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The current automotive catalytic converter is highly dependable and provides excellent emissions reduction while at the same time it offers little resistance to the flow of gasses through the exhaust system. As automobile performance requirements increase, and as the allowable tailpipe emissions are tightened, there is a need on the one hand to reduce the back pressure even further, and on the other, to increase the already excellent catalytic performance. This paper will analyze the substrate factors which influence the pressure drop and conversion efficiency of the catalyst system. The converter frontal area has the most significant influence on both pressure drop and conversion efficiency, followed in order by part length, cell density, and wall thickness.

Previous papers have considered the role of the substrate in the catalyst system. It has been shown that the total catalyzed surface area of the substrate (defined as the substrate geometric surface area multiplied by the substrate volume) can act as a surrogate for the catalyst performance. The substrate affects the back pressure of the exhaust system and therefore, the available power. Relationships have been developed between the substrate physical characteristics, and both the pressure drop and total surface area of the substrate. The substrate pressure drop has also been related to power loss. What has been lacking is a means of quantitatively relating the substrate properties to the conversion efficiency. This paper proposes a simple relationship between the substrate total surface area and the emissions of the vehicle as measured on the FTP cycle.

This paper details the development of the EX-80 composition, a new cordierite material for use as a diesel particulate filter (DPF), that was developed based on the following objectives; (1) improved thermal durability, (2) high filtration efficiency and (3) low pressure drop. The achievement of these goals was demonstrated through engine testing, stress modeling, and other evaluations. EX-80 has a low coefficient of thermal expansion (CTE) averaging less than 4x10-7°C-1 (25°C-800°C), the Modulus of Rupture (MOR) averages greater than 350 psi and the Modulus of Elasticity (MOE) averages less than 0.8 x 106 psi. The improvement of these three properties has resulted in improved thermal durability for EX-80 as compared to the current Corning DPF compositions (EX-47, EX-54 and EX-66). The new cordierite composition has been designed to achieve a low pressure drop as a function of soot loading (0.30 inHg/gm of soot collected), coupled with high efficiency, averaging greater than 90%.

The emission and flow restriction characteristics of three different ceramic substrates with varying wall thickness and cell density (400 cpsi/6.5 mil, 600/4.3, and 600/3.5) are compared. These 106mm diameter substrates were catalyzed with similar amounts of washcoat and fabricated into catalytic converters having a total volume of 2.0 liters. A Pd/Rh catalyst technology was applied at a concentration of 6.65 g/l and a ratio of 20/1. Three sets of converters (two of each type) were aged for 100 hours on an engine dynamometer stand. After aging, the FTP performance of these converters were evaluated on an auto-driver FTP stand using a 2.4L, four-cylinder prototype engine and on a 2.4L, four-cylinder prototype vehicle. A third set of unaged converters was used for cold flow restriction measurements and vehicle acceleration tests.