Gasoline Particulate Filter Ash Layer via Atomic Layer Deposition
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Solution Overview
Problem
Gasoline particulate filters (GPFs) initially have lower filtration efficiency and increased pressure drop due to the absence of an ash layer, which can lead to reduced engine performance and fuel efficiency, and the addition of washcoats to improve efficiency increases complexity and cost.
Innovation Solution
A single layer of ash is deposited on the GPF using atomic layer deposition (ALD) before installation, reducing pressure drop and enhancing filtration efficiency without the need for washcoats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a washcoat is included with the GPF to improve filtration efficiency, then particulate filter efficiency is improved, but pressure drop across the GPF increases causing increased exhaust backpressure and reduced fuel efficiency
Solution Approach 1:
The patent applies preliminary action by depositing an ash layer on the GPF before its first use. This pre-deposited ash layer mimics the condition of a used GPF, providing high filtration efficiency from the start without requiring a washcoat. The ash layer is applied through atomic layer deposition (ALD) or other coating techniques prior to installation in the exhaust system.
2Reliability
If a washcoat is added to increase GPF efficiency, then filtration performance is improved, but device complexity and cost increase
Solution Approach 1:
The invention uses preliminary action by pre-depositing an ash layer on the GPF during manufacturing or before first use. This eliminates the need for a washcoat component, simplifying the overall system architecture. The GPF substrate alone, with the pre-applied ash layer, provides the necessary filtration functionality without additional coating layers or complex multi-component structures.
3Reliability
If a washcoat is included to improve GPF efficiency, then filtration performance increases, but the washcoat becomes redundant after usage period
Solution Approach 1:
The patent applies preliminary action by pre-depositing the ash layer before first use, which means the GPF starts operation in its optimal state. Unlike a washcoat that degrades over time, the pre-deposited ash layer is designed to be stable and maintain its filtration effectiveness throughout the GPF's service life, eliminating the redundancy issue.
4Reliability
If a single layer of ash is deposited using ALD before first use, then GPF efficiency is increased from first use, but additional manufacturing step is required
Solution Approach 1:
The invention implements preliminary action by incorporating the ash layer deposition as a pre-treatment step during GPF manufacturing or before first installation. While this adds a manufacturing step, it eliminates the need for washcoat application and subsequent degradation management. The ALD process provides precise control over ash layer thickness and uniformity, ensuring consistent performance.
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 ALD technique provides a uniform ash layer that increases GPF efficiency from the first use, maintaining lower exhaust backpressure and improving engine efficiency while eliminating the need for washcoats, thus enhancing fuel economy and reducing system complexity.
Implementation Method 1
A material deposition process such as atomic layer deposition (ALD) may be used to deposit a single layer of material constituting ash onto a substrate, the substrate being the GPF
Implementation Method 2
Water vapor or oxygen may then be introduced to the chamber to oxidize the metalorganic complex and form a desired layer of metal oxide (constituting ash) on the deposition surface
Implementation Method 3
The GPF may be inserted in a deposition chamber and the surface of the GPF to be coated may be heated to an elevated temperature
Data Source
AI summary
Methods and systems are provided for depositing one or more layers of ash on a surface of a new or cleaned gasoline particulate filter (GPF) prior to installation of the GPF in an engine and first use of the GPF. In one example, a method may include coating the GPF with the one or more layers of ash via an atomic layer deposition (ALD) technique in which two precursors react to form a layer of ash on the GPF surface.