Gasoline Particulate Filter With Needle-Like Crystal Coating
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Solution Overview
Problem
Gasoline particulate filters face challenges in achieving high fresh filtration efficiency with minimal back pressure increase to meet stringent emission regulations.
Innovation Solution
A particulate filter design incorporating a layer of inorganic particles with needle-like morphology in the inlet and/or outlet channels of the filter substrate, which enhances filtration efficiency without significant back pressure rise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a layer of inorganic particles is coated on the filter substrate to improve filtration efficiency, then fresh filtration efficiency is improved, but back pressure increases
Solution Approach 1:
The patent applies inorganic particles with needle-like morphology specifically in the inlet channels where fresh particulate matter enters the filter. This localized coating strategy concentrates the filtration enhancement where it is most needed for cold start emissions, while minimizing the coating extent to reduce overall back pressure increase.
Solution Approach 2:
The patent changes the morphological parameter of the inorganic particles from conventional spherical or irregular shapes to needle-like morphology. This parameter change allows the particles to align with the flow direction and provide effective filtration with lower resistance to exhaust gas flow, thus improving filtration efficiency while controlling back pressure.
2Manufacturing precision
If conventional spherical inorganic particles are used for coating, then filtration is provided, but fresh filtration efficiency is insufficient and back pressure increases significantly
Solution Approach 1:
The patent fundamentally changes the morphological parameter of the inorganic particles from spherical to needle-like. The needle-like shape with aspect ratios of 2:1 or higher provides more surface area for particle capture while maintaining lower flow resistance compared to spherical particles of equivalent volume, directly addressing the contradiction between filtration efficiency and back pressure.
Solution Approach 2:
The patent uses composite structures where needle-like inorganic particles (such as alumina, silica, or titania) are combined with the filter substrate material. This composite approach optimizes both filtration performance and flow characteristics by leveraging the high surface area-to-volume ratio of needle-like particles while maintaining the structural integrity of the substrate.
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 filter achieves improved fresh filtration efficiency while maintaining low back pressure, addressing the need for enhanced performance in gasoline engine exhaust treatment.
Implementation Method 1
a layer of inorganic particles loaded on surfaces of porous walls in the inlet channels and/or outlet channels, wherein the layer of inorganic particles comprises inorganic particles of needle-like crystals
Implementation Method 2
the particle distribution may help to prevent a significant amount of the synthetic ash from entering the pores of the porous substrate
Data Source
AI summary
The present invention relates to a particulate filter, which comprises a substrate comprising a plurality of porous walls extending longitudinally to form a plurality of parallel channels extending from an inlet end to an outlet end, wherein a quantity of the channels are inlet channels that are open at the inlet end and closed at the outlet end, and a quantity of channels are outlet channels f that are closed at the inlet end and open at the outlet end; and a layer of inorganic particles loaded on surfaces of porous walls in the inlet channels and/or outlet channels, wherein the layer of inorganic particles comprises inorganic particles of needle-like crystals. The f present invention also relates to a method for producing a particulate filter which includes applying inorganic particles or precursors thereof on surfaces of porous walls in the inlet channels and/or outlet channels wherein at least part of the inorganic particles or precursors thereof are particles of needle-like crystals.