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A new converter concept is introduced, which utilizes the additional space in the inlet cone of the converter. An optimized design is obtained by the application of computational fluid dynamics (CFD) and flow distribution measurements, resulting in up to 20% improved flow distribution through the substrate. In addition, the volume of the converter can be increased by approximately 15% using the same space envelope. Durability tests of the converter system have been performed using a thermal cycling test on an engine test bench for 135 hours. No deterioration of the substrate or mounting system occurred. The emissions performance was evaluated on a stationary dynamometer. The impact of the flow distribution on the temperature field and the conversion behavior during light-off and steady state operation were investigated. Under the current testing conditions, no differences in light-off behavior were determined, despite significant differences in the temperature field.

Over the past decade, regulations for mobile source emissions have become more stringent thus, requiring advances in emissions systems to comply with the new standards. For the popular diesel powered passenger cars particularly in Europe, diesel particulate filters (DPFs) have been integrated to control particulate matter (PM) emissions. Corning Incorporated has developed a new proprietary aluminum titanate-based material for filter use in passenger car diesel applications. Aluminum titanate (hereafter referred to as AT) filters were launched commercially in the fall of 2005 and have been equipped on more than several hundred thousand European passenger vehicles. Due to their outstanding durability, filtration efficiency and pressure drop attributes, AT filters are an excellent fit for demanding applications in passenger cars. Extensive testing was conducted on engine to evaluate the survivability and long-term thermo-mechanical durability of AT filters.