Nonwoven composites and related products and methods
AssigneeGE02 Technologies, Inc.
InventorsGordon S. Alward, Robert A. DiChiara, Jr., Bilal Zuberi
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Abstract
A porous honeycomb substrate including a non-woven fibrous ceramic body is provided herein. The fibrous ceramic body is substantially composed of bonded ceramic fibers forming a rigid non-woven matrix. Washcoat and catalyst materials can be applied to at least partially coat the honeycomb channels. The porous honeycomb substrate provides an improved substrate for use in filtration applications such as exhaust particulate filtration of internal combustion engines.
Claims23
An improved diesel particulate filter for a vehicle comprising:
- a vehicle having a diesel engine;
- a substrate comprising;
- bonded ceramic fibers forming a rigid non-woven matrix, wherein the ceramic fibers are bonded by a sintering process;
- pore space of greater than 60% in the substrate;
- a plurality of channels in the substrate, wherein the channels are in a cellular configuration;
- and
- wherein the substrate is a non-pleated construction;
- the substrate having a wall-flow configuration;
- and
- the substrate adapted for use in the vehicle as a diesel exhaust particulate filter.
A catalytic converter comprising:
- a substrate comprising;
- bonded ceramic fibers forming a rigid non-woven matrix, wherein the ceramic fibers are bonded by a sintering process;
- pore space of greater than 60% in the substrate;
- a plurality of channels in the substrate, wherein the channels are in a cellular configuration;
- at least one catalyst;
- and
- wherein the substrate is a non-pleated construction;
- the substrate mounted in a canister, the canister comprising a housing and a matting;
- the substrate adapted for use as a catalytic converter in a vehicle.
An exhaust system comprising:
- a catalytic converter including a substrate comprising;
- bonded ceramic fibers forming a rigid non-woven matrix, wherein the ceramic fibers are bonded by a sintering process;
- pore space of greater than 60% in the substrate;
- a plurality of channels in the substrate, wherein the channels are in a cellular configuration;
- at least one catalyst;
- and
- wherein the substrate is a non-pleated construction;
- the substrate mounted in a canister, the canister comprising a housing and a matting;
- the exhaust system adapted for use as an exhaust system of a small engine.
A catalytic converter substrate comprising:
- ceramic fibers bonded in a rigid non-woven matrix;
- pore space of greater than 60% in the substrate;
- wherein the substrate is a non-pleated construction;
- a catalyst;
- and
- wherein said substrate has a plurality of channels in a cellular configuration, and a shape suitable for use in a catalytic converter used with an internal combustion engine.
A filtering substrate comprising:
- bonded ceramic fibers forming a rigid non-woven matrix, wherein the ceramic fibers are bonded by a sintering process;
- pore space of greater than 60% in the substrate;
- a plurality of channels in the substrate forming a honeycomb configuration;
- and
- wherein the substrate is a non-pleated construction.
Dependencies are inferred from the claim text.