Honeycomb Filter Void Design Reduces Pressure Loss
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Solution Overview
Problem
Honeycomb filters experience significant pressure loss and decreased trapping efficiency due to the highest flow rate occurring in the downstream region, which is exacerbated by PM deposition, and existing improvements have not been sufficient.
Innovation Solution
Incorporating a void between the sealing portion and the trapping layer on the outlet side of the cell, which reduces permeation resistance and separates the maximum flow rate portion from the deposition portion, thereby reducing pressure loss and improving trapping efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the flow rate increases in the downstream region, then the fluid passes through the filter faster, but pressure loss increases significantly
Solution Approach 1:
The invention divides the cell into multiple regions along the flow direction: an upstream region with the trapping layer, a middle region with intermediate flow paths, and a downstream region with different flow characteristics. This segmentation allows different regions to handle flow at different rates, preventing excessive flow concentration in the downstream region and reducing overall pressure loss.
Solution Approach 2:
The invention creates local quality differences by providing different flow path characteristics in different regions of the cell. The upstream region has higher flow resistance due to the trapping layer, while the downstream region has lower resistance. This local differentiation balances the flow distribution throughout the cell, reducing peak flow rates and associated pressure losses.
2Reliability
If PM deposits on the trapping layer, then trapping efficiency improves, but pressure loss increases
Solution Approach 1:
The invention segments the flow paths into multiple channels with different characteristics. As PM deposits on the trapping layer in the upstream region, the segmented middle and downstream regions provide alternative flow paths that are less affected by deposition, maintaining lower pressure loss while preserving trapping efficiency in the upstream region.
Solution Approach 2:
The intermediate flow paths act as mediators between the upstream trapping region and the downstream outlet. These intermediate paths provide alternative routes that reduce the direct impact of PM deposition on overall pressure loss, allowing the trapping layer to maintain high efficiency while the system experiences smaller pressure increases.
3Reliability
If the trapping layer thickness increases, then trapping efficiency improves, but permeation resistance increases
Solution Approach 1:
The invention segments the trapping function across different regions and flow paths. Rather than requiring a single thick trapping layer, the trapping function is distributed across the upstream region with optimized thickness, while the middle and downstream regions provide additional flow paths with lower resistance, achieving both high trapping efficiency and acceptable permeation resistance.
Solution Approach 2:
The invention applies local quality optimization by positioning the trapping layer with specific thickness characteristics in the upstream region where trapping is most needed, while providing different flow path resistances in downstream regions. This allows the trapping layer to be sufficiently thick for high efficiency where required, while maintaining overall permeation through alternative paths.
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 void design enhances fluid flow and reduces pressure loss while maintaining or improving trapping efficiency, even under high flow rates and with PM deposition, by optimizing the shape and thickness of the trapping layer and the sealing portion.
Implementation Method 1
the void can reduce the permeation resistance of the trapping layer at the outlet end
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
A honeycomb filter 20 includes a plurality of porous partition portions 22 each forming a cell 23 serving as a flow path of a fluid, a sealing portion 26 for sealing an end of the cell 23, a trapping layer 24 for trapping solid components contained in the fluid, the trapping layer 24 being disposed on each of the partition portions 22, and a void 25 between the sealing portion 26 on an outlet side of the cell 23 and the trapping layer 24. Preferably, the trapping layer 24 has a convex closed end facing the sealing portion 26 on the outlet side. Preferably, the sealing portion 26 on the outlet side has a convex end facing the trapping layer 24. Preferably, the void 25 is larger on the partition portion 22 side than on the center side of the cell 23.