Porous Composite Filter for Low Pressure Loss and High Collection Efficiency
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Solution Overview
Problem
Existing honeycomb filters face a trade-off between low pressure loss and high collection efficiency, with most achieving one at the expense of the other, and there is a need for improved particulate matter collection efficiency while maintaining low pressure loss.
Innovation Solution
A porous composite with a honeycomb base material and a porous collection layer, where the collection layer covers less than 70% of the collection surface area and has a porosity of 70-90%, featuring particles with cavities and catalysts like CeO2 or composite oxides, selectively deposited in pores to enhance oxidation of particulate matter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a porous collection layer is provided on the collection surface to improve particulate matter collection efficiency, then collection efficiency is improved, but pressure loss increases
Solution Approach 1:
The collection layer is selectively formed only in pore regions rather than uniformly across the entire collection surface. This local quality approach ensures that the collection layer is positioned where it can effectively capture particulate matter (in the pores) while leaving non-pore regions uncovered to maintain low pressure loss. The selective formation based on pore identification resolves the contradiction between collection efficiency and pressure loss.
Solution Approach 2:
The invention uses a porous collection layer with controlled porosity (50-90%) formed from particles with specific size distributions. The porous structure allows the collection layer to maintain high permeability (low pressure loss) while still providing sufficient surface area and pore trapping for effective particulate matter collection. The porosity parameter directly addresses the trade-off between filtration efficiency and flow resistance.
2Productivity
If the collection layer covers a larger proportion of the collection surface to improve collection efficiency, then collection efficiency is improved, but pressure loss increases
Solution Approach 1:
The collection layer coverage is localized to pore regions only, with the coverage ratio controlled at 10-70% of the total collection surface area. This ensures that the collection layer is present where needed (in pores for particle capture) while maintaining sufficient open area (non-pore regions) for gas flow. The local quality principle resolves the area trade-off by concentrating the collection layer in specific locations rather than uniform coverage.
Solution Approach 2:
The collection layer is formed with partial coverage (10-70% of collection surface area) rather than complete coverage. This partial action is sufficient to achieve high collection efficiency through pore-based trapping mechanisms while avoiding the excessive coverage that would block flow paths and increase pressure loss. The optimal coverage ratio balances collection performance with flow resistance.
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 achieves both low pressure loss and high collection efficiency, with improved catalytic activity for oxidation of particulate matter, making it suitable for gasoline particulate filters.
Implementation Method 1
a porous collection layer provided on a collection surface of the base material. The collection layer includes particles deposited in pores of the collection surface
Implementation Method 2
The third metal is a transition metal or a rare-earth metal other than cerium and lanthanum. The cerium content in the metal content is higher than or equal to 5 mol % and lower than or equal to 95 mol %, the lanthanum content is higher than or equal to 2 mol % and lower than or equal to 93 mol %, and the third metal content is higher than or equal to 2 mol % and lower than or equal to 93 mol %
Implementation Method 3
a porous collection layer provided on a collection surface of the base material. The collection layer includes particles deposited in pores of the collection surface
Data Source
AI summary
A porous composite includes a porous base material and a porous collection layer provided on a collection surface of the base material. The collection layer includes particles deposited in pores of the collection surface. In a plan view of the collection surface, the proportion of the area of a covered region that is covered with the collection layer out of the collection surface is less than or equal to 70%, and the proportion of the area of a pore region out of a non-covered region that is not covered with the collection layer is less than or equal to 15%.