Honeycomb Filter Gradient Capturing Layer for PM Removal
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Solution Overview
Problem
Honeycomb filters with existing capturing layers do not efficiently address flow velocity distribution and regeneration efficiency, leading to uneven PM capture and removal in exhaust gas treatment.
Innovation Solution
The honeycomb filter design features capturing layers with a thickness gradient decreasing from the outer peripheral region to the central region, optimizing flow velocity and temperature distribution to enhance PM capture and removal efficiency, with a thickness ratio of 60% to 95% in the central region to the outer peripheral region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a capturing layer is formed on the partition portion to enhance PM capturing performance, then PM removal efficiency is improved, but flow velocity distribution is not considered and regeneration efficiency deteriorates
Solution Approach 1:
The capturing layer thickness is varied locally across the honeycomb filter structure. The thickness decreases from the outer peripheral region toward the central region, creating different local properties that match the flow velocity distribution. This local variation optimizes both PM capture in high-velocity central regions and regeneration in low-velocity outer regions
Solution Approach 2:
The thickness parameter of the capturing layer is changed spatially to resolve the contradiction. By adjusting the thickness parameter from uniform to gradient distribution, the system achieves improved PM removal while maintaining regeneration efficiency, as the thinner central region allows better flow through while the thicker outer region provides sufficient capture capacity
2Productivity
If the capturing layer thickness is increased to improve PM capture, then PM removal efficiency is improved, but pressure loss increases
Solution Approach 1:
The capturing layer is designed with non-uniform thickness where the central region (handling higher flow velocities) has smaller thickness to reduce pressure loss, while the outer peripheral region has larger thickness to maintain PM capture efficiency. This local differentiation allows the system to reduce overall pressure loss while preserving PM removal performance
3Loss of energy
If the capturing layer thickness is decreased to reduce pressure loss, then pressure loss is reduced, but PM removal efficiency deteriorates
Solution Approach 1:
Different thicknesses are assigned to different regions based on their functional requirements. The outer peripheral region maintains larger thickness for effective PM capture where flow velocity is lower, while the central region uses smaller thickness to minimize pressure loss where flow velocity is higher, achieving both goals simultaneously
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 improves PM removal efficiency and reduces pressure loss, allowing for more efficient regeneration processes and shorter regeneration times, thereby enhancing fuel efficiency and reducing fuel costs.
Implementation Method 1
capturing layers that capture and remove solid components in the fluid are formed on the porous partition portion
Implementation Method 2
regeneration process that burns captured PM is performed
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 an outer peripheral region of the honeycomb filter toward a central region of the honeycomb filter, the central region and the outer peripheral region being included in an orthogonal plane orthogonal to the cells 23. In this manner, the outer side, which is less likely to burn and remove the solid components, is made less likely to capture the solid components, and a central side, which is easy to burn and remove the solid components, is easy to capture more solid components.