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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 advance in emission control technologies towards Ultra Thin Wall (UTW) substrates has presented packaging challenges. With respect to mounting mats, there are two main problems with the traditional intumescent mats. First, intumescent mats typically generate too much pressure during assembly over their normal mounting range for the promised substrate strength; this can lead to broken substrates during assembly. Second, large pressure spikes occur in heated intumescent mats that could cause broken substrates in the field. As a result, non-intumescent mats are being used to alleviate the two main problems that occur with intumescent mats. A third alternative, a composite or “hybrid” mat, may offer a higher level of performance at lower cost compared to the non-intumescent mat solutions. The hybrid mats referred to in this paper consist of a layer of intumescent mat and a layer of non-intumescent mat.