Exhaust Gas Filter with Zig-Zag Channels for Uniform Regeneration
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Solution Overview
Problem
Conventional particulate filters face issues with inhomogeneous deposit formation and temperature profiles leading to uneven regeneration, and their manufacturing is complex due to alternately closed and open exhaust gas channels.
Innovation Solution
A stack of porous material layers with concave and convex surface areas creates a zig-zag flow path, ensuring uniform particulate deposition and homogeneous regeneration, while the manufacturing method involves folding and embossing to simplify the creation of alternately closed and open exhaust gas flow channels without complex cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional particulate filter with alternately closed and open exhaust gas channels is used, then particulate filtration is achieved, but inhomogeneous deposit formation and temperature profile occur leading to uneven regeneration
Solution Approach 1:
The filter structure is segmented into multiple channels with alternating open/closed configurations at entry and exit sides. This segmentation creates distinct flow paths that collectively achieve uniform particulate deposition across the entire filter surface, preventing localized clogging while maintaining effective filtration.
Solution Approach 2:
Different regions of the filter are designed with locally optimized channel configurations. By alternating which channels are open at the entry side versus the exit side, the invention creates local variations in flow distribution that collectively produce homogeneous deposit formation and temperature profiles across the entire filter structure.
2Reliability
If conventional particulate filter with alternately closed and open exhaust gas channels is manufactured, then filtration function is achieved, but manufacturing complexity increases
Solution Approach 1:
The invention merges the functions of multiple separate filter elements into a single integrated structure. By combining alternating open/closed channel configurations within one filter body, the design achieves the required filtration function while reducing the number of separate components and assembly steps needed.
Solution Approach 2:
The filter structure serves multiple functions simultaneously: it provides particulate filtration, ensures uniform deposit distribution, and facilitates homogeneous regeneration all within a single integrated component. This multi-functionality eliminates the need for separate devices or complex multi-stage systems.
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 solution achieves uniform particulate filtration, prevents local clogging, and enhances mechanical stability through turbulent flow and catalytic coating, with a simplified manufacturing process that maintains filter effectiveness and stability.
Implementation Method 1
a turbulent through flow of the exhaust gas through the particulate filter is caused by the concave and convex surface areas of the material layers
Implementation Method 2
the material layers are made of a porous material being permeable to the exhaust gas
Implementation Method 3
a turbulent through flow of the exhaust gas through the particulate filter is caused by the concave and convex surface areas of the material layers. Thereby, a uniform deposition of particulates on the filtering material layers is achieved
Implementation Method 4
The material layers may have a catalytic coating, such that, since the deposition on the material layers is uniform, also a homogenous regeneration of the material layers is caused
Data Source
AI summary
An exhaust gas cleaning apparatus for cleaning an exhaust gas emitted from a combustion engine has a stack of plural material layers successively arranged on each other in a stacking direction. The material layers are made of a porous material being permeable to the exhaust gas. The stack has an entry side and an exit side. Plural exhaust gas flow channels are defined in the stacking direction between two adjacent material layers in the stack. The exhaust gas flow channels are defined by surfaces of the material layers which have, when viewed in a flow direction of the exhaust gas from the entry side to the exit side, a plurality of concave and convex areas. A first group of exhaust gas flow channels is formed to be open at the entry side of the stack and closed at the exit side thereof.