Porous Material Bending Strength via Zircon Phase Transformation
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Solution Overview
Problem
Porous materials used in diesel particulate filters (DPFs) face a trade-off between high porosity, which reduces pressure loss, and mechanical strength, where increasing porosity compromises the material's mechanical properties.
Innovation Solution
A porous material composed of aggregate particles and a binding material containing cordierite and zircon particles, with a specific ratio of zircon particles to the binding material, which enhances mechanical strength while maintaining high porosity, is developed. The method involves molding a mixture of aggregate and binding material raw materials, followed by firing at a high temperature to generate zircon particles and form a honeycomb structure with partition walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If porosity is increased to reduce pressure loss, then pressure loss is reduced, but mechanical strength deteriorates
Solution Approach 1:
The patent employs a composite material system consisting of aggregate particles (silicon carbide, silicon nitride, or aluminum nitride) combined with a binding material containing cordierite and zircon particles. This composite structure allows the material to achieve both high porosity (50-70%) for reduced pressure loss and sufficient mechanical strength (bending strength ≥7.5 MPa) through the synergistic combination of different materials with complementary properties.
Solution Approach 2:
The patent utilizes parameter changes during the firing process, specifically heating to 1430°C or higher to transform zirconia particles into zircon particles. This phase transformation and parameter change during processing enables the binding material to develop optimal mechanical properties while maintaining the desired porous structure formed by the aggregate particles and pore-forming materials.
2Ease of operation
If porosity is increased to improve flow characteristics, then flow characteristics are improved, but bending strength deteriorates
Solution Approach 1:
The composite material system with aggregate particles and binding material containing zircon particles provides both the porous structure needed for good flow characteristics and the mechanical reinforcement required for adequate bending strength. The specific composition ratios and particle size distributions are optimized to balance flow and strength requirements.
Solution Approach 2:
The patent applies local quality by having different regions and components serve different functions: the aggregate particles and pore-forming materials create the porous structure for flow, while the cordierite and zircon particles in the binding material provide localized mechanical reinforcement at critical points within the porous matrix.
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 resulting porous material achieves a balance of high porosity and mechanical strength, specifically a bending strength of at least 7.5 MPa, effectively reducing pressure loss while maintaining structural integrity.
Implementation Method 1
the zircon particles are generated by firing in the operation b)
Implementation Method 2
a binding material that contains cordierite and zircon particles and binds the aggregate particles together in a state where pores are formed
Data Source
AI summary
A porous material includes aggregate particles, and a binding material that contains cordierite and zircon particles and binds the aggregate particles together in a state where pores are formed.