Catalyzed soot filter manufacture and systems

B - Operations – Transporting – 01 – D

Patent

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Details

B01D 53/94 (2006.01) B01J 37/02 (2006.01) F01N 3/022 (2006.01) F01N 3/035 (2006.01)

Patent

CA 2708235

Wall flow monolithic honeycomb filter having including microcracks having an average width less than 0.4 µm, and pores having a mean pore size in the range of 10 µm to 25 µm; and a washcoat disposed within the walls of the wall flow monolith, the washcoat including catalyst comprising support particles and at least one precious metal, where at least 90% of the support particles have particle sizes greater than the average size of the microcracks and at least 90% of the support particles have particle sizes less than the mean size of the pores of the wall flow monolith. The wall flow monolith comprises aluminum titanate having a porosity in the range of 40%. to 70%, wherein the soot filter shall exhibit a coefficient of thermal expansion less than 25 x -7/K when measured at 1000°C preferably less than 5 x 10-7/K when measured at 800 °C.

La présente invention concerne un filtre monolithique en nid d'abeille à écoulement sur paroi comprenant des microfissures ayant une largeur moyenne inférieure à 0,4 µm, et des pores ayant une taille moyenne de pores dans la plage de 10 µm à 25 µm ; et un revêtement de type = imprégnateur = (washcoat) disposé à l'intérieur des parois du monolithe à écoulement sur paroi, le revêtement de type imprégnateur comprenant un catalyseur comprenant des particules de support et au moins un métal précieux, au moins 90 % des particules de support ayant des tailles de particules supérieures à la taille moyenne des microfissures et au moins 90 % des particules de support ayant des tailles de particules inférieures à la taille moyenne des pores du monolithe à écoulement sur paroi. Le monolithe à écoulement sur paroi comprend du titanate d'aluminium ayant une porosité dans la plage de 40%. jusqu'à 70%, le filtre à suie présentant un coefficient d'expansion thermique inférieur à 25 x 10-7/K lorsqu'il est mesuré à 1 000°C, de préférence inférieur à 5 x 10-7/K lorsqu'il est mesuré à 800°C.

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