Exhaust Gas Filter with Localized Catalyst for HC Purification
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Solution Overview
Problem
Conventional exhaust gas purifying filters struggle to achieve sufficient hydrocarbon (HC) purification due to insufficient thickness of the catalytic layer, leading to inadequate reaction with HC and increased pressure loss when attempting to improve HC purifying performance.
Innovation Solution
The exhaust gas purifying filter features a honeycomb structure with partitions having numerous pores and a catalyst layer supported on the partition surfaces, where the catalyst layer is thicker around narrow pore sections, ensuring effective HC removal without increasing catalyst load, thereby maintaining low pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the catalytic layer thickness is increased to improve HC purifying performance, then HC removal efficiency is improved, but pressure loss increases
Solution Approach 1:
The patent applies local quality by creating non-uniform catalyst distribution within the partition pores. The catalyst layer is concentrated in specific regions (such as near the pore openings or at specific depth ranges) rather than being uniformly distributed throughout the entire partition thickness. This localized catalyst placement ensures effective HC removal at critical interfaces while minimizing the total catalyst quantity and reducing pressure loss compared to uniform thick coating.
Solution Approach 2:
The patent utilizes the porous structure of the partition walls to support the catalyst layer. The pores provide a high surface area framework that allows efficient catalyst utilization. By forming the catalyst layer on or within the porous partition structure, the patent achieves high purifying performance with reduced catalyst loading, thereby minimizing pressure loss while maintaining effective HC removal.
2Reliability
If the catalyst loading is increased to enhance HC removal, then HC purifying performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent implements local quality by concentrating the catalyst in specific zones within the partition structure rather than uniform distribution. This strategic localization ensures that the catalyst is positioned where it is most effective for HC removal (such as near gas-catalyst interface regions), maximizing purifying performance per unit of catalyst while minimizing total catalyst quantity required.
Solution Approach 2:
The porous partition structure serves as a high-surface-area support that enables efficient catalyst utilization. The pore network provides extensive contact area between the exhaust gas and catalyst with minimal catalyst material, achieving high HC removal efficiency while reducing the quantity of expensive catalyst substance required.
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 configuration enhances HC removal efficiency while minimizing pressure loss, achieving superior HC purifying performance without the need for excessive catalyst loading.
Implementation Method 1
an exhaust gas purifying filter used with a HC purifying catalyst carried thereon
Data Source
AI summary
Provided is an exhaust gas purifying filter used with a HC purifying catalyst supported thereon. Numerous pores are formed in partitions of the exhaust gas purifying filter. In a cross-section of the partition, pores are open at a passage surface, having an open end of which the opening diameter is 50 μm or larger. In the cross-section of the partitions, the partitions include a narrow part where a pore diameter is 5 μm or more and the pore diameter becomes a minimum in a region. In the cross-section of the partitions, the region is positioned between a pair of virtual lines L1 and L2 extending from opposing sides of the opening end to a passage surface positioned opposite to the opening end along the wall thickness direction X, Z. The pore diameter at the narrow part is 6% or more and less than or equal to 20% of the opening diameter.


