Honeycomb Filter with Segmented Pore Diameters
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Solution Overview
Problem
Honeycomb filters with catalyst-loaded porous partition walls face deteriorated trapping performance and increased pressure loss, while stricter exhaust gas regulations demand improved purification performance without increasing catalyst loading.
Innovation Solution
A honeycomb filter design with distinct inflow and outflow side regions, featuring specific average pore diameters and porosity, allows for optimal catalyst loading on the surface in the inflow side for enhanced purification and reduced penetration in the outflow side for effective trapping, maintaining low catalyst amounts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a catalyst is loaded in a porous partition wall to improve exhaust gas purification performance, then purification performance is improved, but trapping performance deteriorates and pressure loss increases
Solution Approach 1:
The patent divides the honeycomb structure into two distinct regions: an inflow side region (first region) and an outflow side region (second region). The inflow side region has smaller average pore diameters (9-14 μm) optimized for catalyst loading and purification, while the outflow side region has larger average pore diameters (15-20 μm) optimized for trapping performance. This segmentation allows each region to perform its specific function optimally without compromising the other.
Solution Approach 2:
The patent applies different pore diameter characteristics to different regions of the honeycomb structure. The inflow side region is designed with smaller pores (9-14 μm) to facilitate catalyst loading and exhaust gas purification, while the outflow side region is designed with larger pores (15-20 μm) to maintain high trapping performance. This local differentiation of properties resolves the contradiction between purification and trapping functions.
2Productivity
If more catalyst is loaded in the porous partition wall to improve exhaust gas purification performance, then purification performance is improved, but trapping performance deteriorates more remarkably
Solution Approach 1:
The patent segments the honeycomb structure into two regions with different pore diameter characteristics. The inflow side region (first region) with smaller pores (9-14 μm) is designed to accommodate catalyst loading, while the outflow side region (second region) with larger pores (15-20 μm) is designed to maintain trapping performance. This segmentation allows catalyst to be loaded in the inflow side region without significantly impacting the trapping performance of the outflow side region.
Solution Approach 2:
The patent implements local quality by assigning different pore diameter ranges to different regions. The inflow side region has smaller pores (9-14 μm) optimized for catalyst interaction and purification, while the outflow side region has larger pores (15-20 μm) optimized for particle trapping. This local differentiation enables the system to achieve both purification and trapping functions without compromising either.
3Productivity
If the porous partition wall is designed for high catalyst loading to improve purification performance, then purification performance is improved, but pressure loss increases
Solution Approach 1:
The patent divides the honeycomb structure into an inflow side region and an outflow side region with different pore diameter characteristics. The inflow side region (first region) with smaller pores (9-14 μm) is designed for catalyst loading and purification, while the outflow side region (second region) with larger pores (15-20 μm) is designed to minimize flow resistance and pressure loss. This segmentation allows the system to achieve high purification performance without excessive pressure loss.
Solution Approach 2:
The patent applies different pore diameter characteristics to different regions to optimize local functions. The inflow side region has smaller pores (9-14 μm) optimized for catalyst interaction and purification reactions, while the outflow side region has larger pores (15-20 μm) optimized for maintaining low flow resistance and minimizing pressure loss. This local quality differentiation resolves the contradiction between purification performance and pressure 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 design achieves excellent trapping and purification performance by ensuring sufficient catalyst contact in the inflow side and effective filtration in the outflow side, improving exhaust gas treatment without increasing catalyst loading.
Implementation Method 1
the porous partition wall serves as a filter for removing PM. Specifically, the exhaust gas containing PM is flowed in from an inflow end face of the honeycomb filter and is filtered by trapping the PM with a porous partition wall
Implementation Method 2
it has been carried out to load a catalyst for purifying exhaust gas in a porous partition wall
Data Source
AI summary
A honeycomb filter includes a honeycomb structure having a porous partition wall disposed to surround a plurality of cells; and a plugging portion provided at one end of the cell, wherein the honeycomb structure has an inflow side region including a range of up to at least 30% with respect to the total length of the honeycomb structure with the inflow end face as the starting point and an outflow side region including a range of up to at least 20% with respect to the total length of the honeycomb structure with the outflow end face as the starting point, in the extending direction of the cell of the honeycomb structure, an average pore diameter of the partition wall in the inflow side region is 9 to 14 μm and an average pore diameter of the partition wall in the outflow side region is 15 to 20 μm.