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Low pressure-loss, especially for a catalyzed DPF(Diesel Particulate Filter), is a very significant performance. Higher-porosity DPF materials provide this lower pressure-loss parameter. This paper describes the successful material development of highly porous (up to 65% porosity) SiC materials. In addition, the influence of porosity and pore size distribution on pressure-loss and filtration efficiency with and without various catalyst loadings is presented.

Among the durability items of the DPF (Diesel Particulate Filter), high accumulated soot mass limit is important for the low fuel consumption and also for the robustness. In case of catalyzed DPF, it depends on the following two properties during soot regeneration. One is the lower maximum-temperature inside of the DPF during usual regeneration in order to preserve the catalyst performance. The other is the higher thermal resistance against the unusual regeneration of excess amount of soot. This paper presents the improvement in the soot mass limit of Si bonded SiC DPF. Maximum-temperature inside of the DPF was lowered by the improvement of thermal conductivity of the material, resulted from the controlling of the microstructure. Additionally the thermal resistance was improved by the surface treatment of the Si and SiC.