Outercoat Particulate Filter for PM Capture and Low Pressure Drop
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing particulate filters face a challenge in achieving both high PM capturing performance and pressure drop suppression performance simultaneously, as reducing the average pore diameter for improved PM capturing often leads to increased pressure drop.
Innovation Solution
A particulate filter with a porous outercoat layer composed of granules, featuring a D90 pore diameter of 1 μm to 10 μm, a thickness of 20 μm to 80 μm, and a porosity of 30% to 70%, along with specific pore and granule dimensions, to enhance PM capturing while minimizing pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the average pore diameter of the outercoat layer is decreased to improve PM capturing performance, then the PM capturing performance is improved, but the pressure drop increases due to reduced gas passing rate
Solution Approach 1:
The patent applies parameter changes by precisely controlling the D90 pore diameter within 1-10 μm, thickness within 20-80 μm, and porosity within 30-70%. This optimization of physical parameters enables the outercoat layer to achieve both high PM capturing performance and acceptable pressure drop characteristics, resolving the technical contradiction between filtration efficiency and gas flow resistance
Solution Approach 2:
The patent forms the outercoat layer as a composite structure consisting of multiple granules with controlled pore distribution. This composite material approach, combining granular particles with specific pore structures, allows simultaneous achievement of fine PM capture and maintained gas permeability, addressing the contradiction between capturing performance and pressure drop
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 filter achieves both high PM capturing performance and pressure drop suppression by optimizing the outercoat layer's pore and granule characteristics, ensuring effective particulate matter capture without significant pressure increase.
Implementation Method 1
a porous outercoat layer formed by multiple granules and is formed on a surface of the partition in contact with the inlet cell. In the particulate filter, a D90 pore diameter of pores in the outercoat layer is from 1 μm to 10 μm inclusive
Data Source
AI summary
A particulate filter capable of PM capturing performance and pressure drop suppression function. The filter captures a particulate matter PM contained in exhaust gas. The filter includes: a base material including inlet cells each with an opening at an exhaust gas inlet end, outlet cells each with an opening at an exhaust gas outlet end, and porous partitions partitioning the inlet and outlet cells; and an outercoat layer provided on an inlet surface of each of the partitions. The D90 pore diameter of pores in the outercoat layer is from 1 μm to 10 μm inclusive. In the outercoat layer, a thickness t1 of pores is from 20 μm to 80 μm inclusive, and a porosity Pcoat of the pores is from 30% to 70% inclusive. According to the outercoat layer with such a configuration, the particulate matter PM can be suitably captured with appropriate control of pressure drop increase.