# US 2017/0282124 A1 · Exhaust filter with active plugs

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- Number: US 2017/0282124 A1
- Document ID: US20170282124A1
- Status: Published application
- Kind: A1
- Application number: 15/508,812
- Filed: 2015-09-02
- Published: 2017-10-05
- Earliest claimed: 2014-09-03
- Assignees: Coming Incorporated
- Applicants: Coming Incorporated
- Inventors: Christian Bischof; David Robert Heine; Ameya Joshi; Barbara Anna Oyer; Todd Parrish St Clair; Patrick David Tepesch
- Web page: https://patentgrep.com/patent/US20170282124A1

## CPC

- B01D 53/9418: {for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas}
- B01J 29/06: Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J 29/763: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 35/57: Honeycombs
- B01J 37/0203: {the impregnation liquid containing organic compounds}
- B28B 11/006: {Making hollow articles or partly closed articles}
- C04B 28/24: containing alkyl, ammonium or metal silicates; containing silica sols {(reaction mixtures resulting in mineral polymers C04B28/006; polymeric reaction products of alkali metal silicates with isocyanates C08G18/3895)}
- C04B 35/195: Alkaline earth aluminosilicates, e.g. cordierite {or anorthite}
- C04B 38/0006: {Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083)}
- C04B 38/0012: {characterised by the material used for sealing or plugging (some of) the channels of the honeycombs}
- B01D 2251/2062: Ammonia
- B01D 2255/20761: Copper
- B01D 2255/50: Zeolites
- B01D 2255/9155: Wall flow filters
- C04B 2111/00793: {as filters or diaphragms}
- C04B 2111/0081: {as catalysts or catalyst carriers}
- C04B 2235/3463: Alumino-silicates other than clay, e.g. mullite
- C04B 2235/3481: Alkaline earth metal alumino-silicates other than clay, e.g. cordierite, beryl, micas such as margarite, plagioclase feldspars such as anorthite, zeolites such as chabazite
- C04B 2235/449: Organic acids, e.g. EDTA, citrate, acetate, oxalate
- Y02A 50/20: Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
- Y02T 10/12: Improving ICE efficiencies
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- Y02A: TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A ceramic honeycomb body having intersecting walls that form channels extending axially from a first end face to a second end face and plugs to seal the channels at least at one of the first end face and the second end face. The plugs include a first active component, such as a catalytically active component or a chemically active component, of the plug structure, wherein the intersecting walls comprise no first active component and optionally have a second active component of the wall structure or disposed on the walls. Included are methods of making the ceramic honeycomb body having plugs of the first active component and walls with no first active component.

## Claims

### Claim 1

A porous ceramic honeycomb body, comprising:
intersecting walls that form channels extending axially from a first end face to a second end face; and
active plugs to seal at least one of a first portion of the channels at the first end face and a second portion of the channels at the second end face, each active plug comprising:
a first active component, wherein the first active component comprises at least one of a catalytically active component and a chemically active component of the plug structure, wherein the intersecting walls do not comprise the first active component.

### Claim 2 (depends on 1)

The porous ceramic honeycomb body of claim 1, wherein the intersecting walls comprise a second active component comprising at least one of a catalytically active component and a chemically active component,
wherein the second active component is at least one of disposed on wall surfaces, disposed in pores of the walls and disposed throughout the structure of the walls.

### Claim 3 (depends on 1)

The porous ceramic honeycomb body of claim 1, wherein each plug comprises a first layer disposed in contact with the intersecting walls and a second layer disposed on the first layer inward toward an axial center of each channel from the intersecting walls, and wherein at least one of the first layer and the second layer comprises the first active component.

### Claim 4 (depends on 1)

The porous ceramic honeycomb body of claim 1, wherein a batch cement composition that forms each plug comprises the first active component.

### Claim 5 (depends on 1)

The porous ceramic honeycomb body of claim 1, wherein the first end face comprises a filter inlet and the second end face comprises a filter outlet,
wherein the first active component comprises a plurality of active components, the plurality of active components comprising:
a first temperature active component at the inlet end active in a first temperature range and a second temperature active component at the outlet end active in a second temperature range.

### Claim 6 (depends on 5)

The porous ceramic honeycomb body of claim 5, wherein the first temperature range has a lower boundary less than a lower boundary of the second temperature range and the second temperature range has an upper boundary greater than an upper boundary of the first temperature range.

### Claim 7 (depends on 1)

The porous ceramic honeycomb body of claim 1, further comprising non-active plugs disposed to seal channels at least at one of the first end face and the second end face.

### Claim 8 (depends on 1)

The porous ceramic honeycomb body of claim 1, wherein the first end face comprises a filter inlet and the second end face comprises a filter outlet,
wherein the first active component comprises a plurality of active components, the plurality of active components comprising:
a first temperature active component in a first group of channels at the inlet end active in a first temperature range and a second temperature active component in a second group of channels at the inlet end active in a second temperature range.

### Claim 9 (depends on 1)

The porous ceramic honeycomb body claim 1, wherein the first temperature range has a lower boundary less than a lower boundary of the second temperature range and the second temperature range has an upper boundary greater than an upper boundary of the first temperature range.

### Claim 10 (depends on 1)

The porous ceramic honeycomb body of claim 1, wherein the first end face comprises a filter inlet and the second end face comprises the filter outlet,
wherein the first active component comprises a plurality of active components, the plurality of active components comprising:
a catalytically active component at the inlet end effective to convert at least 40% of NOx in an exhaust gas and a chemically active component at the outlet end effective to convert HC in the exhaust gas.

### Claim 11 (depends on 1)

The porous ceramic honeycomb body of claim 1, wherein the active plugs in at least one of the first portion of the channels and the second portion of the channels are axially spaced apart from the respective end face.

### Claim 12 (depends on 1)

The porous ceramic honeycomb body of claim 1, wherein the active plugs comprise between 10 wt % and 80 wt % of the first active component.

### Claim 13 (depends on 1)

The porous ceramic honeycomb body of claim 1 wherein the first active component comprises at least one of copper-zeolite, HC traps, high surface area material plus a noble metal, high surface area material, on board diagnosis oxygen storage material, ceria:zirconia solid solution material, ceria:zirconia multi phase material, a three way catalyst (TWC), a platinum group metal (PGM), rhodium-titania, calcium carbonate, zeolite, Cu-exchanged zeolite, Fe-exchanged zeolite, PGM disposed on alumina, small pore zeolite, Cu-chabazite zeolite, and an alkali earth metal oxide.

### Claim 14

A method of plugging a porous ceramic honeycomb body comprising intersecting walls that form channels extending axially from a first end face to a second end face, the method comprising:
applying to the honeycomb body to form active plugs, a composition comprising:
an active component;
a refractory filler having a particle size distribution;
an organic binder;
an inorganic binder; and
a liquid vehicle;
wherein the active component comprises at least one of a catalytically active component and a chemically active component, and
wherein the intersecting walls do not comprise the active component.

### Claim 15 (depends on 14)

The method of claim 14, further comprising drying and firing the ceramic honeycomb body having the composition applied thereto to form a filter or a partial filter.

### Claim 16 (depends on 14)

The method of claim 14, wherein applying comprises:
disposing a first layer patty on a second layer patty;
disposing the second layer patty on a support;
pressing the support and the porous ceramic honeycomb body together in an axial direction a predetermined distance to inject the first layer and the second layer in at least one of a first portion of the channels at the first end face and a second portion of the channels at the second end face to form plugs to seal at least one of first portion of the channels at the first end face and a second portion of the channels at the second end face, the plugs comprising a first layer disposed on the walls of respective channels, and a second layer disposed inward toward an axial center of each respective channel on the first layer,
wherein at least one of the first layer and the second layer comprises the active component.

### Claim 17 (depends on 14)

The method of claim 14, wherein the active plugs comprise between 10 wt % and 80 wt % of the active component.

### Claim 18 (depends on 14)

The method of claim 14, wherein the active component comprises at least one of copper-zeolite, HC traps, high surface area material plus a noble metal, high surface area material, on board diagnosis oxygen storage material, ceria:zirconia solid solution material, ceria:zirconia multi-phase material, a three way catalyst (TWC), a platinum group metal (PGM), rhodium-titania, calcium carbonate, zeolite, Cu-exchanged zeolite, Fe-exchanged zeolite, PGM disposed on alumina; small pore zeolite, Cu-chabazite zeolite, and an alkali earth metal oxide.

### Claim 19 (depends on 14)

The method of claim 14, further comprising a gelling agent comprising at least one of an organic salt, magnesium acetate, and copper acetate,
wherein the inorganic binder comprises colloidal silica, the organic binder comprises methylcellulose, the active component comprises Cu-chabazite.

### Claim 20 (depends on 14)

The method of claim 14, wherein the applying comprises disposing the composition in the channels to form active plugs axially spaced apart from the nearest end face.

### Claim 21 (depends on 14)

The method of claim 14, further comprising applying a non-active composition to the honeycomb body to form non-active plugs, the non-active composition comprising:
a refractory filler having a particle size distribution;
an organic binder;
an inorganic binder; and
a liquid vehicle.