Honeycomb Filter Pore Volume Optimization for Pressure Loss
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Solution Overview
Problem
Existing honeycomb filters face challenges in enhancing trapping performance for solid components in fluids, particularly in suppressing pressure loss increases during high flow rates and soot entry, and maintaining PM combustion efficiency after regeneration.
Innovation Solution
A honeycomb filter design with a two-peak pore distribution in the downstream portion, where the volume of pores ≤10 μm is larger than in the upstream portion by 0.01-0.08 cm3/g, and porosity between 35-70%, along with catalyst loading, to optimize trapping and reduce pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pore volume of pores ≤10 μm in the downstream portion is increased to maintain PM combustion efficiency, then the catalyst loading is sufficient, but the pressure loss increases due to pore clogging
Solution Approach 1:
The patent applies parameter changes by precisely controlling the pore volume of pores ≤10 μm within the range of 0.01 to 0.08 cm³/g in the downstream portion. This quantitative parameter optimization ensures sufficient catalyst loading for PM combustion while preventing excessive pore clogging that would cause high pressure loss.
Solution Approach 2:
The patent applies local quality by creating a non-uniform pore distribution where the downstream portion has a specifically controlled pore volume (0.01-0.08 cm³/g of pores ≤10 μm) that differs from the upstream portion. This local optimization allows the downstream catalyst layer to maintain combustion efficiency without excessive pressure loss.
2Productivity
If the flow rate is increased to handle high exhaust gas volume, then the productivity increases, but soot enters the pores at high speed causing rapid pressure loss increase
Solution Approach 1:
The patent applies preliminary action by pre-optimizing the pore structure of the downstream portion before exhaust gas enters. The controlled pore volume (0.01-0.08 cm³/g of pores ≤10 μm) is established in advance to create a buffer capacity that can handle high flow rates and soot entry without causing rapid pressure loss increase.
3Stress or pressure
If the porosity is increased to reduce initial pressure loss, then the fluid flow improves, but the catalyst loading capacity decreases
Solution Approach 1:
The patent applies parameter changes by optimizing the pore volume of pores ≤10 μm within the specific range of 0.01 to 0.08 cm³/g. This precise parameter control creates an optimal balance where the porosity is sufficient to maintain low initial pressure loss while providing adequate volume for catalyst loading to ensure PM combustion efficiency.
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 design enhances trapping performance by maintaining PM combustion efficiency and reducing pressure loss, preventing catalyst clogging and permeability issues, while ensuring sufficient catalyst loading for effective regeneration.
Implementation Method 1
trapping layers that are formed on the partition portions and configured to trap a solid component contained in the fluid
Implementation Method 2
a volume of pores having a diameter of 10 μm or less in a downstream portion of the cells measured by mercury porosimetry is larger than a volume of pores having a diameter of 10 μm or less in an upstream portion of the cells measured by mercury porosimetry
Data Source
AI summary
In a honeycomb filter 20, partition portions and trapping layers are formed such that a pore volume difference that is obtained from pore distributions measured by mercury porosimetry and is a difference in volume of pores having a diameter of 10 μm or less between the downstream portion and the upstream portion of the honeycomb filter, is in the range of 0.01 cm3/g or more and 0.08 cm3/g or less. In the honeycomb filter, in the downstream portion, a first pore volume peak is present in a first pore diameter range of 2 μm or more and 9 μm or less and a second pore volume peak that is higher than the first pore volume peak is present in a second pore diameter range of 10 μm or more and 25 μm or less.