Honeycomb Filter with Crosslinked Spherical Ceramic Particles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Honeycomb filters used in exhaust gas cleaning devices face challenges with depth filtration, leading to increased pressure loss and reduced collection efficiency due to particle size issues in composite regions, where large particles allow PM to pass through and small particles block gas flow.
Innovation Solution
A honeycomb filter with a filter layer composed of spherical ceramic particles and crosslinking bodies forming a three-dimensional network structure on the surface of cell walls, preventing depth filtration by trapping PM on the surface and allowing gas to pass through, while being robust against detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large particles are used to form the composite region, then the gaps between particles are large allowing gas flow, but large amounts of PM can pass through resulting in reduced collection efficiency
Solution Approach 1:
The patent applies composite materials by combining spherical ceramic particles with crosslinking bodies to form a composite region. This composite structure creates a three-dimensional network that provides both filtration capability and mechanical strength, preventing PM from passing through while maintaining gas flow. The crosslinking bodies act as binding agents that connect the spherical particles, forming a robust filter structure.
Solution Approach 2:
The patent applies local quality by forming a composite region with specific particle size distribution and crosslinking structure at the filter surface. The spherical ceramic particles are specifically sized and arranged in a composite region that provides optimal filtration, while the crosslinking bodies are positioned to bind these particles together. This localized optimization of particle arrangement and bonding creates the desired balance between PM trapping and gas permeability.
2Reliability
If small particles are used to form the composite region, then the gaps between particles are small improving PM trapping, but gas cannot easily pass through resulting in increased pressure loss
Solution Approach 1:
The composite material structure of spherical ceramic particles bound by crosslinking bodies creates an optimized pore structure. The crosslinking bodies form bridges between particles, creating a three-dimensional network with controlled pore sizes that allow gas flow while trapping PM. This composite architecture prevents the complete blockage of gas pathways that would occur with small particles alone.
Solution Approach 2:
The patent utilizes porous materials by creating a composite region with interconnected pores formed by the spherical ceramic particles and crosslinking bodies. This porous structure provides multiple flow paths for gas while maintaining small effective pore sizes for PM filtration. The three-dimensional network creates a tortuous but open pathway system that reduces pressure loss compared to dense small particle structures.
3Ease of manufacture
If particles are deposited by gas-solid two phase flow, then the composite region is formed, but particles may penetrate into cell walls causing depth filtration and increasing pressure loss
Solution Approach 1:
The patent applies preliminary action by forming the composite region with crosslinked spherical particles on the cell wall surface before the exhaust gas flows through the filter. This pre-formed robust structure prevents particle penetration into the cell walls during operation. The crosslinking bodies are already in place to bind the spherical particles, creating a stable barrier that stops further particle migration into the cell wall pores.
Solution Approach 2:
The patent utilizes spheroidality by employing spherical ceramic particles as the base structure of the composite region. The spherical shape provides uniform packing and consistent pore formation, creating a more stable and predictable filter structure compared to irregular particles. This spherical geometry, combined with crosslinking, creates a uniform three-dimensional network that effectively prevents particle penetration while maintaining consistent gas flow characteristics.
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 high collection efficiency and low pressure loss by trapping PM on the surface, preventing depth filtration, and maintaining structural integrity under thermal stress.
Implementation Method 1
a filter layer which, among the surfaces of the cell walls, is formed on the surface of the cell walls of those cells in which the end section at the fluid inlet side is open and the end section at the fluid outlet side is sealed
Implementation Method 2
crosslinking bodies which bind the spherical ceramic particles to each other by crosslinking the spherical ceramic particles
Data Source
AI summary
An object of the present invention is to provide a honeycomb filter capable of preventing depth filtration and achieving a combination of high collection efficiency and low pressure loss. The honeycomb filter of the present invention comprises a ceramic honeycomb substrate in which a multitude of cells through which a fluid flows are disposed in parallel in a longitudinal direction and are separated by cell walls, each cell being sealed at an end section at either the fluid inlet side or the fluid outlet side, and a filter layer which, among the surfaces of the cell walls, is formed on the surface of the cell walls of those cells in which the end section at the fluid inlet side is open and the end section at the fluid outlet side is sealed, wherein the filter layer is composed of a plurality of spherical ceramic particles, and crosslinking bodies which bind the spherical ceramic particles to each other by crosslinking the spherical ceramic particles, and the spherical ceramic particles and the crosslinking bodies form a three-dimensional network structure.