1:
The substrate channels are segmented into alternating open and closed sections along the flow direction. The closed sections provide high particle reduction through wall flow filtration, while the open sections prevent complete clogging by allowing direct gas flow, thus resolving the contradiction between particle reduction and clogging resistance
Solution Approach 2:
Instead of using fully closed channels, the invention applies closed channel sections only partially along the substrate length. This partial application provides sufficient particle filtration while avoiding the complete clogging problem that affects fully closed channel systems
2Reliability
If open channels are used for exhaust gas treatment, then channel clogging is minimized, but particle reduction is poor (10-15%)
Solution Approach 1:
The substrate is divided into alternating open and closed channel sections. The open sections maintain clogging resistance while the closed sections provide enhanced particle reduction, achieving both goals simultaneously through spatial segmentation
Solution Approach 2:
The invention merges open channel and closed channel structures into a single substrate system. This combination allows the substrate to simultaneously exhibit the clogging resistance of open channels and the particle reduction capability of closed channels
3Manufacturing precision
If closed channels are used for exhaust gas treatment, then particle reduction is improved (70-99%), but pressure loss increases
Solution Approach 1:
The channel structure is segmented into alternating open and closed sections. The open sections provide low-pressure-drop flow paths that compensate for the pressure loss in closed sections, maintaining overall pressure efficiency while achieving high particle reduction in the closed sections
4Stress or pressure
If open channels are used for exhaust gas treatment, then pressure loss is low, but particle reduction is poor (10-15%)
Solution Approach 1:
The substrate channels are segmented into alternating open and closed sections along the flow direction. The open sections maintain low pressure loss while the closed sections provide high particle reduction, resolving the contradiction between pressure loss and particle reduction
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 substrate achieves significant improvements in particle and gas impurity reduction, up to 80% and 90% respectively, with minimal clogging and pressure loss, making it suitable for demanding conditions and various applications.
Implementation Method 1
These irregular surfaces and depressions also mix the gas thus minimizing standard deviation of gas retention time
Implementation Method 2
The surfaces of wire mesh sheet(s) also act as an effect open particle trap for exhaust gas particles. Impurity particles are more often attached to mesh sheet compared to smooth sheet
Implementation Method 3
A standard oxidation catalyst can oxidize majority VOF's and reduce this way 10 to 60 % of particle mass
Data Source
Figure 1
AI summary
The present invention relates a substrate having corrugated sheet(s) and chan-nel(s) for treating exhaust gases of combustion engines. The present invention also relates to methods for manufacturing and using said substrate having said open channel(s). The substrate (1) comprises at least one corrugated sheet (3) having depressions (3d) and one flat wire mesh sheet (2) having depressions (2d) which is connected to said corrugated sheet (3) and between said flat wire mesh sheet (2) and said corrugated sheet (3) there are at least partially open channels (POC) for exhaust gas (EG) flow, and the depth of depression (2d) of said flat wire mesh sheet (2) is 0.05-2.0 mm smaller than the height of the corrugation (3c) of said corrugated sheet (3).