Orthorhombic Crystal Coating for Ceramic Filter Pressure Loss

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Solution Overview

Problem

Existing filter elements for particle filters experience increased pressure loss over time due to depth filtration, which compromises filtration performance and requires frequent regeneration, leading to ash accumulation and reduced permeability.

Innovation Solution

A filter element with a porous ceramic body featuring flow channels coated with orthorhombic crystals, which prevents particle penetration into the pores, shifting filtration from depth to surface filtration and reducing pressure loss while maintaining high filtration performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If depth filtration is used in porous ceramic filter bodies, then filtration performance is improved, but pressure loss increases over operating time due to particle deposition in pores

Engineering Contradiction:

Improvefiltration performanceVSAvoidpressure loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent employs a porous ceramic filter body structure that provides depth filtration capability while maintaining controlled porosity to prevent excessive particle deposition. The porous structure allows particles to be trapped within the matrix while managing flow resistance to minimize pressure loss over time.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent combines porous ceramic material with a coating layer comprising orthorhombic crystals (such as mullite or cordierite) to create a composite filter structure. This composite approach enables surface filtration to dominate, reducing particle penetration into the porous substrate and thereby maintaining lower pressure loss while preserving filtration efficiency.

Inventive Principle:

Principle #40Composite materials

2Reliability

If filtration is performed by depth filtration mechanism, then particle capture efficiency is improved, but permeability decreases due to ash accumulation and pore blockage

Engineering Contradiction:

Improveparticle capture efficiencyVSAvoidpermeability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The porous ceramic structure is designed with optimized pore size distribution and porosity to balance particle capture through depth filtration while maintaining sufficient permeability. The controlled pore architecture prevents excessive ash accumulation and maintains flow pathways.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent modifies the filtration mechanism by changing the dominant filtration mode from depth filtration to surface filtration through the application of a crystalline coating. This parameter change in the filtration mechanism improves permeability by preventing particle penetration into the porous structure while maintaining high particle capture efficiency through the coating layer.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the filter body is made of porous ceramic material, then filtration capability is improved, but pressure loss increases over time due to reduced permeability

Engineering Contradiction:

Improvefiltration capabilityVSAvoidpressure loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent creates a composite structure combining porous ceramic material with a crystalline coating layer. This composite design leverages the filtration capability of the porous ceramic while the coating layer protects the porous structure from particle deposition, thereby maintaining lower pressure loss over the filter's operational life.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the dominant filtration mechanism from depth filtration to surface filtration by introducing a crystalline coating. This parameter change in the filtration mode allows the porous ceramic body to maintain its filtration capability while experiencing minimal pressure loss increase, as particles are captured at the surface rather than penetrating and blocking the porous structure.

Inventive Principle:

Principle #35Parameter changes

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 use of orthorhombic crystals in the coating material significantly reduces pressure loss and enhances filtration performance by preventing particle deposition in pores, allowing for efficient surface filtration with minimal increase in counter pressure over the filter's operating life.

Implementation Method 1

shifting filtration from depth to surface filtration

Methodology Applied

Scientific EffectSurface filtration: Filter (physical)

Implementation Method 2

prevents particle penetration into the pores

Methodology Applied

Scientific EffectPhysical barrier effect: Physical Containment

Data Source

PatentUS11591942B2Filter element for a particulate filter, exhaust gas particulate filter, process for manufacturing a filter element, and use of a coating material

Publication Date: 2023.02.28 AUDI AG

AI summary

A filter element for a particle filter having a porous filter body made of a ceramic material and including a plurality of flow channels extending fluidically in parallel. The filter body is provided at least in a part of the flow channels with a coating made of a coating material, which is different from the ceramic material and is made up of orthorhombic crystals. A particle filter, a method for producing a filter element, and the use of a coating material for coating a filter element is also provided.