Gasoline particulate filters with high initial filtering efficiency and methods of making same
AssigneeAfton Chemical Corporation
InventorsHuifang Shao, Joseph W. Roos, Joseph E. Remias
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Abstract
Gasoline Direct Injection (GDI) engines require gasoline particulate filters (GPFs) as a key component of the emissions control system to reduce particulate emissions. GPFs are known to have poor initial performance, with performance increasing after the filter develops a cake. This poor initial performance make it impossible to accurately assess vehicle emissions performance at the mileage requirements for vehicle certification. Compositions and methods are disclosed to improve filtration efficiency in a fresh or low mileage GPF.
Claims7
A gasoline particulate filter comprising:
- a pre-service gasoline particulate filter comprising pores,
- wherein the pores are at least partially filled with a particulate substance including a plurality of particles having a diameter of 10 nanometers to 200 micrometers;
- wherein the particulate substance comprises at least one of a soot surrogate substance, an ash surrogate substance, an aggregate particulate substance, or combinations thereof;
- and
- wherein the particulate substance includes a plurality of particles having a bimodal distribution of particle diameters with a first mode having an average particle diameter of 0.25 micrometers to 2.5 micrometers and a second mode having an average particle diameter of 2.5 micrometers to 10 micrometers;
- and
- wherein the particulate substance is present on the gasoline particulate filter in an amount of 0.5 gram/L to 6 grams/L.
A method of pretreating a gasoline particulate filter,
- comprising:
- contacting the gasoline particulate filter comprising pores with a particulate substance prior to installing the gasoline particulate filter in a vehicle to produce a pre-treated gasoline particulate filter, wherein the pores are at least partially filled with the particulate substance;
- and
- wherein the particulate substance includes one or more of silica powder, talc, gypsum, soot, ash, flours, starches, or combinations thereof;
- wherein the particulate substance comprises a plurality of particles having a diameter of from 10 nanometers to 200 micrometers and having a bimodal distribution of particle diameters with a first mode having an average particle diameter of 0.25 micrometers to 2.5 micrometers and a second mode having an average particle diameter of 2.5 micrometers to 10 micrometers;
- and
- wherein the particulate substance is present on the gasoline particulate filter in an amount of 0.5 gram/L to 6 grams/L.
Dependencies are inferred from the claim text.