Diesel Particulate Filter Single Slurry Washcoat
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Solution Overview
Problem
Current diesel particulate filter systems face challenges in efficiently reducing soot emissions while maintaining fuel efficiency and mechanical integrity, often requiring additional processing steps and increasing costs due to the need for separate membrane applications and catalytic washcoats.
Innovation Solution
A diesel particulate filter with a porous ceramic base coated with a washcoat comprising heat-tolerant micro-particles (1-40 microns) and colloidal particles (1-10 nm), primarily alumina, which also includes catalytic components like platinum and metal oxides, applied as a single slurry to function as both a soot-excluding membrane and a catalyst, reducing the need for separate membrane formation and additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a separate membrane is applied to the DPF surface to reduce soot-induced back pressure, then soot exclusion performance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the membrane function and catalytic washcoat into a single integrated coating layer applied to the DPF surface. This merged structure eliminates the need for separate membrane application steps while maintaining both soot exclusion and catalytic performance, thereby reducing device complexity and manufacturing cost.
Solution Approach 2:
The coating layer is designed to perform multiple functions simultaneously: it acts as a soot-excluding membrane while also providing catalytic activity for soot oxidation. This multi-functional approach consolidates what would traditionally require separate components, reducing overall system complexity.
2Reliability
If separate membrane formation and catalytic washcoat application are performed as distinct steps, then functional performance is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent merges membrane formation and catalytic washcoat application into a single coating step where both functions are deposited simultaneously. This eliminates the need for sequential processing steps, reducing manufacturing time while maintaining the required functional performance through careful formulation of the combined coating composition.
Solution Approach 2:
The coating composition is pre-formulated to contain both membrane-forming materials and catalytic components in appropriate proportions. This preliminary preparation allows both functions to be applied in one step without compromising the quality or performance that would result from separate application steps.
3Object-affected harmful factors
If additional processing steps are added to apply separate membrane and washcoat, then functional performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple processing steps (membrane application and washcoat application) into a single coating operation. This reduction in the number of processing steps directly lowers manufacturing cost while the integrated coating composition maintains the functional performance needed for effective soot emission reduction.
Solution Approach 2:
The single coating layer is designed to provide both membrane and catalytic functions, eliminating the need for multiple specialized processing steps. This multi-functional approach reduces manufacturing complexity and cost while achieving the same or better soot emission reduction performance.
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 approach effectively reduces soot-induced back pressure, simplifies the manufacturing process, and maintains catalytic performance, achieving efficient soot reduction and improved fuel efficiency without the need for extra membrane application steps.
Implementation Method 1
a set of heat tolerant micro-particles, wherein the micro-particles on the order of about 1 microns to about 40 micron across; and a set of heat tolerant colloidal particles, wherein the colloidal particles are on the order of about 1 nm to about 10 nm across, wherein said first and said second set of particles are deposited as a washcoat on at least one surface of the porous ceramic base
Data Source
Figure 1~2
Figure 3A~3D
Figure 4A~4B
AI summary
Aspects of the invention include Diesel Particulate Filters that include a layer of inert particles some of which are in contact with a catalyst and are associated with the surface of the filter. Particles associated with the inlet side of the filter are sized such that they coat portions of the inlet surface and portions of the channels that connect the inlet surface to the wall separating the inlet surface from the outlet surface.