Exhaust gas filter

• US 5,423,904 A
• Filed: 11/09/1994
• Issued: 06/13/1995
• Est. Priority Date: 05/28/1993
• Status: Expired due to Term

• Current Assignee: Sankar Dasgupta
• Original Assignee: Sankar Dasgupta
• Inventors: Dasgupta, Sankar
• Primary Examiner(s): Chiesa, Richard L.
• Application Number:
  US08/338,731
• Time in Patent Office: 216 Days
• Field of Search: 96/146, 96/153, 55/523, 55/267, 55/301, 55/282, 55/283, 55/385.3, 55/DIG. 30, 95/278, 95/148, 95/283, 219/201, 219/205, 422/174, 422/199, 60/300, 60/303, 60/311, 60/320
• US Class Current: 96/146
• CPC Class Codes: B01D 2279/30 for treatment of exhaust gases from IC Engines
• CPC Class Codes: B01D 46/10 Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces
• CPC Class Codes: B01D 46/62 connected in series
• CPC Class Codes: B01D 46/84 by heating only
• CPC Class Codes: F01N 13/0097 the purifying devices are arranged in a single housing
• CPC Class Codes: F01N 2330/06 Ceramic, e.g. monoliths
• CPC Class Codes: F01N 2330/14 Sintered material
• CPC Class Codes: F01N 3/027 using electric or magnetic heating means
• CPC Class Codes: Y10S 55/30 Exhaust treatment

Abstract

An electrically conducting ceramic composition is described which can be utilized in an exhaust gas filter. The ceramic composition is compacted into discs or ceramic plates, are subsequently fired or sintered and then equipped with electrodes. Electrode leads are attached to the sintered filter discs or plates bearing electrodes which are subsequently connected to a power source. The ceramic filter discs or plates are supported and enclosed in a metallic housing. In another embodiment an insulator ring is placed between the housing and the ceramic filter plate. The housing enclosing the ceramic filter or filters, and equipped with electrodes and appropriate leads, is incorporated in the exhaust system of an internal combustion engine. The ceramic filter is used for trapping combustible carbon particles carried by the exhaust gas emanating from the engine. The carbon particles collected by the filter can be eliminated by heat generated electrically by means of an electrical current being passed through the filter between the electrodes when so desired.

Claims

1. An exhaust gas filtering device comprising,

i) a porous ceramic filter element having interconnecting channels for allowing exhaust gases to flow therethrough and trapping particles carried by said exhaust gases, said porous ceramic filter element being a unitary body composed of an electrically resistive ceramic substance comprising an electrically conducting ceramic component selected from the group consisting of molybdenum disilicide, titanium nitride, titanium carbonitride, titanium boride and zirconium boride, said electrically conducting ceramic component being homogenously dispersed in an electrically insulating ceramic component selected from the group consisting of silicon nitride, zirconia, alumina, cordierite, an alumina-silicate bearing chemical composition and mixtures thereof, said unitary body having uniform electrical conductivity, said unitary body of said porous ceramic filter element being defined by internal and external faces and a perimeter;

ii) a pair of electrodes in contact with said porous ceramic filter element, each of said electrodes having means to connect it to an electrical power source for generating an electrical current flowing between said pair of electrodes and within said porous ceramic filter element, thereby providing means to heat said porous ceramic filter element to a temperature above the ambient; and

iii) a housing having means to enclose the perimeter of said porous ceramic filter element, said housing having an inlet port in communication with an engine combustion chamber, and an outlet port, thereby facilitating the passage of exhaust gases from said combustion chamber through said internal face of said porous ceramic filter element to said outlet port.

2. An exhaust gas filtering device according to claim 1, wherein said electrically conducting ceramic component is present in said electrically resistive ceramic substance in 30-70 vol. %.

3. An exhaust gas filtering device according to claim 1, wherein said electrically resistive ceramic substance additionally comprises sintering additives.

4. An exhaust gas filtering device according to claim 1, wherein said interconnecting channels of said porous ceramic filter element have apertures ranging between 1 μ

m and 500 μ

m diameter.

5. An exhaust gas filtering device according to claim 1, wherein one of said pair of electrodes is a metallic coating deposited on one of said faces of said porous ceramic filter element and said metallic coating has a brazed metallic lead means for connecting said metallic coating to said electrical power source.

6. An exhaust gas filtering device according to claim 5, wherein the other of said pair of electrodes in contact with said porous ceramic filter element comprises said housing, and said housing has means for connecting said housing to said electrical power source or to ground.

7. An exhaust gas filtering device according to claim 1, wherein said electrodes are metallic bars embedded along the perimeter of said porous ceramic filter element in opposing sections of said perimeter and each of said bars has an attached metallic lead means to connect said bar to said electrical power source.

8. An exhaust gas filtering device according to claim 7, wherein the perimeter of said porous ceramic filter element is congruously enclosed in an annular insulator ring having an insulator ring perimeter and lower porosity than said porous ceramic filter element, and said housing has means to enclose said insulator ring perimeter.

9. An exhaust gas filtering device according to claim 7, wherein said perimeter of said ceramic filter element is congruously enclosed in an insulator plate having a circular insulator plate perimeter and lower porosity than said porous ceramic filter element, and said housing has means to enclose said circular insulator plate perimeter.

10. An exhaust gas filtering device according to claim 1, wherein said housing further comprises means to protect said porous ceramic filter element from mechanical shock.

11. An exhaust gas filtering device according to claim 1, wherein said housing is located within the exhaust gas handling system of an internal combustion device.

12. An exhaust gas filtering device according to claim 11, wherein said internal combustion device is an automotive engine.

13. An exhaust gas filtering device comprising a plurality of porous ceramic filter elements, each porous ceramic filter element having interconnecting channels for allowing exhaust gases to flow therethrough and trapping particles carried by said exhaust gases, said porous ceramic filter element being a unitary body composed of an electrically resistive ceramic substance further comprising an electrically conducting ceramic component selected from the group consisting of molybdenum disilicide, titanium nitride, titanium carbonitride, titanium boride and zirconium boride, said electrically conducting ceramic component being homogenously dispersed in an electrically insulating ceramic component selected from the group consisting of silicon nitride, zirconia, alumina, cordierite, an alumina-silicate bearing chemical composition and mixtures thereof, said unitary body having uniform electrical conductivity, said unitary body of said porous ceramic filter element being defined by an internal face, an external face and a perimeter, each porous ceramic filter element having a pair of electrodes in contact with said porous ceramic filter element, each of said electrodes having means to connect it to an electrical power source for generating an electrical current flowing between said electrodes and within said porous ceramic filter element, thereby providing means to heat said porous ceramic filter element to a temperature above the ambient;

and a housing having means to enclose the perimeter of each of said plurality of said porous ceramic filter elements in succession such that the external face of each but the last of said plurality of said porous ceramic filter elements, opposes the internal face of a successive porous ceramic filter element, said housing having an inlet port in communication with an engine combustion chamber and an outlet port, thereby facilitating the passage of exhaust gases from said chamber to the internal face of the first of said plurality of said porous ceramic filter elements, subsequently through each porous ceramic filter element to said outlet port.

14. An exhaust gas filtering device according to claim 13, wherein one of each of said pair of electrodes in contact with each of said plurality of said porous ceramic filter elements comprises a metallic coating deposited on one of said faces of said porous ceramic filter element, said metallic coating having metallic lead means to connect said metallic coating to an electrical power source, and the other of said pair of electrodes comprises said housing enclosing the perimeter of said porous ceramic filter element, and said housing has means to connect said housing to said electrical power source or to ground.