Filtration Plate Spacer Design for Exhaust Back Pressure Reduction
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Solution Overview
Problem
Existing filtration plates for particle filters in internal combustion engines are prone to clogging due to their wave shape, leading to increased exhaust gas back pressure and reduced rigidity, which complicates handling and service life, and often require additional components like spacers that can obstruct gas flow.
Innovation Solution
The filtration plate design incorporates spacer elements with inner elevations and outer depressions that extend from the surface, ensuring mutual contact between adjacent plates and maintaining a consistent spacing to prevent contact and ensure continuous flow through channels, thereby enhancing rigidity and reducing back pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If wave-shaped filtration plates are used to form flow channels, then the filter structure is created, but the channels become clogged with ash quickly and exhaust gas back pressure increases
Solution Approach 1:
The filtration plates are segmented into multiple functional zones: inflow channels, outflow channels, and filtration areas. This segmentation allows for optimized flow distribution and prevents clogging by directing exhaust gas through designated pathways rather than allowing random flow patterns that cause ash accumulation.
Solution Approach 2:
The patent introduces intermediate structures (support elements and spacing elements) between filtration plates to maintain channel geometry and prevent plate deformation. These intermediaries ensure stable flow channels that resist clogging and maintain consistent exhaust gas back pressure.
2Shape
If wave-shaped filtration plates are used to form flow channels, then the filter structure is created, but the channels result in highly directed flow that prevents distribution and increases exhaust gas back pressure
Solution Approach 1:
Different regions of the filtration plate are given different properties: inflow channels are designed for gas distribution, outflow channels for collected gas removal, and filtration zones for particle capture. This local differentiation optimizes flow distribution and reduces back pressure by matching structure to function in each region.
3Strength
If filtration plates are pressed together with pre-stress and installed horizontally, then the filter body is assembled, but the space between plates becomes smaller and can be eliminated completely causing flow impediment
Solution Approach 1:
Spacing elements are pre-installed between filtration plates during assembly to maintain the required gap before operational forces are applied. This preliminary action ensures that even under pre-stress and horizontal installation conditions, the channels maintain sufficient height for exhaust gas flow.
Solution Approach 2:
Rigid support elements act as intermediaries between filtration plates to maintain structural stability while preventing excessive compression. These support elements distribute mechanical loads and prevent the channels from closing completely under operational stress.
4Stability of the object's composition
If additional spacer elements are inserted into filter pockets to prevent deformation, then the filter pockets maintain shape, but the spacer elements represent additional manufacturing expenditure and can obstruct exhaust gas flow
Solution Approach 1:
The spacing function and structural support function are merged into integrated support elements that are part of the filtration plate assembly. This eliminates the need for separate spacer components while maintaining channel geometry and preventing plate deformation under operational loads.
Data Source
AI summary
A filtration plate (1, 1′) for a particle filter which serves to separate particles from an exhaust gas flow of an internal combustion engine is composed of a gas-permeable carrier material which is coated with sintered metal powder, and has a surface region (2) which extends substantially in one plane and on which at least one spacer element (3, 3′) is situated. The at least one spacer element (3, 3′) has an inner elevation (9) or depression (9′) which extends away from the surface region (2) in one direction, and an outer depression (10) or elevation (10′) which surrounds the inner elevation (9) or depression (9′) at least partially and extends away from the surface region (2) in the opposite direction to the inner elevation (9) or depression (9′).