Particulate Filter Ash Density Enhancement via Water Evaporation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Particulate filters in diesel and gasoline after-treatment systems face increased pressure drop due to accumulating ash particles, which do not burn during filter regeneration, leading to reduced fuel efficiency and requiring frequent maintenance for ash removal, with existing methods like thermal sintering posing risks and inefficiencies.
Innovation Solution
Introducing a work fluid, such as water, into the particulate filter channels to increase ash packing density by agglomeration through evaporation, reducing the ash volume and extending filter life, which can be done in-situ or during maintenance, using existing on-board hardware for fluid injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal sintering is used to remove ash from the filter, then ash removal effectiveness is improved, but fuel consumption increases and filter damage risks increase
Solution Approach 1:
The patent applies phase transition of water from liquid to vapor state through evaporation. Water is introduced in liquid form into the filter channels, where it then evaporates into vapor, creating expansion forces that mechanically disrupt and remove ash deposits from the filter walls and channels, thereby achieving ash removal without requiring high-temperature thermal sintering
Solution Approach 2:
The patent replaces the thermal-mechanical sintering process with a phase-change-based mechanical disruption mechanism. Instead of using high temperature to sinter and then mechanically remove ash, the invention uses water evaporation to create expansion forces that directly disrupt and eject ash deposits, substituting thermal-mechanical processing with phase-change mechanics
2Reliability
If thermal sintering is used to remove ash from the filter, then ash removal effectiveness is improved, but filter material damage and catalyst deactivation risks increase
Solution Approach 1:
The patent uses water evaporation phase transition to achieve ash removal at lower temperatures. Water is introduced as liquid and evaporates to vapor, creating expansion forces that mechanically remove ash without subjecting the filter material and catalyst to the high temperatures required for thermal sintering, thus avoiding thermal damage and catalyst deactivation
Solution Approach 2:
Water serves as an intermediary substance that facilitates ash removal without directly damaging the filter. The water is introduced into the filter channels, undergoes phase transition to create disruptive forces, and then evaporates completely, leaving no residue that could harm the filter material or catalyst while effectively removing ash deposits
3Productivity
If ash accumulates in the filter channels, then filtration capacity is maintained, but pressure drop increases and fuel efficiency decreases
Solution Approach 1:
The patent introduces water in liquid form into the filter channels containing ash deposits. The water then evaporates into vapor, creating expansion forces that mechanically disrupt and remove ash from the channels. This phase transition process reduces ash volume and improves channel flow characteristics, thereby reducing pressure drop while maintaining filtration capacity
Solution Approach 2:
The patent changes the physical state of water from liquid to vapor during the treatment process. This parameter change creates a volume expansion effect that generates mechanical forces to remove ash deposits. The transformation from liquid water to water vapor produces the necessary pressure differential to disrupt and eject ash particles from the filter channels
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 method significantly reduces the ash volume, leading to lower pressure drops and extended filter operation life, with the ash density increasing by up to 100% post-treatment, thereby delaying the need for filter replacement and reducing maintenance costs.
Implementation Method 1
removing the work fluid from the at least one channel in a vaporized state
Implementation Method 2
increase ash packing density by agglomeration through evaporation
Data Source
AI summary
A method of treating a particulate filter includes introducing a work fluid, such as water, into one or more channels of the filter and then removing the work fluid in a vaporized state. The channels contain an amount of ash and the density of the ash is greater subsequent to the removal of the work fluid than prior to the introduction of the work fluid.