Methods and systems for a particulate filter

Patent metadata

Field	Value
Publication number	US-10794309-B2
Application number	US-201816103792-A
Country	US
Kind code	B2
Filing date	Aug 14, 2018
Priority date	Oct 18, 2017
Publication date	Oct 6, 2020
Grant date	Oct 6, 2020

Abstract

Methods and systems are provided for a particulate filter comprising a pretreatment. In one example, a method may include applying a pretreatment to an unused particulate filter, wherein the particulate filter is subjected to incomplete oxidation conditions following application of the pretreatment.

First claim

The invention claimed is:

1. A method comprising:
manufacturing a particulate filter;
applying a hydrocarbon-containing composition onto at least a portion of the particulate filter;
arranging the particulate filter in an exhaust passage of a vehicle; and
adjusting engine operating parameters during a first combustion of an engine of the vehicle to incompletely oxidize the hydrocarbon-containing composition
wherein the incomplete oxidation includes an air/fuel ratio of greater than or equal to stoichiometric.

2. The method of claim 1 , wherein a duration of the incomplete oxidation is terminated in response to a backpressure being equal to at least a threshold minimum backpressure.

3. The method of claim 2 , wherein terminating the incomplete oxidation includes decreasing the air/fuel ratio to at least slightly below stoichiometric.

4. The method of claim 1 , wherein pores of the particulate filter are slightly oversized relative to a desired operating pore size in anticipation of the hydrocarbon-containing composition being incompletely oxidized.

5. The method of claim 1 , wherein the carbon-containing composition is a synthetic resin.

6. The method of claim 1 , wherein the particulate filter is a diesel particulate filter or a spark-ignition fuel particulate filter.

7. A method for pretreating a particulate filter comprising:
applying a pretreatment comprising a hydrocarbon-containing composition to a portion of a particulate filter in response to an exhaust backpressure being less than a threshold minimum backpressure;
wherein the pretreatment is partially oxidized by adjusting air/fuel ratio when the particulate filter first receives exhaust gas.

8. The method of claim 7 , wherein the threshold minimum backpressure is equal to a backpressure generated by a minimum desired soot layer arranged on the particulate filter.

9. The method of claim 7 , wherein the pretreatment is applied to an unused particulate filter, wherein the unused particulate filter has not filtered exhaust gas, and where the pretreatment is applied over a catalytic coating of the unused particulate filter.

10. The method of claim 9 , wherein the pretreatment is applied to the unused particulate filter in or outside of an exhaust passage of a vehicle.

11. The method of claim 7 , wherein an injector is positioned to inject the pretreatment into an exhaust passage or directly into a particulate filter housing, wherein the injector injects the pretreatment during a first combustion of an engine following installing the particulate filter into an exhaust passage shaped to receive exhaust gas from the engine.

12. The method of claim 11 , wherein the injector is shaped to additionally inject fluids different than the pretreatment, including one or more of water, urea, and fuel.

13. The method of claim 7 , further comprising sizing a plurality of pores of the particulate filter to a size greater than a desired pore size, wherein the desired pore size is based on an optimal size of the plurality of pores to capture particulates in an exhaust gas flow.

14. A system comprising:
a particulate filter treated with a pretreatment comprising a pore size greater than a desired pore size, and where the particulate filter is free of soot and arranged in an exhaust passage shaped to receive exhaust gas from an engine; and
a controller with computer-readable instructions stored on non-transitory memory thereof that when executed enable the controller to:
increase an air/fuel ratio upon a first ignition of the engine to partially oxidize the pretreatment;
decrease the air/fuel ratio upon an exhaust backpressure being equal to a threshold minimum backpressure.

15. The system of claim 14 , wherein the pretreatment is a synthetic resin comprising a hydrocarbon-containing composition.

16. The system of claim 14 , wherein the pore size is equal to the desired pore size in response to the exhaust backpressure being equal to the threshold minimum backpressure.

17. The system of claim 14 , wherein the particulate filter is treated with the pretreatment before or after the particulate filter is arranged in the exhaust passage.

18. The system of claim 14 , wherein partially oxidizing the pretreatment further includes forming a soot layer on at least a portion of the particulate filter.

Assignees

• Ford Global Tech Llc

Inventors

• Ruhland Helmut Hans
• Carberry Brendan Patrick
• Linsel Jan
• Boerensen Christoph

Classifications

• F02D41/029

  the exhaust gas treating apparatus being a particulate filter · CPC title

• F01N2610/00

  Adding substances to exhaust gases · CPC title

• F01N2900/1406

  Exhaust gas pressure · CPC title

• F02D41/1475

  Regulating the air fuel ratio at a value other than stoichiometry · CPC title

• B01D2255/9155

  Wall flow filters · CPC title