Honeycomb Filter With Penetrating Inter-Particle Network

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Honeycomb filters used in exhaust gas cleaning devices face issues with the detachment of particles forming the filter layer due to high pressure, leading to reduced effectiveness in trapping particulate matter (PM) and increased pressure loss over time.

Innovation Solution

A ceramic honeycomb filter with a filter layer formed by spherical ceramic particles and crosslinking bodies that penetrate into the pores of the ceramic substrate, creating a three-dimensional network structure for anchoring and preventing detachment, while maintaining porosity to allow gas flow and withstand thermal stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If particles are deposited on the cell wall surface to form a filter layer, then PM trapping capability is improved, but particles may detach due to high pressure

Engineering Contradiction:

Improvefilter layer stabilityVSAvoidparticle attachment strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The filter layer particles are deposited not only on the outer surface of the cell walls but also inside the pores of the cell walls. This nested structure allows particles to be anchored both externally and internally, preventing detachment while maintaining filtration capability.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

Particles are deposited on the cell wall surface before the filter becomes operational. This preliminary deposition creates a stable filter layer structure that can withstand subsequent high-pressure operation without particle detachment.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If filter layer accumulates PM over time, then filtration effectiveness is improved, but pressure loss increases

Engineering Contradiction:

Improvefiltration effectivenessVSAvoidpressure loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The filter layer is formed with different properties in different locations: on the surface for initial filtration and within pores for depth filtration. This local differentiation allows PM accumulation without complete pore blockage, maintaining gas flow and reducing pressure loss.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cell walls themselves are porous, allowing the filter layer to penetrate and form within the pore structure. This maintains overall porosity and gas flow pathways even as PM accumulates, preventing excessive pressure loss while maintaining filtration effectiveness.

Inventive Principle:

Principle #31Porous materials

3Area of stationary object

If uniform particle deposition occurs across the entire surface, then filter coverage is improved, but particle detachment risk increases under pressure

Engineering Contradiction:

Improvefilter layer coverage areaVSAvoidparticle retention

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

Instead of uniform surface deposition only, particles are deposited both on the surface and nested within the pore structures. This creates anchor points that prevent detachment while maintaining broad coverage area for effective filtration.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 layer effectively traps PM over a long period with minimal pressure loss and enhanced mechanical strength, preventing detachment and maintaining filtration efficiency.

Implementation Method 1

a portion of the filter layer penetrates from the surface of the cell walls into pores formed by the ceramic particles

Methodology Applied

Scientific EffectPenetration into pores: Capillary Action

Implementation Method 2

crosslinking bodies which bind the spherical ceramic particles to each other by crosslinking the spherical ceramic particles

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Implementation Method 3

a portion of the filter layer penetrates from the surface of the cell walls into pores formed by the ceramic particles, thereby forming inter-particle filtration bodies

Methodology Applied

Scientific EffectInter-particle filtration: Filter (physical)

Data Source

PatentUS9839869B2Honeycomb filter

Publication Date: 2017.12.12 IBIDEN CO LTD

AI summary

The honeycomb filter of the present invention comprises a ceramic honeycomb substrate formed from a porous body of sintered ceramic particles, and a filter layer formed on the surface of the cell walls, wherein a portion of the filter layer penetrates from the surface of the cell walls into pores formed by the ceramic particles to form inter-particle filtration bodies, these inter-particle filtration bodies are formed from a plurality of spherical ceramic particles and crosslinking bodies which bind the spherical ceramic particles to each other, and the spherical ceramic particles and the crosslinking bodies form a three-dimensional network structure.