Washable Filter Bodies with Fused Inorganic Particle Coatings
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Solution Overview
Problem
Air particulate filters with ceramic honeycomb structures initially have low filtration efficiency, and existing methods for improving efficiency often compromise regeneration capabilities, leading to decreased performance after washing.
Innovation Solution
A filtration article comprising a plugged honeycomb filter body with inorganic particles fused to each other or the filter body, achieving high initial filtration efficiency and maintaining efficiency after water flush regeneration, using materials like cordierite, low melting glass, and mineral particles with specific porosity and particle size distributions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter bodies are designed to accumulate particles to improve filtration efficiency, then clean filtration efficiency increases, but the filter body loses regeneration capability and performance decreases after washing
Solution Approach 1:
The patent applies preliminary action by pre-coating the filter body with a porous ceramic layer containing inorganic particles before the filter is put into service. This pre-applied coating provides immediate high filtration efficiency while maintaining the porous structure that allows for subsequent regeneration through washing, thus resolving the contradiction between initial efficiency and regeneration capability
Solution Approach 2:
The patent utilizes porous materials by employing a porous ceramic coating layer with controlled porosity (5-50%) that allows particle filtration while maintaining permeability for water flow during regeneration. The porous structure enables the coating to trap particles effectively while still permitting wash water to penetrate and remove accumulated contaminants, thereby preserving regeneration capability
2Reliability
If a porous ceramic coating is applied to improve as-new filtration efficiency, then particle trapping capability increases, but the coating may clog during regeneration reducing washability
Solution Approach 1:
The patent applies parameter changes by carefully controlling the porosity parameter of the ceramic coating (maintaining it between 5-50%) and adjusting the particle size distribution of the inorganic particles in the coating. These parameter optimizations ensure the coating has sufficient pore space to trap particles while maintaining adequate permeability for water flow during regeneration, thus achieving both high initial efficiency and good washability
Solution Approach 2:
The patent employs composite materials by creating a ceramic coating that combines multiple inorganic particles (such as alumina, silica, and titania) with controlled pore structures. This composite approach allows the coating to exhibit both high filtration efficiency through particle trapping and good regeneration capability through maintained permeability, resolving the contradiction between these two properties
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 provides a filtration efficiency of greater than 80% initially and maintains efficiency with less than 10% decrease after regeneration, ensuring effective air purification and washability.
Implementation Method 1
inorganic fusion bonding between at least some of the inorganic particles by fusion bonds formed by low-melting inorganic particles constituting at least some of the inorganic particles
Implementation Method 2
aerosolizing a plurality of inorganic particles having a particle d50 of between 10 nm and 500 nm, depositing the particles on, in, or both on and in, the porous walls of the plugged honeycomb body
Implementation Method 3
the deposits having a porosity in a range of greater than 95% to less than or equal to 99.9%
Data Source
AI summary
A filtration article is disclosed comprising a plugged porous honeycomb filter body, deposits of inorganic particles within the plugged honeycomb filter body, the deposits having a porosity in a range of greater than 95% to less than or equal to 99.9% and an average thickness in a range of greater than or equal to 0.5 μm to less than or equal to 200 μm, and at least some of the inorganic particles being fused to each other and/or to the filter body. The particles are fused by one or more of low-melting inorganic particles, inorganic particles capable of chemical bonding organic fusion bonds or organic chemical bonds between inorganic particles coated with an organic binder.