Perforated Metallic Exhaust Substrate with Axial Strength Pillars

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Solution Overview

Problem

Exhaust gas purification devices using perforated metal substrates face a trade-off between high purification performance and insufficient mechanical durability due to the presence of holes, which affect gas flow and mechanical strength.

Innovation Solution

A perforated metal substrate with a combination of axially extending perforated and non-perforated portions, where the non-perforated portions act as 'pillars' to enhance mechanical strength while maintaining high purification performance, by adjusting the area ratios and opening ratios of these portions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If holes are introduced in the corrugated foil and flat foil to reduce heat capacity and improve purification performance, then exhaust gas purification performance is improved, but mechanical durability in the axial direction becomes insufficient

Engineering Contradiction:

Improveexhaust gas purification performanceVSAvoidmechanical durability in axial direction

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent applies local quality by creating different structural zones within the foil: axially extending perforated portions for high purification performance and axially extending non-perforated portions for mechanical strength. This spatial differentiation allows each region to optimize for its specific function while working together as an integrated structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The foil is segmented into distinct perforated and non-perforated axial portions, dividing the structure into functional segments. The non-perforated portions act as reinforcement zones that do not participate in gas flow but provide structural integrity, while the perforated portions handle the purification function.

Inventive Principle:

Principle #1Segmentation

2Loss of energy

If holes are introduced throughout the axial direction to improve gas flow and purification efficiency, then pressure loss is reduced, but mechanical strength deteriorates

Engineering Contradiction:

Improvepressure lossVSAvoidmechanical strength

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

Different axial regions are assigned different quality characteristics: perforated zones optimize for gas flow and low pressure loss, while non-perforated zones optimize for mechanical strength. This local differentiation resolves the contradiction by allowing each region to excel at its primary function.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of perforating the entire axial length, the patent applies perforation partially to specific axial portions. The non-perforated portions provide excessive structural reinforcement beyond what would be needed if the entire structure were perforated, ensuring mechanical strength is maintained while still achieving purification benefits in the perforated zones.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentEP3922352B1Metallic base material for exhaust purging, and exhaust purging device using same

Publication Date: 2024.07.17 CATALER CORP

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Figure 2(a)~2(c)
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AI summary

This perforated metallic base material (10) for purging exhaust is obtained by laminating a wavy foil (1) having pores (1a) and a flat foil (2) having pores (2a) and forming the same into a cylindrical shape, wherein the wavy foil (1) and/or the flat foil (2) has axially perforated portions (11, 21) having pores throughout the axial direction of the cylindrical shape and axially non-perforated portions (12, 22) not having pores overall in the axial direction of the cylindrical form.