Honeycomb Structure Pore Diameter Control for Diesel Filter Pressure Loss
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Solution Overview
Problem
Conventional honeycomb structures used in diesel particulate filters face challenges in achieving both high particulate matter collection efficiency and low pressure loss, as particulate matter penetration into porous partition walls leads to increased pressure loss.
Innovation Solution
A honeycomb structure with partition walls having an average pore diameter of 5.0 to 30.0 µm and a surface open area ratio of 0.05 to 0.45, made from materials like silicon carbide, alumina, or cordierite, with a single layer structure and specific manufacturing methods involving plate-like raw materials to control pore sizes and porosity, reducing pressure loss while maintaining collection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If porous partition walls are used to enable fluid flow through the honeycomb structure, then the honeycomb structure can function as a filter, but particulate matter penetrates into the partition walls causing pressure loss to rapidly increase
Solution Approach 1:
The partition walls are designed with controlled porosity (10-50%) and specific pore diameter (5-30 μm) to balance filtration capability and pressure loss. The porous structure allows fluid passage while the controlled pore characteristics prevent excessive PM penetration that would cause rapid pressure loss increase.
Solution Approach 2:
The invention optimizes specific parameters including pore diameter (5-30 μm), porosity (10-50%), and surface open area ratio (0.05-0.45) to achieve the desired balance between filtration performance and pressure loss characteristics.
2Reliability
If the pore size in partition walls is reduced to improve particulate matter collection efficiency, then collection performance increases, but pressure loss during fluid flow increases
Solution Approach 1:
The invention identifies an optimal parameter range for pore diameter (5-30 μm) that balances collection efficiency and pressure loss. This parameter optimization allows the partition walls to capture particulate matter effectively while maintaining acceptable pressure loss characteristics during fluid flow.
Solution Approach 2:
The partition walls are made from composite ceramic materials that provide both the necessary porosity for filtration and sufficient mechanical strength to maintain structural integrity while resisting pressure loss.
3Loss of energy
If a collecting layer is disposed on the surfaces of partition walls to prevent PM penetration, then pressure loss increase is suppressed, but the structure complexity and manufacturing difficulty increase
Solution Approach 1:
The invention extracts the filtration function from a separate collecting layer and integrates it directly into the partition wall structure itself. By forming the partition walls with controlled pore characteristics, the filtration capability is built-in, eliminating the need for additional collecting layers and reducing overall structure complexity.
Solution Approach 2:
The invention merges the structural function of partition walls with the filtration function of collecting layers into a single integrated component. The partition walls simultaneously provide structural support and filtration capability through their controlled porosity and pore diameter, simplifying the overall filter structure.
4Loss of energy
If high porosity ceramic material is used to reduce pressure loss, then fluid flow resistance decreases, but manufacturing precision and control over pore characteristics become more difficult
Solution Approach 1:
The invention establishes specific parameter ranges for porosity (10-50%) and pore diameter (5-30 μm) that can be reliably controlled during manufacturing. These parameter specifications provide clear manufacturing targets that balance pressure loss reduction with achievable manufacturing precision.
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 proposed honeycomb structure effectively collects particulate matter with low pressure loss, as the controlled pore sizes and material composition minimize particulate matter deposition and pressure drop, enhancing both collection efficiency and flow resistance.
Implementation Method 1
partition walls with which a plurality of cells are formed to become through channels of a fluid... the partition walls have a single layer structure... average pore diameter of the pores formed in the partition walls
Data Source
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AI summary
There is disclosed a honeycomb structure which has an excellent collecting performance of a particulate matter and in which a pressure loss during flowing of a fluid through the honeycomb structure is low. The honeycomb structure includes a honeycomb base material having porous partition walls with which a plurality of cells are formed to become through channels of a fluid, a value of a ratio of an average open frontal area diameter of pores which are open in the surfaces of the partition walls to an average pore diameter of the pores formed in the partition walls is from 0.05 to 0.45, the partition walls have a single layer structure, and preferably, an open frontal area diameter of each of the pores which are open in the surfaces of the partition walls is from 0.5 to 10 µm.