Reinforced exhaust treatment article, exhaust line, and methods

Patent metadata

Field	Value
Publication number	US-12576356-B2
Application number	US-202519073897-A
Country	US
Kind code	B2
Filing date	Mar 7, 2025
Priority date	Aug 31, 2021
Publication date	Mar 17, 2026
Grant date	Mar 17, 2026

Abstract

An exhaust treatment apparatus for treating exhaust gas flowing through an exhaust line housing from an upstream location to a downstream location in a downstream direction, the exhaust treatment apparatus comprising a ceramic filter body having a honeycomb structure of a plurality of intersecting porous ceramic walls extending from a first end to a second end in an axial direction and defining a plurality of channels extending in the axial direction, wherein a first transverse face at the first end comprises metal oxide particles affixed to a portion of the intersecting walls. The metal oxide particles may be affixed to the upstream end, or the downstream end, or both the upstream and downstream ends. Preferably the metal oxide particles provide reinforcement to the underlying portion of the walls, and of the honeycomb structure itself.

First claim

What is claimed is:

1 . A ceramic body for treating an exhaust gas, comprising:
a first end and a second end opposite the first end; a honeycomb structure extending from a first end face at the first end to a second end face at the second end face in an axial direction, the honeycomb structure formed by a plurality of intersecting porous ceramic walls defining a plurality of channels extending in the axial direction, at least some channels of the plurality of channels comprising a plugging material disposed in an end thereof; a metal oxide coating disposed on at least one of the first end face of the honeycomb structure or the second end face of the honeycomb structure; and wherein the metal oxide coating comprises alumina nanoparticles with a median particle size between 10 nm and 50 nm and alumina microparticles with a median particle size between 0.1 um and 20 μm.

2 . The ceramic body of claim 1 , wherein the metal oxide coating extends to a depth into the honeycomb structure of at least 0.01 inches but not exceeding 2.0 inches from the respective end face of the honeycomb structure.

3 . The ceramic body of claim 1 , wherein the metal oxide coating extends to a depth into the honeycomb structure of at least 0.01 inches but not exceeding 1.0 inch from the respective first or second end face of the honeycomb structure.

4 . The ceramic body of claim 1 , wherein the metal oxide coating extends to a depth into the honeycomb structure of at least 0.01 inches but not exceeding 0.5 inches from the respective first or second end face of the honeycomb structure.

5 . The ceramic body of claim 1 , wherein the metal oxide coating coats surfaces of the plurality of intersecting porous walls no greater than 0.5 inches into the honeycomb structure from the respective first or second end face of the honeycomb structure.

6 . The ceramic body of claim 1 , wherein the metal oxide coating is present at a loading between 40 grams/liter (g/l) and 200 g/l per liter of the ceramic body in contact with the metal oxide coating.

7 . The ceramic body of claim 1 , wherein the metal oxide coating is free of a HC oxidation catalyst material or a NO oxidation catalyst material.

8 . An exhaust treatment apparatus for treating exhaust gas, comprising:
a reducing agent injector disposed on the exhaust line housing; a ceramic filter body comprising a first end and a second end opposite the first end, the ceramic filter body further comprising:
a honeycomb structure extending from a first end face of the honeycomb structure at the first end of the ceramic filter body to a second end face at the second end of the ceramic filter body in an axial direction, the honeycomb structure formed by a plurality of intersecting porous ceramic walls defining a plurality of channels extending in the axial direction;
a metal oxide coating disposed on at least one of the first end face or the second end face; and
wherein the metal oxide coating comprises alumina nanoparticles with a median particle size between 10 nm and 50 nm and alumina microparticles with a median particle size between 0.1 μm and 20 μm.

9 . The exhaust treatment apparatus of claim 8 , wherein the metal oxide coating extends to a depth into the honeycomb structure of at least 0.01 inches but not exceeding 2.0 inches from the respective end face of the honeycomb structure.

10 . The exhaust treatment apparatus of claim 8 , wherein the metal oxide coating extends to a depth into the honeycomb structure of at least 0.01 inches but not exceeding 1.0 inch from the respective first or second end face of the honeycomb structure.

11 . The exhaust treatment apparatus of claim 8 , wherein the metal oxide coating extends to a depth into the honeycomb structure of at least 0.01 inches but not exceeding 0.5 inches from the respective first or second end face of the honeycomb structure.

12 . The exhaust treatment apparatus of claim 8 , wherein the metal oxide coating coats surfaces of the plurality of intersecting porous walls no greater than 0.5 inches into the honeycomb structure from the respective first or second end face of the honeycomb structure.

13 . The exhaust treatment apparatus of claim 8 , wherein the metal oxide coating is present at a loading between 40 grams/liter (g/l) and 200 g/l per liter of the ceramic body in contact with the metal oxide coating.

14 . The exhaust treatment apparatus of claim 8 , wherein the metal oxide coating is free of a HC oxidation catalyst material or a NO oxidation catalyst material.

15 . The exhaust treatment apparatus of claim 8 , wherein the reducing agent junction is positioned upstream of the ceramic filter body relative to a flow direction of the exhaust gas.

16 . The exhaust treatment apparatus of claim 8 , wherein the reducing agent junction is positioned downstream of the ceramic filter body relative to a flow direction of the exhaust gas.

17 . The exhaust treatment apparatus of claim 8 , wherein the reducing agent injector configured to inject a reducing agent comprising at least one of ammonia or urea into the exhaust line.

18 . The exhaust treatment apparatus of claim 8 , at least some of the channels comprise a plugging material plugging an end thereof.

Assignees

• Corning Inc

Inventors

• Beall Douglas Munroe
• Deshmane Vishwanath Ganpat
• George Sam
• Heibel Achim Karl-Erich
• Viswanathan Sandeep

Classifications

• C04B38/0096

  Pores with coated inner walls · CPC title

• B01D39/2068 Primary

  Other inorganic materials, e.g. ceramics · CPC title

• B01D46/0001

  Making filtering elements · CPC title

• B01D2279/30

  for treatment of exhaust gases from IC Engines · CPC title

• C04B38/0006

  Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083) · CPC title