Honeycomb Filter Variable Thickness Capturing Layer
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Solution Overview
Problem
Honeycomb filters with existing capturing layers do not effectively address flow velocity distribution issues, leading to inconsistent PM capture efficiency across the central and peripheral regions, resulting in incomplete PM removal.
Innovation Solution
The honeycomb filter design features capturing layers with a thickness that decreases from the central region to the outer peripheral region, optimizing flow velocity distribution and enhancing PM capture efficiency by ensuring more fluid flows through the peripheral regions where the layers are thinner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a capturing layer is formed on the partition portion to enhance PM capturing performance, then PM capture efficiency is improved, but flow velocity distribution is not considered resulting in insufficient PM capture in certain regions
Solution Approach 1:
The capturing layer thickness is varied locally across different regions of the honeycomb filter. Specifically, the thickness is greater in the central region and smaller in the outer peripheral region, creating local quality differences that compensate for the natural flow velocity distribution and achieve more uniform PM capture across all regions.
Solution Approach 2:
The physical parameter of capturing layer thickness is changed across different spatial locations to optimize performance. By adjusting the thickness parameter from the central region to the outer peripheral region, the system compensates for flow velocity variations and achieves uniform PM capture efficiency throughout the filter.
2Ease of manufacture
If the capturing layer thickness is uniform across the honeycomb filter, then manufacturing is simplified, but PM capture performance becomes inconsistent between central and outer peripheral regions
Solution Approach 1:
Instead of uniform thickness, the capturing layer is designed with local quality variations where thickness differs between central and outer peripheral regions. This local differentiation ensures that each region's capturing performance matches its local flow characteristics, achieving overall uniformity in PM capture despite manufacturing complexity.
Solution Approach 2:
The design transitions from a one-dimensional uniform thickness approach to a two-dimensional variable thickness approach, where thickness becomes a function of radial position. This dimensional change allows optimization of PM capture across different spatial locations while maintaining manufacturing feasibility through controlled variation.
3Reliability
If the capturing layer thickness decreases from central to outer peripheral region, then flow distribution is improved and PM capture is enhanced, but pressure loss may increase
Solution Approach 1:
The capturing layer thickness parameter is optimized to achieve the best balance between PM removal efficiency and pressure loss. By carefully controlling the thickness gradient from central to outer peripheral regions, the design maximizes PM capture while minimizing the adverse impact on pressure loss.
Solution Approach 2:
Different thickness values are assigned to different regions based on local flow characteristics and PM capture requirements. The central region has greater thickness for high flow velocity compensation, while the outer peripheral region has smaller thickness, creating local quality optimization that balances efficiency and energy loss.
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 PM removal efficiency, reduces pressure loss, and improves the PM deposition limit by ensuring uniform flow velocity and increased PM capture at the outer peripheral regions, thereby improving overall filtration performance.
Implementation Method 1
a porous partition portion that forms a plurality of cells each having one end open and the other end sealed and functioning as a channel of a fluid; and capturing layers that capture and remove solid components in the fluid
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3
AI summary
In honeycomb filter 20, capturing layers 24 which are layers that capture and remove solid components in a fluid are formed on a porous partition portion 22 that forms a plurality of cells 23 each having one end open and the other end sealed and functioning as a channel of a fluid. The capturing layers 24 are formed so that the thickness has a tendency to decrease from a central region of the honeycomb filter toward an outer peripheral region of the honeycomb filter, the central region and the outer peripheral region being included in an orthogonal plane orthogonal to the cells 23. Accordingly, the fluid is led to flow at the outer peripheral side and more solid components can be captured and removed at the outer peripheral side.