Particulate filter with low soot loaded coating
AssigneeCorning Incorporated
InventorsDavid Henry, Maxime Moreno, Christophe Michel Remy
Life of this patent
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Abstract
A ceramic particulate filter having a porous catalytic material deposited on walls within the filter. Particulate matter is trapped in the walls of the filter and the catalytic material removes gases, such as nitrogen oxides (NOx), from gases passing through the filter. The filter, in one embodiment, is adaptable for use with internal combustion (gas and diesel) engines. A method of making the filter is also described.
Claims24
A ceramic particulate filter for internal combustion engines, the ceramic particulate filter comprising:
- a. a ceramic body comprising a plurality of inlet channels, a plurality of outlet channels, and a plurality of porous walls separating the inlet channels from adjacent outlet channels, wherein each of the porous walls has a continuous porous structure capable of trapping particulate matter;
- and
- b. a porous catalytic coating deposited on an outer surface of the porous walls, wherein each of the inlet channels is in fluid communication with at least one of the outlet channels through the catalytic coating and the porous wall separating the inlet channel from the outlet channel.
The ceramic particulate filter according to claim 13, wherein the porous support material comprises at least one of alumina, titania, silica, zeolite, zirconia, activated carbon, and combinations thereof.
A catalytic coating for a ceramic particulate filter, the catalytic coating comprising a porous ceramic support material and a catalytic material, wherein the catalytic coating has a macroporosity in a range from about 15% up to about 70%, wherein the catalytic coating is disposable on a surface of at least one of an outlet channel and an inlet channel of the ceramic particulate filter.
A method of making a ceramic particulate filter, the method comprising the steps of:
- a. providing a ceramic body comprising a plurality of inlet channels, a plurality of outlet channels, and a plurality of porous walls separating the inlet channels from adjacent outlet channels;
- b. filling pores in the porous walls with an intermediate material;
- and
- c. coating an outer surface of each of the porous walls in at least one of the inlet channels and the outlet channels with a porous catalytic material to make the ceramic particulate filter.
A method of making a porous multilayer ceramic article, the method comprising the steps of:
- a. providing a ceramic body, the ceramic body comprising at least one porous wall;
- b. filling pores in the porous wall with an intermediate material;
- c. coating an outer surface of the porous wall with a second porous material;
- and
- d. removing the intermediate material from the pores in the porous wall to form the porous multilayer ceramic article.
The method according to claim 24, wherein the ceramic article is adaptable for use as a filter for an internal combustion engine.
The method according to claim 24, wherein the filter has a honeycomb structure defining a plurality of inlet channels and outlet channels, and wherein the second porous material is deposited in at least one of the inlet channels and outlet channels.
Dependencies are inferred from the claim text.