Particulate Filter Regeneration via Bi-Phase Flow
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Solution Overview
Problem
Existing methods for regenerating particulate filters in vehicles are inefficient, requiring long regeneration cycles, high energy consumption, and risk structural damage due to high pressure pulses, while also being costly and time-consuming.
Innovation Solution
A method and apparatus that uses a bi-phase fluid of washing liquid and gas passing through the filter simultaneously, with controlled low-pressure flows and temperatures, to effectively remove particulate deposits without damaging the filter, and includes prewashing and drying steps to enhance regeneration efficiency and reduce energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high pressure pulses are used to remove particulate deposits, then cleaning effectiveness is improved, but structural damage risk increases
Solution Approach 1:
The patent changes the pressure parameter from high to low range, using pressures between 1-5 bar instead of high pressure pulses. This resolves the contradiction by achieving adequate cleaning effectiveness through extended treatment time combined with low pressure, thereby eliminating structural damage risk while maintaining cleaning capability.
Solution Approach 2:
The patent employs periodic alternation between liquid washing phases and gas drying phases. The liquid phase removes particulate deposits at low pressure, followed by gas phase to dry the filter. This periodic action maintains cleaning effectiveness while avoiding continuous high pressure exposure that would cause structural damage.
2Productivity
If high temperature thermal treatment is used to combust particles, then regeneration effectiveness is improved, but energy consumption increases
Solution Approach 1:
The patent replaces the thermal combustion system with a mechanical washing system. Instead of using high temperature to combust particles, the invention uses liquid washing followed by gas drying to mechanically remove and evaporate particulate deposits. This substitution dramatically reduces energy consumption while maintaining regeneration effectiveness.
Solution Approach 2:
The patent utilizes phase transition of water from liquid to vapor state during the drying phase. Gas is passed through the filter to evaporate residual washing liquid and remove particulate matter. This phase transition mechanism achieves particle removal and drying without requiring high temperature thermal treatment, thus reducing energy consumption.
3Manufacturing precision
If long washing cycles are used to ensure complete regeneration, then cleaning quality is improved, but time consumption increases
Solution Approach 1:
The patent implements continuous circulation of washing liquid through the filter during the washing phase, ensuring all channels are continuously exposed to cleaning action. This is followed by continuous gas flow during drying phase. The continuity of these actions achieves complete regeneration in a optimized time frame, balancing cleaning quality with time efficiency.
Solution Approach 2:
The patent performs preliminary wetting of the filter with washing liquid before the main washing phase. This preliminary action ensures that all channels are adequately filled and prepared for effective particulate removal, reducing the total time required for complete regeneration while maintaining high cleaning quality.
4Manufacturing precision
If multiple washing and drying phases are used, then regeneration completeness is improved, but process complexity increases
Solution Approach 1:
The patent merges the washing and drying functions into a single integrated apparatus. The same device alternates between liquid washing mode and gas drying mode, using unified infrastructure for both functions. This merging approach achieves complete regeneration through multiple phases while minimizing process complexity compared to separate dedicated systems.
Solution Approach 2:
The patent employs dynamic switching between different operational modes within the same apparatus. The system dynamically transitions from liquid washing phase to gas drying phase and can repeat cycles as needed. This dynamic operation achieves comprehensive regeneration completeness while maintaining relatively simple apparatus structure through flexible mode switching rather than requiring multiple static systems.
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 method achieves complete regeneration of particulate filters in significantly shorter times with minimal energy consumption and reduced risk of damage, allowing for effective cleaning of both particulate filters and associated catalytic devices, while avoiding the need for furnaces and high-pressure flows.
Implementation Method 1
a flow of washing liquid and a flow of gas simultaneously pass through the body of the filter according to successive pulses
Implementation Method 2
a flow of gas simultaneously pass through the body of the filter according to successive pulses, preceded by a step of wetting the filter by immersing it in a wetting solution
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a method and the corresponding apparatus (1) for at least partially regenerating a used particulate filter (F), in particular a filter (F) for use in automobiles of the type commonly identified by the acronym FAP or DPF. A jet of a washing liquid, for example water, and a flow of a washing gas, for example air, are continuously fed to the particulate filter for the entire duration of the washing of the filter and simultaneously pass through the filter (F) in the opposite direction with respect to the direction in which the exhaust gases of the relative vehicle pass through the filter (F) when the filter (F) is in use. The water-air fluid is preferably bi-phase and the temperature of the air is comprised in the range 70÷90°C. The method allows used particulate filters to be completely or almost completely regenerated in about 20-30 minutes.