Non-Uniform Oxide Coating for Porous Ceramic DPF Strength
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Solution Overview
Problem
Current diesel particle filters (DPFs) face challenges with high porosity leading to fragile structures, limited catalyst loading, and temperature restrictions, which affect their mechanical strength and catalytic efficiency, especially during active regeneration in off-road applications.
Innovation Solution
A porous ceramic substrate with a non-uniform oxide component coating in dead-end pores, enhancing mechanical strength and allowing for a lower catalyst loading while maintaining high porosity and catalytic activity, including SCR functionality, to achieve efficient NOx reduction and soot oxidation at elevated temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high porosity is used to achieve high catalyst loading, then catalytic activity is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent applies local quality by creating a non-uniform coating layer where oxide components are concentrated in dead-end pores rather than uniformly distributed. This localized reinforcement in specific regions (dead-end pores) provides mechanical strength where needed without compromising the overall porosity and catalyst loading capacity of the substrate.
Solution Approach 2:
The patent uses composite materials by combining the porous ceramic substrate with a non-uniform coating layer containing oxide components. This composite structure integrates the high porosity and catalytic activity of the substrate with the mechanical reinforcement provided by the oxide-containing coating, particularly in dead-end pores.
2Productivity
If high porosity is used to maintain catalytic activity, then catalytic efficiency is improved, but structural stability deteriorates
Solution Approach 1:
The patent applies local quality by creating a non-uniform coating layer where oxide components are concentrated in dead-end pores rather than uniformly distributed. This localized reinforcement in specific regions (dead-end pores) provides mechanical strength where needed without compromising the overall porosity and catalyst loading capacity of the substrate.
Solution Approach 2:
The patent applies preliminary action by pre-coating the substrate with oxide-containing material before final catalyst application. This preliminary coating reinforces the fragile high-porosity structure in advance, preventing structural collapse during subsequent high-temperature catalytic operations.
3Productivity
If catalyst loading is increased to improve NOx reduction, then catalytic activity is improved, but temperature restrictions worsen
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical parameters of the substrate surface through the non-uniform oxide coating. This coating alters the thermal properties and catalytic characteristics, enabling the substrate to withstand higher temperatures while maintaining catalytic activity for NOx reduction.
Solution Approach 2:
The patent uses composite materials by combining the porous ceramic substrate with a non-uniform coating layer containing oxide components. This composite structure integrates the high porosity and catalytic activity of the substrate with the mechanical reinforcement provided by the oxide-containing coating, particularly in dead-end pores.
4Strength
If porosity is reduced to increase mechanical strength, then structural integrity is improved, but catalytic activity deteriorates
Solution Approach 1:
The patent applies local quality by creating a non-uniform coating layer where oxide components are concentrated in dead-end pores rather than uniformly distributed. This localized reinforcement in specific regions (dead-end pores) provides mechanical strength where needed without compromising the overall porosity and catalyst loading capacity of the substrate.
Solution Approach 2:
The patent applies porous materials by utilizing the existing dead-end pores of the porous ceramic substrate as receptacles for the oxide coating. This approach maintains the overall porous structure necessary for catalytic activity while using the dead-end pores to deliver mechanical reinforcement through localized oxide deposition.
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 solution provides a DPF with high mechanical strength, >99.9% particulate number (PN) efficiency at low back pressure, and improved catalytic activity for NOx reduction, soot, HC, and CO oxidation, with enhanced thermoshock resistance for active regeneration.
Implementation Method 1
a non-uniform coating layer of an oxide component in contact with a surface of the ceramic substrate, which oxide component is distributed on the surface and in dead-end pores of the ceramic substrate
Implementation Method 2
SCR is the reduction of NO and NO2 with NH3 to water and nitrogen according to the following three reactions: 4NH3+4NO+O2→4N2+6H2O ('Standard SCR'), 2NH3+NO+NO2→2N2+3H2O ('Fast SCR'), 8NH3+6NO2→7N2+12H2O ('NO2SCR')
Implementation Method 3
the catalyst, which has the function to oxidize the accumulated soot but also to oxidize carbon monoxide (CO) and hydrocarbon (HC)
Data Source
AI summary
A porous ceramic substrate for use as a particle filter, with a porosity of at least 50%, which includes a non-uniform coating layer of an oxide component in contact with a surface of the ceramic substrate, which oxide component is distributed on the surface and in dead-end pores of the ceramic substrate and creates the non-uniform coating layer on the substrate support, wherein the coating layer has a substantially smooth surface. Such substrate is typically a particle filter or part of a particle filter, e.g. a DPF.