Honeycomb Filter Porous Inorganic Layer Pressure Drop
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Solution Overview
Problem
There is an ongoing need to improve the filtration efficiency (FE) and reduce the pressure drop of particulate filters, such as gasoline particulate filters, used in engine exhaust systems, while maintaining high filtration performance and low pressure drop penalties.
Innovation Solution
A honeycomb filter body comprising a porous ceramic honeycomb body with a porous inorganic layer applied to its walls, which enhances filtration efficiency and maintains a low pressure drop by acting as a primary filtration component, with specific parameters such as overall performance parameter 'X' greater than or equal to 1.75 and filtration performance 'F' greater than or equal to 0.25, and morphology parameter 'Y' greater than or equal to 0.02, defined by specific formulas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a porous inorganic layer is applied to the honeycomb filter body to improve filtration efficiency, then filtration performance increases, but pressure drop increases
Solution Approach 1:
The patent applies a porous inorganic layer with controlled porosity (5-50%) and pore size (0.1-10 micrometers) to the honeycomb filter body. This porous structure allows the layer to trap particulates while maintaining sufficient permeability to minimize pressure drop increase to less than 25%, resolving the contradiction between filtration efficiency and pressure drop.
Solution Approach 2:
The patent optimizes multiple parameters of the porous inorganic layer including porosity (5-50%), pore size (0.1-10 micrometers), and thickness (1-50 micrometers) to achieve the desired balance. By carefully controlling these parameters, the filter achieves high filtration efficiency while limiting pressure drop increase, directly addressing the technical contradiction.
2Reliability
If the porous inorganic layer thickness is increased to improve filtration efficiency, then particulate removal improves, but pressure drop penalty increases
Solution Approach 1:
The patent specifies an optimal thickness range of 1-50 micrometers for the porous inorganic layer. This controlled thickness provides sufficient filtration capability while minimizing the pressure drop penalty, preventing excessive energy loss. The thin yet effective layer design resolves the contradiction between filtration efficiency and energy loss.
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 solution achieves high filtration efficiency and low pressure drop, with a pressure drop increase of less than 25% and a significant improvement in filtration performance, characterized by the defined parameters, effectively addressing the need for improved particulate filter performance.
Implementation Method 1
a porous inorganic layer disposed on one or more of the wall surfaces of the porous ceramic honeycomb body
Implementation Method 2
the particulates being trapped on or within the inlet cell walls as the gas traverses and then exits the filter
Data Source
AI summary
A honeycomb filter body comprises: a clean filter pressure drop of (P1) and a clean filtration efficiency of (FE1); a porous ceramic honeycomb body comprising a first end, a second end, and a plurality of walls having wall surfaces defining a plurality of inner channels, the porous ceramic honeycomb body comprising a base clean filter pressure drop (P0) and a base clean filtration efficiency (FE0); and a porous inorganic layer disposed on one or more of the wall surfaces of the porous ceramic honeycomb body.