Porous Composite Filter with Praseodymium Oxide Layer
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Solution Overview
Problem
Current honeycomb filters used in vehicles to collect particulate matter from diesel engines face challenges in accelerating the oxidation of particulate matter, leading to increased pressure loss and inefficient regeneration processes.
Innovation Solution
A porous composite structure is introduced, featuring a honeycomb base material with a porous collection layer containing praseodymium oxide and optionally cerium oxide, which accelerates the oxidation of particulate matter by optimizing the layer's thickness, pore distribution, and binding force with the base material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a porous collection layer is provided on the inner surfaces of cells to collect particulate matter, then infiltration of particulate matter into the partition wall is suppressed, but oxidation of particulate matter is not accelerated sufficiently
Solution Approach 1:
The invention changes the chemical composition parameters of the collection layer by incorporating specific metal oxides (praseodymium oxide at 5-75 wt%, cerium oxide at 5-75 wt%, and alumina at 10-90 wt%) to enhance catalytic activity and accelerate oxidation reactions while maintaining collection functionality
Solution Approach 2:
The invention creates a composite collection layer material combining multiple metal oxides (praseodymium oxide, cerium oxide, and alumina) to achieve synergistic effects that simultaneously improve particulate matter collection and accelerate oxidation during regeneration processes
2Reliability
If the collection layer thickness is increased to improve collection efficiency, then more particulate matter is collected, but pressure loss increases
Solution Approach 1:
The invention optimizes the thickness parameter of the collection layer to a specific range (6-50 μm) that balances collection efficiency with pressure loss, and adjusts the pore diameter parameter (3-20 μm) to maintain adequate flow pathways while capturing particulate matter
Solution Approach 2:
The invention utilizes a porous collection layer structure with controlled porosity and specific pore size distribution to enable efficient particulate matter capture while maintaining sufficient permeability to minimize pressure loss across the filter
3Ease of manufacture
If conventional collection layer materials are used, then manufacturing is simpler, but oxidation acceleration is insufficient
Solution Approach 1:
The invention modifies the chemical composition parameters by incorporating specific ratios of praseodymium oxide (5-75 wt%), cerium oxide (5-75 wt%), and alumina (10-90 wt%) to achieve optimal catalytic activity for accelerating oxidation while maintaining compatibility with conventional manufacturing processes
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 porous composite effectively reduces the combustion starting temperature of particulate matter, enhances oxidation efficiency, and prevents pressure loss, making it suitable for use in gasoline particulate filters.
Implementation Method 1
the collection layer contains praseodymium oxide... This porous composite can accelerate oxidation of particulate matter
Implementation Method 2
a regeneration process is performed in which the particulate matter collected by the filter is heated, oxidized, and removed from the filter
Data Source
AI summary
A porous composite includes a porous base material, and a porous collection layer. The collection layer is provided on the base material. The collection layer contains praseodymium oxide.