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We studied the use of SiC porous material for diesel particulate filters. Crystallities of SiC grow into hexagonal plates during sintering,but their sizes have not been controllable yet. We developed a production process that makes the average pore diameter as desired in limiting the pore size distribution to a narrow range. Diesel particulate filters made of SiC greatly reduce pressure loss even when a large quantity of particulates accumulates as compared with conventional wall-flow type filter of cordierite of the same size. This enables particulate filter to be made smaller. The good thermal conductivity of SiC allows fast regeneration without a temperature spike, but its large coefficient of thermal expansion causes heat cracks during rig tests and engine bench tests. The rig tests showed that the heat cracking problem can be solved if the length and diameter are below a certain threshold for each.

The characteristics of a new diesel particulate filter material made of SiC were studied through engine tests in varying material properties, such as average pore diameter, and wall thickness. Compared to a conventional cordierite filter of the same size, particulate trapping efficiency is almost the same, and the pressure loss and the deterioration of fuel consumption can be reduced to about half with the optimum material properties. If the same pressure loss is allowed, the filter size can be reduced by 30%. Its good thermal conductivity prevents local temperature increases, which doubles the permissible amount of trapped particulates. As heat crack problems occurred in integral-type filters due to the high thermal expansion of SiC, a split-type filter having 49 filter segments with a square section was developed.

In Europe, where diesel engine cars enjoy widely popularity, the major diesel-engine car manufacturers have already announced that they will equip their diesel engine vehicles with DPF systems. Silicon carbide(SiC) has good fundamental properties. And the crack problem during regeneration could be successfully controlled by using split-type DPF which consists of multiple filter segments. The functional characteristics were focused on. For DPF, a model test by which events that may actually occur on vehicles can be produced is said to have not yet been established. From this point of view, in this study, SiC-DPF functions are characterized and evaluated under a regeneration system, and their correlation is discussed.

This work determined the suitability of two silicon carbide (SiC) monoliths (one regular and one coated with a micromembrane), as well as a coated cordierite monolith for use as aerodynamically regenerated particulate filters for diesel engines. These ceramic honeycomb monoliths were tested for their filtration efficiency, their post filtration particulate size distribution and their ability to be aerodynamically regenerated at pre-selected operating temperatures (200, 300 and 400°C). Through combined laboratory and field testing, the uncoated silicon carbide filter produced the most satisfactory results in all of these tests. This filter resulted in excellent regeneration characteristics while maintaining the highest filtration efficiencies at all particle sized tested. All filters were found to clean effectively at all temperatures. However, upon normalization with the volumetric flow rate through the monolith, it was found that the filters were most thoroughly cleaned at 400°C.