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A new platform of advanced ceramic composite filter materials for diesel particulate matter and exhaust gas emission control has been developed. These materials exhibit high porosity, narrow pore-size distribution, robust thermo-mechanical strength, and are extruded into high cell density honeycomb structures for wall-flow filter applications. These new high porosity filters provide a structured filtration surface area and a highly connected wall pore space which is fully accessible for multi-phase catalytic reactions. The cross-linked microstructure (CLM™) pore architecture provides a large surface area to host high washcoat/catalyst loadings, such as those required for advanced multi-functional catalysts (4-way converter applications).

Advances in emission control technologies have demanded development of new ceramic chemistries and improved microstructures in catalytic substrates and especially in diesel particulate filters. High porosity filters are desirable, as they decrease engine backpressure and enable application of advanced catalysts including, but not limited to, multi-functional filters (MFF). A significant recent development has been in the use of ceramic fibers to create cross-linked microstructures in extruded honeycomb ceramics. This development allows high porosities to be attained while maintaining mechanical strength. However, according to the World Health Organization, certain classes of ceramic fibers are considered to have adverse health effects if released in air and inhaled.

GEO2 Technologies has developed an extruded fiber-based cross linked microstructure (CLM™) for use as a nano-particulate filter in gasoline 2-stroke exhaust emission control. CLM™ materials exhibit high porosity, narrow pore-size distribution, robust thermo-mechanical properties, and are extruded into high cell density honeycomb structures for wall-flow filter applications. GEO2 has demonstrated basic emission performance and durability of the CLM™ filter on a Piaggio 50cc scooter as well as on a 29cc Homelite leaf blower. The results show significant reduction in particulate emissions of greater than 97% while maintaining gas phase emissions (leaf blower) and without significant impact on engine performance or power output. In addition, a 16,000 km dynamometer durability test was conducted on the Piaggio scooter. During testing, ash loading in the CLM™ filter exceeded 10 grams/liter.