Honeycomb Filter Porosity and Pore Diameter Optimization
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Solution Overview
Problem
Honeycomb filters face challenges in balancing filtration efficiency and isostatic strength, as increasing porosity to improve filtration efficiency leads to reduced strength, while decreasing porosity to enhance strength increases pressure loss and reduces engine output.
Innovation Solution
A honeycomb filter design with a pillar-shaped structure, specific porosity (52-58%), average pore diameter (6-12 μm), and pore volume rate (≤13.5% for pores ≥20 μm) to maintain filtration efficiency while suppressing pressure loss and ensuring isostatic strength for canning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the porosity of the partition wall is increased to improve filtration efficiency, then the pressure loss decreases, but the isostatic strength decreases
Solution Approach 1:
The invention applies parameter changes by precisely controlling multiple parameters of the partition wall: porosity (50-60%), average pore diameter (5-15 μm), and pore volume rate of large pores (≤15%). This multi-parameter optimization resolves the contradiction by finding the optimal balance point where filtration efficiency is improved while maintaining sufficient isostatic strength for canning.
2Strength
If the porosity of the partition wall is decreased to increase strength, then the isostatic strength increases, but the pressure loss increases and engine output is reduced
Solution Approach 1:
The invention resolves this contradiction by changing the pore structure parameters within an optimal range. By setting porosity to 50-60% and average pore diameter to 5-15 μm, the partition wall achieves sufficient strength while maintaining low pressure loss, thereby preventing engine output reduction.
3Strength
If the open frontal area of cells is reduced to increase strength, then the isostatic strength increases, but the pressure loss increases and engine output is reduced
Solution Approach 1:
The invention addresses this contradiction by optimizing the open frontal area parameter within the range of 70-80%. This parameter change ensures that the honeycomb filter maintains sufficient isostatic strength while keeping pressure loss at acceptable levels, thus avoiding engine output reduction.
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 effectively improves filtration efficiency while preventing a rise in pressure loss and maintaining the necessary strength for housing, optimizing the honeycomb filter's performance across these parameters.
Implementation Method 1
a porous partition wall disposed to surround a plurality of cells acting as fluid through channels
Data Source
AI summary
A honeycomb filter includes a pillar-shaped honeycomb structure body having a porous partition wall surrounding cells each of which has one end plugged by a plugging portion. An open frontal area O (%) of the cells in the honeycomb structure body is 75 to 80%, a porosity P (%) of the partition wall measured by a mercury press-in method is 52 to 58%, an average pore diameter D (μm) of the partition wall measured by the mercury press-in method is 6 to 12 μm, and a pore volume rate A (%) of pores whose pore diameters are not less than 20 μm with respect to an overall pore volume of the partition wall is not more than 13.5%.