Sinuous Web Ceramic Substrate for Radial Flow and Pressure Drop

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Solution Overview

Problem

Current ceramic honeycomb filters for exhaust gas treatment, particularly in diesel engines, face limitations in radial flow efficiency and pressure drop, leading to suboptimal particulate removal and regeneration temperatures.

Innovation Solution

The development of a substrate with sinuous web structures and support webs that enhance radial flow through porous ceramic walls, featuring transverse and bridging web portions forming a sinuous shape, which connects to support legs optimizing fluid flow and reducing pressure drops.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional straight axial channels with uniform cross-sections are used, then manufacturing is simple, but radial flow efficiency is limited and pressure drop is high

Engineering Contradiction:

Improveradial flow efficiencyVSAvoidchannel structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies curvature by replacing straight axial channels with sinuous (curved) channels that wind through the honeycomb structure. The sinuous web includes transverse web portions and bridging web portions that form curved pathways, allowing exhaust gas to follow a more efficient radial flow pattern through the filter walls, thereby improving radial flow efficiency while managing pressure drop

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent introduces a third dimension by creating sinuous channels that extend radially through the honeycomb structure rather than simply axially. The sinuous web connects the first support web to the second support web through curved pathways, adding radial flow capability to the traditional axial channel arrangement, thus enhancing three-dimensional flow utilization

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Stability of the object's composition

If wall flow honeycombs with low thermal expansion materials are used, then thermal stability is improved, but regeneration temperature increases

Engineering Contradiction:

Improvethermal stabilityVSAvoidregeneration temperature

Core Design Contradiction:

Stability of the object's compositionVSTemperature

Solution Approach 1:

The patent changes the geometric parameters of the honeycomb structure by introducing sinuous channels with varying cross-sectional areas along their length. The channels have different dimensions at different radial positions, creating optimized flow paths that improve gas residence time and heat transfer efficiency, thereby lowering regeneration temperature while maintaining thermal stability through the low thermal expansion material

Inventive Principle:

Principle #35Parameter changes

3Productivity

If plugs are placed in alternating checker board patterns to force exhaust gas through cell channel walls, then flow distribution is improved, but pressure drop increases

Engineering Contradiction:

Improveparticulate removal efficiencyVSAvoidpressure drop

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

The sinuous channels provide curved flow paths that reduce flow resistance compared to straight channels. The curved geometry allows exhaust gas to follow the contour of the filter walls more efficiently, reducing turbulence and pressure losses while maintaining effective particulate removal through the optimized flow distribution

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

This design achieves improved radial flow efficiency, lower pressure drops, and reduced regeneration temperatures compared to traditional square cell honeycomb filters, with increased filtering capacity and soot loading capabilities.

Implementation Method 1

substrate with sinuous web structures and support webs that enhance radial flow through porous ceramic walls

Methodology Applied

Scientific EffectFluid flow through porous materials: Porosity

Implementation Method 2

longitudinal channels through which a fluid may pass... bridging web portions alternatively connect ends of adjacent transverse web portions

Methodology Applied

Scientific EffectPressure gradient driven flow: Pressure Gradient

Data Source

PatentUS10030554B2Substrate with sinuous web and particulate filter incorporating the same

Publication Date: 2018.07.24 CORNING INC

AI summary

Described herein is a substrate including a central longitudinal axis, a first support web, and a second support web. A sinuous web may be positioned between the first support web and the second support web. The sinuous web may include transverse web portions and bridging web portions, where the bridging web portions alternatively connect ends of adjacent transverse web portions. The sinuous web may be connected to the first support web by support legs extending between bridging web portions and a surface of the first support web. The sinuous web may be connected to the second support web by support legs extending between bridging web portions and a surface of the second support web. A support leg length to distance between transverse web portions ratio may be from about 1.0 to about 4.0.