Nonwoven Composites and Related Products and Methods
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Abstract
The present invention in certain embodiments is directed to a catalytic substrate suitable for use in a number of applications, including as a substrate in a catalytic converter or a particulate filter. Another aspect of the present invention is a filtering substrate suitable for use in a number of applications, including as a substrate in a particulate filter, such as a diesel particulate filter (DPF), or diesel particulate trap (DPT). The invention also provides an improved substrate for removing and/or eliminating pollutants from the exhaust of combustion engines. The catalytic substrate and filtering substrate provide, in certain embodiments, improvements in removing pollutants from an exhaust gas. The improvements include one or more of the following: faster light-off period, depth filtration of PM, less backpressure, lower probability of clogging, ability to be placed in multiple locations in the exhaust system including the manifold or the head itself, high probability of catalytic reaction, high conversion ratios of NOx, HC, and CO, a faster burnoff of PM, minimization of catalyst material use, and the like.
85 Citations
70 Claims
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1-47. -47. (canceled)
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48. An improved diesel particulate filter for a vehicle comprising:
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a vehicle having a diesel engine; a substrate comprising; bonded ceramic fibers forming a rigid non-woven matrix, wherein the ceramic fibers are bonded by a sintering process; pore space of greater than 60% in the substrate; a plurality of channels in the substrate, wherein the channels are in a cellular configuration; and wherein the substrate is a non-pleated construction; the substrate having a wall-flow configuration; and the substrate adapted for use in the vehicle as a diesel exhaust particulate filter. - View Dependent Claims (49, 50, 51, 52, 53)
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54. A catalytic converter comprising:
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a substrate comprising; bonded ceramic fibers forming a rigid non-woven matrix, wherein the ceramic fibers are bonded by a sintering process; pore space of greater than 60% in the substrate; a plurality of channels in the substrate, wherein the channels are in a cellular configuration; at least one catalyst; and wherein the substrate is a non-pleated construction; the substrate mounted in a canister, the canister comprising a housing and a matting; the substrate adapted for use as a catalytic converter in a vehicle. - View Dependent Claims (55, 56, 57, 58)
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59. An exhaust system comprising:
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a catalytic converter including a substrate comprising; bonded ceramic fibers forming a rigid non-woven matrix, wherein the ceramic fibers are bonded by a sintering process; pore space of greater than 60% in the substrate; a plurality of channels in the substrate, wherein the channels are in a cellular configuration; at least one catalyst; and wherein the substrate is a non-pleated construction; the substrate mounted in a canister, the canister comprising a housing and a matting; the exhaust system adapted for use as an exhaust system of a small engine. - View Dependent Claims (60)
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61. A catalytic converter substrate comprising:
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ceramic fibers bonded in a non-woven arrangement; pore space of greater than 60% in the substrate; wherein the substrate is a non-pleated construction; a catalyst; and wherein said substrate has a plurality of channels, and a shape suitable for use in a catalytic converter used with an internal combustion engine. - View Dependent Claims (62)
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63. A filtering substrate comprising:
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bonded ceramic fibers forming a rigid non-woven matrix, wherein the ceramic fibers are bonded by a sintering process; pore space of greater than 60% in the substrate; a plurality of channels in the substrate forming a honeycomb configuration; and wherein the substrate is a non-pleated construction. - View Dependent Claims (64, 65, 66, 67, 68, 69, 70)
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Specification