EGR Filter Twill Weave Asymmetric Thermal Expansion
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Solution Overview
Problem
Conventional EGR filters clog easily due to soot, carbon, and foreign materials, leading to increased differential pressure and deteriorated cooling performance in the EGR system, as they are woven in plain weave with equal thermal expansion coefficients, making it difficult to remove deposited substances.
Innovation Solution
The EGR filter is woven in a twill weave with weft and warp wires of different materials, such as SUS 300 and SUS 400 series, which have different thermal expansion ratios, increasing the effective space and allowing for asymmetric thermal expansion to self-clean the filter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the EGR filter is woven with plain weave using wires of the same material, then the manufacturing process is simple and the structure is stable, but the filter clogs easily due to equal thermal expansion of weft and warp yarns making deposit removal difficult
Solution Approach 1:
The patent applies asymmetry by using different materials for weft and warp yarns, creating different thermal expansion coefficients. This asymmetric design allows differential thermal expansion that prevents deposit accumulation, resolving the contradiction between manufacturing simplicity and clogging resistance
Solution Approach 2:
The patent changes the material parameters of the yarns, specifically selecting materials with different thermal expansion coefficients (e.g., stainless steel for one direction, Invar for the other). This parameter change enables differential thermal expansion behavior that prevents clogging while maintaining ease of manufacture
2Stability of the object's composition
If the EGR filter uses wires with equal thermal expansion coefficients, then the structural stability is maintained, but the filter cannot self-clean as deposits accumulate between meshes
Solution Approach 1:
The patent introduces asymmetry in material selection between weft and warp yarns, creating different thermal expansion characteristics. This asymmetric design enables self-cleaning through differential expansion while maintaining overall structural stability of the filter
Solution Approach 2:
The patent enables self-service by designing the filter to automatically clean itself through differential thermal expansion. The asymmetric material properties cause the mesh to expand and contract differently in each direction, naturally dislodging deposits without external intervention
3Manufacturing precision
If the EGR filter mesh is tightly woven, then the filtration efficiency is high, but the effective space is reduced leading to faster clogging
Solution Approach 1:
The patent applies local quality by creating different mesh characteristics in different directions through the use of different yarn materials. The asymmetric thermal expansion creates localized space variations that prevent clogging while maintaining high filtration efficiency in the required direction
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 design prevents clogging by increasing the effective space and enabling easy removal of carbon, soot, and foreign materials, thereby maintaining the EGR system's performance and preventing filter blockages.
Implementation Method 1
woven in a twill weave with weft and warp wires of different materials, such as SUS 300 and SUS 400 series, which have different thermal expansion ratios, increasing the effective space and allowing for asymmetric thermal expansion to self-clean the filter
Data Source
AI summary
An EGR filter is configured for preventing clogging, which is disposed in an EGR line which recirculates a portion of the exhaust gas exhausted from an engine to the engine, and mounted in an EGR filter assembly which filters foreign material contained in the exhaust gas, wherein the EGR filter is woven to the twill weave with a weft and a warp of metal material.