EGR Cooler EM Filter Twill Weave to Prevent Soot Clogging
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Solution Overview
Problem
Conventional EM filters in EGR coolers suffer from clogging due to the accumulation of soot and foreign materials, which affects their efficiency and requires costly solutions to mitigate.
Innovation Solution
An EM filter with a twill weave structure is developed, utilizing metal wires with a specific diameter ratio and weaving pattern to create a three-dimensional space that prevents clogging, comprising horizontal and vertical wires forming a regular twill weave, optimized for effective gas flow and material discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plain weave structure is used in the EM filter, then the manufacturing process is simple, but clogging occurs due to accumulation of soot and foreign materials between meshes
Solution Approach 1:
The patent transitions from a two-dimensional plain weave structure to a three-dimensional twill weave structure. This dimensional change creates additional space and depth within the filter mesh, allowing soot and foreign materials to be trapped in the third dimension rather than accumulating in a flat plane, thereby preventing clogging while maintaining manufacturing feasibility
Solution Approach 2:
The patent utilizes the porous structure created by the twill weave pattern, where the intersecting horizontal and vertical wires form a three-dimensional network of pores. This porous configuration allows exhaust gas to pass through while trapping particulate matter in the depth of the mesh structure, improving filter performance without compromising ease of manufacture
2Reliability
If a hot wire method is used to solve soot clogging, then clogging is reduced, but costs increase due to installation of additional devices
Solution Approach 1:
The patent makes the filter structure itself perform the function of preventing soot accumulation through its three-dimensional twill weave configuration. The structural design inherently provides soot management capabilities without requiring external heating elements or additional active components, thereby maintaining reliability while avoiding increased device complexity
Solution Approach 2:
The patent replaces the thermal field approach (hot wire heating) with a structural/mechanical field solution (twill weave geometry). The three-dimensional mesh structure passively manages soot through its physical configuration rather than requiring thermal energy input, eliminating the need for additional heating devices and reducing overall system complexity
3Reliability
If the wire diameter ratio of horizontal to vertical wire is optimized in twill weave, then three-dimensional space is secured to prevent clogging, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies an optimized wire diameter ratio range (1.05 to 1.2) rather than requiring exact precision. This parameter optimization creates the necessary three-dimensional space for clogging prevention while providing a tolerable range that accommodates normal manufacturing variations, thereby balancing reliability improvement with manufacturing feasibility
Data Source
AI summary
An EM filter for an EGR cooler includes a gasket and a mesh filter including a horizontal wire and a vertical wire that are metal wires, wherein the horizontal wire and the vertical wire form a twill weave structure, and wherein a wire diameter of the horizontal wire with respect to a wire diameter of the vertical wire is greater than 1 and less than or equal to 1.3.