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This paper employs a systematic approach to packaging design and testing of a system and its components in order to determine the long term durability of light duty diesel filters. This effort has utilized a relatively new aluminum titanate filter technology as well as an advanced support mat technology engineered to provide superior holding force at lower temperatures while maintaining its high temperature performance. Together, these two new technologies form a system that addresses the unique operating conditions of diesel engines. Key physical properties of both the filter and the mat are demonstrated through laboratory testing. The system behavior is characterized by various laboratory techniques and validation procedures.

The advent of thermally durable catalyst technologies has created the opportunity to move catalytic converters closer to the engine, providing a potential solution for cold start emissions. Close-coupled positioning exposes the converter to higher exhaust gas temperatures than experienced in underbody applications, permitting earlier catalyst light-off. The proximity of the converter to the engine will result in increased exposure to the vibrational energy created by combustion processes as well as intake and exhaust valve dynamics. This study investigated the thermo-mechanical challenges of mounting a ceramic substrate under severe conditions. In some instances ceramic substrates have been overlooked for application in the more demanding close-coupled environment. It will be shown that ceramic substrates mounted with standard intumescent mats survive under the most severe hot vibration testing conditions in the industry. Hot vibration testing is a very expensive activity.