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Low fuel consumption and improved power output are the main market drivers in the automotive industry. For these challenges, Gasoline Direct Injection (GDI) technology provides higher thermal efficiency than Multi Point Injection (MPI) engines and this technology is expanding as a solution to reduce CO₂ and improve driveability. In Europe under the Euro 5 regulation, engine downsizing becomes a major solution to reduce CO₂ of gasoline engines. For this concept GDI is essential together with turbocharging technology. However GDI technology increases particulate matter (PM) emissions compared to MPI engines. As the introduction of a Particle Number (PN) regulation for Euro 6 GDI vehicles has been decided, technologies to reduce GDI PN emissions start to become necessary. For this requirement, a gasoline particulate filter (GPF) is an effective solution.

In order to meet the challenging CO2 targets beyond 2020 without sacrificing performance, Gasoline Direct Injection (GDI) technology, in combination with turbo charging technology, is expanding in the automotive industry. However, while this technology does provide a significant CO2 reduction, one side effect is increased Particle Number (PN) emission. As a result, from September 2017, GDI vehicles in Europe are required to meet the stringent PN emission limits of 6x1011 #/km under the Worldwide harmonized Light vehicles Test Procedure (WLTP). In addition, it is required to meet PN emission of 9x1011 #/km under Real Driving Emission (RDE) testing, which includes a Conformity Factor (CF) of 1.5 to account for current measurement inaccuracies on the road. This introduction of RDE testing in Europe and China will especially provide a unique challenge for the design of exhaust after-treatment systems due to its wide boundary conditions.

A Particle Number (PN) limit for Gasoline Direct Injection (GDI) vehicles was introduced in Europe from September 2014 (Euro 6b). In addition, further certification to Real Driving Emissions (RDE) is planned [1] [2], which requires low and stable emissions in a wide range of engine operation, which must be durable for at least 160,000 km. To achieve such stringent targets, a ceramic wall-flow Gasoline Particulate Filter (GPF) is one potential emission control device. This paper focuses on a catalyzed GPF, combining particle trapping and catalytic conversion into a single device. The main parameters to be considered when introducing this technology are filtration efficiency, pressure drop and catalytic conversion. This paper portrays a detailed study starting from the choice of material recipe, design optimization, engine bench evaluation, and final validation inside a standard vehicle from the market during an extensive field test up to 160,000 km on public roads.

The LDV gasoline emission regulation is set to be tightened for Euro7. In particular, the particulate number (PN) requirement has been significantly tightened requiring a GPF with extra - high filtration efficiency to meet the target requirement. In order to meet the stricter PN requirements, GPF substrate material improvement is necessary. However, conventional GPF material improvement for high filtration efficiency will increase the filter backpressure significantly. The relationship between pressure drop and CO2 emission is difficult to quantify but high pressure drop can potentially increase the CO2 emission. Therefore, Membrane Technology (MT) is the key to break through the trade-off between filtration performance and pressure drop. MT is thin and dense layer of small grains applied on the GPF surface. MT application can increase particulate filtration efficiency significantly with minimal pressure drop increase.