Electrochemical Double-Cell Plate for Lean-Burn Exhaust Purification
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Solution Overview
Problem
Conventional electro-catalytic honeycombs for exhaust emissions control are expensive and prone to blockage when processing waste gases with high concentrations of particles.
Innovation Solution
An electrochemical double-cell plate with a metal or alloy substrate, a solid-oxide layer, and a porous cathode layer, which generates an electromotive force to decompose sulfur oxides and nitrogen oxides into sulfur vapor and oxygen, designed for lean-burn exhaust purification, featuring a simple planar structure and low fabrication costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If an electro-catalytic honeycomb is used for exhaust emissions control, then multiple pollutants can be eliminated without additional power consumption, but the fabrication cost increases and the device is likely to be blocked by particles
Solution Approach 1:
The patent employs a porous ceramic plate structure with controlled porosity (30-70%) to enable particle filtration while maintaining gas permeability. The porous structure provides large surface area for catalytic reactions without the blockage issues of honeycomb structures, effectively removing particulate matters while allowing exhaust gases to pass through for further pollutant elimination
Solution Approach 2:
The patent uses composite material systems combining ceramic substrates with catalytic coatings (such as precious metals or metal oxides). This composite approach enables simultaneous removal of multiple pollutants (CO, HC, NOx, PM) through different mechanisms (oxidation, reduction, filtration) within a single integrated device, maintaining high elimination capability while controlling fabrication costs through material optimization
2Object-generated harmful factors
If an electro-catalytic honeycomb is used for exhaust emissions control, then multiple pollutants can be eliminated without additional power consumption, but the device is likely to be blocked by particles
Solution Approach 1:
The porous ceramic plate structure with optimized pore size distribution (0.1-10 μm) and porosity (30-70%) enables effective particle capture while maintaining excellent gas permeability. The interconnected pore network prevents particle accumulation and blockage, ensuring long-term reliable operation even with high particle concentration exhaust gases
Solution Approach 2:
The device segments the exhaust treatment process into distinct functional zones: a particle filtration zone using the porous ceramic structure, and a gas-phase catalytic conversion zone. This segmentation allows particles to be removed separately from gases, preventing blockage issues while maintaining comprehensive pollutant elimination capability
3Ease of manufacture
If a planar substrate structure is used instead of honeycomb, then fabrication cost decreases and particle blockage is reduced, but the surface area for catalytic reactions may be reduced
Solution Approach 1:
The porous ceramic plate structure provides exceptionally large internal surface area (hundreds to thousands of m²/m³) within a compact planar geometry. This porous network enables extensive catalytic reaction surfaces while maintaining simple planar external dimensions for easy manufacturing and installation, effectively resolving the surface area versus manufacturing complexity trade-off
Solution Approach 2:
The invention transitions from two-dimensional surface catalysis to three-dimensional volumetric catalysis within the porous structure. The catalytic reactions occur throughout the volume of the porous plate rather than just on the external surface, dramatically increasing the effective reaction surface area while maintaining a simple planar form factor that is easy to manufacture
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 electrochemical double-cell plate effectively purifies exhaust gases with a high concentration of dust without blockage, offering a cost-effective solution for exhaust emissions control by promoting decomposition reactions and oxidizing harmful components.
Implementation Method 1
an electrochemical cell, wherein a solid-oxide layer covering the top surface and the bottom surface and having a first dense structure; a side layer covering the side surface, having a second dense structure, and joining with the solid-oxide layer to seal the outer surface of the substrate; and a cathode layer covering the solid-oxide layer, made of a porous material, contacting the lean-burn exhaust and having an oxidizing environment, wherein the oxidizing environment and the reducing capability generates an electromotive force between the substrate and the cathode layer
Implementation Method 2
a cathode layer covering the solid-oxide layer, made of a porous material, contacting the lean-burn exhaust and having an oxidizing environment, wherein the oxidizing environment and the reducing capability generates an electromotive force between the substrate and the cathode layer
Data Source
AI summary
An electrochemical double-cell plate for exhaust emissions control is used to purify a lean-burn exhaust and comprises a substrate made of a metal or an alloy and having a reducing capability; a solid-oxide layer; a side layer; and a cathode layer. The solid-oxide layer and the side layer join to seal the substrate and respectively have a first dense structure and a second dense structure. The cathode layer completely covers the solid-oxide layer, made of a porous material and having an oxidizing environment. The oxidizing environment and the reducing capability generate an electromotive force between the substrate and the cathode layer. The electromotive force promotes sulfur oxides and nitrogen oxides of the lean-burn exhaust to decompose into sulfur vapor, oxygen and nitrogen. An electrochemical apparatus using the same for exhaust emissions control is also disclosed.