Gasoline particulate filters with high initial filtering efficiency and methods of making same

Patent metadata

Field	Value
Publication number	US-2020370452-A1
Application number	US-202016988932-A
Country	US
Kind code	A1
Filing date	Aug 10, 2020
Priority date	Sep 4, 2018
Publication date	Nov 26, 2020
Grant date	—

Abstract

Gasoline Direct Injection (GDI) engines require gasoline particulate filters (GPFs) as a key component of the emissions control system to reduce particulate emissions. GPFs are known to have poor initial performance, with performance increasing after the filter develops a cake. This poor initial performance make it impossible to accurately assess vehicle emissions performance at the mileage requirements for vehicle certification. Compositions and methods are disclosed to improve filtration efficiency in a fresh or low mileage GPF.

First claim

What is claimed is:

1 . A gasoline particulate filter comprising:
a pre-service gasoline particulate filter comprising pores, wherein the pores are at least partially filled with a particulate substance.

2 . The gasoline particulate filter of claim 1 , wherein the pre-service gasoline particulate filter provides a filtration efficiency of at least 80% after 100 initial miles.

3 . The gasoline particulate filter of claim 1 , wherein the particulate substance comprises at least one of a soot surrogate substance, an ash surrogate substance, and an aggregate particulate substance.

4 . The gasoline particulate filter of claim 3 , wherein the particulate substance comprises one or more of silica powder, alumina powder, talc, gypsum, soot, ash, flours, starches, and salts.

5 . The gasoline particulate filter of claim 1 , wherein the particulate substance is present on the gasoline particulate filter in an amount of at least about 0.5 gram/L.

6 . The gasoline particulate filter of claim 1 , wherein the particulate substance is present on the gasoline particulate filter in an amount up to about 6 grams/L.

7 . The gasoline particulate filter of claim 1 , wherein the particulate substance comprises a plurality of particles having a diameter of from about 10 nanometers to about 200 micrometers.

8 . A method of pretreating a gasoline particulate filter, comprising:
contacting the gasoline particulate filter comprising pores with a particulate substance prior to installing the gasoline particulate filter in a vehicle to produce a pre-treated gasoline particulate filter, wherein the pores are at least partially filled with the particulate substance.

9 . The method of claim 8 , wherein the particulate substance comprises one or more of a surrogate soot substance, a surrogate ash substance, and an aggregate surrogate substance.

10 . The method of claim 9 , wherein the particulate substance comprises one or more of silica powder, alumina powder, talc, gypsum, soot, ash, flours, starches, and salts.

11 . The method of claim 8 , wherein the particulate substance comprises a plurality of particles, wherein each particle has a diameter from about 10 nanometers to about 200 micrometers.

12 . The method of claim 8 , wherein the contacting is via pneumatic conveyance of the particulate substance into the gasoline particulate filter.

13 . The method of claim 8 , wherein the pre-treated gasoline particulate filter is operable to provide a filtration efficiency of greater than 80% after 100 initial miles.

14 . A method of increasing an initial in-service filtration efficiency of a gasoline particulate filter, comprising:
contacting a newly installed gasoline particulate filter with an exhaust stream comprising particulate matter derived from a priming composition.

15 . The method of claim 14 , wherein the priming composition comprises a fuel and an organometallic compound comprising manganese, and wherein the organometallic compound is present in the priming composition in an amount effective to provide about 2 to about 36 milligrams of manganese per liter of priming composition.

16 . The method of claim 15 , wherein priming composition comprises methylcyclopentadienyl manganese tricarbonyl (MMT).

17 . The method of claim 14 , wherein the priming composition comprises at least one compound containing a chemical element selected from the group consisting of Ca, Mg, Mo, Zn, P, Ti, Mn, W, Na, and K.

18 . The method of claim 17 , wherein the priming composition further comprises a fuel.

19 . The method of claim 14 , further comprising measuring a filtration efficiency of the gasoline particulate filter contacted with the priming composition, wherein the filtration efficiency is greater than 80% after 100 initial miles.

20 . The method of claim 14 , further comprising:
treating a fuel tank with the priming composition during original equipment manufacturing, and adding a fuel to the fuel tank.

Assignees

• Afton Chemical Corp

Inventors

• Shao Huifang
• Roos Joseph W
• Remias Joseph E

Classifications

• C10N2010/14

  Group 7 · CPC title

• F01N3/022 Primary

  characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous · CPC title

• B01D2275/30

  Porosity of filtering material · CPC title

• C10N2040/25

  Internal-combustion engines · CPC title

• C10L10/06

  for facilitating soot removal · CPC title