Filter Catalyst Pore Opening Preservation via Local Quality
Solution Overview
Problem
Conventional filter catalysts face issues with ventilation hole closure due to the catalytic layer forming on the surface of the catalyst-support substrate, leading to increased pressure loss and reduced particulate capture efficiency.
Innovation Solution
A filter catalyst design where the catalytic layer is formed with a ratio of outer peripheral length to cross-sectional area of 0.5 or more, ensuring uniform coverage and preventing pore closure, allowing for effective particulate capture and burning while maintaining sufficient ventilation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the catalytic layer is formed by coating slurry onto the catalyst-support substrate, then the catalytic layer is formed on the surface, but the opening diameters of the ventilation holes are narrowed or closed
Solution Approach 1:
The patent applies local quality by creating a catalytic layer with non-uniform thickness distribution. The layer is designed to be thinner at the pore openings and thicker in the intermediate regions, achieving both sufficient coverage for catalysis and adequate opening diameters for ventilation. This localized variation in layer properties resolves the contradiction between uniform coverage and pore openness.
Solution Approach 2:
The patent inverts the conventional approach by intentionally designing the catalytic layer to be thinner at critical locations (pore openings) rather than uniformly thick. This inversion of the expected uniform thickness pattern allows the layer to cover the substrate adequately while preserving ventilation hole openings, thus resolving the contradiction between coverage and ventilation.
2Loss of energy
If the opening diameters of ventilation holes are enlarged to reduce pressure loss, then pressure loss decreases, but particulate capture becomes impossible
Solution Approach 1:
The patent applies local quality by creating a catalytic layer with non-uniform thickness distribution. The layer is designed to be thinner at the pore openings and thicker in the intermediate regions, achieving both sufficient coverage for catalysis and adequate opening diameters for ventilation. This localized variation in layer properties resolves the contradiction between uniform coverage and pore openness.
Solution Approach 2:
The patent inverts the conventional approach by intentionally designing the catalytic layer to be thinner at critical locations (pore openings) rather than uniformly thick. This inversion of the expected uniform thickness pattern allows the layer to cover the substrate adequately while preserving ventilation hole openings, thus resolving the contradiction between coverage and ventilation.
3Reliability
If the catalytic layer is formed with sufficient coverage to capture particulates, then particulate capture efficiency improves, but the ventilation holes are closed leading to increased pressure loss
Solution Approach 1:
The patent applies local quality by creating a catalytic layer with non-uniform thickness distribution. The layer is designed to be thinner at the pore openings and thicker in the intermediate regions, achieving both sufficient coverage for catalysis and adequate opening diameters for ventilation. This localized variation in layer properties resolves the contradiction between uniform coverage and pore openness.
Solution Approach 2:
The patent inverts the conventional approach by intentionally designing the catalytic layer to be thinner at critical locations (pore openings) rather than uniformly thick. This inversion of the expected uniform thickness pattern allows the layer to cover the substrate adequately while preserving ventilation hole openings, thus resolving the contradiction between coverage and ventilation.
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 design enhances the filter catalyst's ability to capture and burn particulates without increasing pressure loss, improving its purifying performance and maintaining adequate pore opening diameters.
Implementation Method 1
a catalytic layer for burning particulates
Data Source
AI summary
To provide a filter catalyst in which the closure of ventilation holes by a catalytic layer is inhibited.A filter catalyst of the present is characterized in that, in a filter catalyst comprising: a catalyst-support substrate; and a catalytic layer; an SEM photograph on a cross section of the filter catalyst is turned into electronic data so that, in a processed image in which image processing is performed to the SEM photograph, a ratio of a number of pixels forming an outer periphery of the catalytic layer to a number of pixels forming the catalytic layer is 0.5 or more. An analyzing method of the present invention finds a ratio a number of pixels forming an outer periphery of the catalytic layer to a number of pixels forming the catalytic layer by performing image processing to a cross section of the filter catalyst. The filter catalyst of the present invention has an effect of being capable of inhibiting the rise of pressure loss when sufficient particulates deposit. Moreover, the analyzing method of the present invention can analyze the uniformity of the catalytic layer of the filter catalyst.