Particulate Filter Low Thermal Conductive Layer Insulation
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Solution Overview
Problem
Current particulate filters face challenges in efficiently regenerating soot at low temperatures, leading to increased fuel consumption, NOx emission, and lubricating oil dilution, while existing solutions impair engine efficiency and NOx purification performance.
Innovation Solution
A particulate filter with a pillar-shaped honeycomb structure coated with a low thermal conductive layer, which reduces heat escape from the outer peripheral surface, allowing efficient regeneration even with low-temperature exhaust gas, and is integrated into a canning structure with a buffer mat for enhanced heat insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature of exhaust gas is raised to burn off soot, then the regeneration of filter is achieved, but the fuel consumption increases and NOx emission increases
Solution Approach 1:
The patent changes the thermal parameter of the filter structure by adding insulation layers and modifying the wall structure to reduce heat loss. This allows the exhaust gas to maintain higher temperature for longer duration, enabling soot combustion without requiring continuous additional fuel injection, thus reducing fuel consumption while maintaining regeneration effectiveness
Solution Approach 2:
The patent converts the normally harmful heat loss from the filter into a beneficial feature by implementing thermal insulation. The heat that would otherwise be wasted is now retained within the filter structure, creating a thermal environment that promotes soot oxidation while reducing the need for extra fuel and minimizing NOx formation
2Reliability
If the temperature of exhaust gas is raised to burn off soot, then the regeneration of filter is achieved, but the NOx purification efficiency by urea SCR is impaired
Solution Approach 1:
The patent modifies the thermal parameters of the exhaust system by implementing insulation structures that maintain a more uniform temperature distribution. This prevents localized overheating that would otherwise oxidize ammonia and reduce SCR efficiency, while still providing sufficient heat for soot combustion
Solution Approach 2:
The patent converts the harmful effect of high temperature on SCR catalyst into a benefit by using controlled thermal insulation. The insulation creates a thermal gradient that protects the downstream SCR catalyst from excessive temperature while maintaining adequate temperature for filter regeneration upstream
3Reliability
If post injection of fuel is performed to raise gas temperature, then the regeneration of filter is promoted, but the lubricating oil is diluted and lubricity is deteriorated
Solution Approach 1:
The patent changes the thermal parameter of the exhaust gas by reducing heat loss through insulation structures. This maintains higher exhaust gas temperature for longer periods, enabling soot combustion to proceed with minimal or no post-injection fuel, thereby preventing lubricating oil dilution and maintaining oil lubricity
4Quantity of substance
If the filter regeneration time is extended to burn off more soot, then the soot accumulation is reduced, but the pressure loss increases and regeneration efficiency decreases
Solution Approach 1:
The patent optimizes the thermal parameters of the filter by implementing insulation structures that maintain elevated temperatures throughout the regeneration process. This creates more uniform combustion conditions that efficiently burn off accumulated soot in a shorter time, reducing pressure loss while improving regeneration efficiency
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
This solution enables rapid and efficient soot regeneration at lower temperatures, reducing fuel consumption, minimizing NOx emission, and maintaining lubricating oil quality, while improving engine efficiency and NOx purification performance.
Implementation Method 1
a low thermal conductive layer covering a part or the whole of an outer peripheral side surface of the pillar-shaped honeycomb structure portion, the thermal conductivity in a thickness direction of the low thermal conductive layer being 0.6 W/(m·K) or less
Data Source
AI summary
A particulate filter, including: a pillar-shaped honeycomb structure portion having a plurality of first cells extending from a first end face to a second end face, the first end face being open and the second end face being plugged, and a plurality of second cells extending from the first end face to the second end face, the first end face being plugged and the second end face being open, in which the first cells and the second cells are alternately arranged adjacent to each other with porous partition walls interposed therebetween; and a low thermal conductive layer covering a part or the whole of an outer peripheral side surface of the pillar-shaped honeycomb structure portion, the thermal conductivity in a thickness direction of the low thermal conductive layer being 0.6 W/(m·K) or less.