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A wall flow diesel particulate filter (DPF) having a novel wall pore structure design for reducing backpressure, increasing robustness, and increasing filtration efficiency is presented. The filter offers a linear relationship between soot loading and backpressure, offering greater accuracy in estimating the amount of soot loading from backpressure. Basic experiments were performed on small plate test pieces having various pore structure designs. Soot generated by a Cast-2F propane burner having a controlled size distribution was used. Cold flow test equipment that was carefully designed for flow distribution and soot/air mixing was used for precise measurement of backpressure during soot loading. The upstream and downstream PM numbers were counted by Scanning Mobility Particle Sizer (SMPS) to determine soot concentration in the gas flow and filtration efficiency of the test pieces. Microscope observations of the soot trapped in the wall were also carried out.

Although diesel engines are superior to gasoline engines in terms of the demand to reduce CO2 emissions, diesel engines suffer from the problem of emitting Particulate Matter (PM). Therefore, a Diesel Particulate Filter (DPF) has to be fitted in the engine exhaust aftertreatment system. From the viewpoint of reducing CO2 emissions, there is a strong demand to reduce the exhaust system pressure drop and for DPF designs that are able to help reduce the pressure drop. A wall flow DPF having a novel wall pore structure design for reducing pressure drop, increasing robustness and increasing filtration efficiency is presented. The filter offers a linear relationship between PM loading and pressure drop, offering lower pressure drop and greater accuracy in estimating the accumulated PM amount from pressure drop. First, basic experiments were performed on small plate test samples having various pore structure designs.

Combustion phenomena in the regeneration of a diesel particulate filter (DPF) were clarified through a visualization experiment, using a half-cylindrical wall-flow DPF covered by a quartz glass plate. At a constant oxygen concentration (8.5% and 10% in the current study) of a working gas used for regeneration, in the cases of large particulate masses and high working gas temperatures, the particulate matter trapped on the filter surface is burned in a narrow reaction zone which can be observed as a high brightness zone moving slowly toward the downstream side. Just after the reaction zone passes, a sharp temperature peak is detected and there remains no particulate matter on the filter surface. Furthermore, the particulate matter is ignited first around the middle of the DPF, and then, the reaction zone propagates toward both the upstream and the downstream sides.

A regeneration of DPF with collected PM was investigated using the low temperature atmospheric pressure nonthermal plasma. The method is to use the NO2 and radicals induced by the plasma reactor to burn carbon soots deposited on DPF. First, the performances on the conversion of NO to NO2 of the three types of DPF plasma reactors were evaluated on various conditions. Next, a regeneration experiment was carried out using a barrier type pulsed corona plasma reactor. As a result, the regeneration of DPF using the plasma was confirmed when the gas temperature was 250°C.

Gasoline Direct Injection (GDI) engines achieve better fuel economy but have the drawback of increased Particulate Matter (PM) emissions. As known from diesel engine applications particulate filters are an effective PM reduction device which is expected to be effective for reduction of particulates emitted by GDI engines as well. For this investigation new filter concepts especially designed for GDI applications are proposed. Filtration efficiency, pressure drop and regeneration performance were verified by cold flow bench and engine and chassis dynamometer testing. The experimental data were used to discuss the validity of these new filter design concepts.

Ammonia Selective Catalytic Reduction (SCR) and Lean NOx Trap (LNT) systems are key technologies to reduce NOx emission for diesel on-highway vehicles to meet worldwide tighter emission regulations. In addition DeNOx catalysts have already been applied to several commercial off-road applications. Adding the DeNOx catalyst to existing Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) emission control system requires additional space and will result in an increase of emission system back pressure. Therefore it is necessary to address optimizing the DeNOx catalyst in regards to back pressure and downsizing. Recently, extruded zeolite for DeNOx application has been considered. This technology improves NOx conversion at low temperature due to the high catalyst amount. However, this technology has concerned about strength and robustness, because the honeycomb body is composed of catalyst.

Development of the ultra thin wall ceramic catalytic substrate is necessary to meet increasingly strict emissions regulations. The cell walls need to be thinner in order to improve the warm-up characteristics related to the reduction of emissions and to lower the back pressure. However, the thinner the wall thickness, the smaller the mechanical strength of the substrate becomes. For substrates with 2.5mil wall thickness, we densified a conventional material with 35% porosity to less than 30%[1] to improve erosion resistance. Furthermore, for substrates less than 2.5mil wall thickness, a denser material and strengthened end surface is necessary to protect against erosion. In addition to that, we think that a reinforced periphery is necessary for isostatic strength. In this paper, we evaluated the effect of a densified material, strengthened end surface, and a reinforced periphery.