Diesel particulate filter apparatus

• US 5,611,831 A
• Filed: 11/13/1995
• Issued: 03/18/1997
• Est. Priority Date: 11/16/1994
• Status: Expired due to Fees

• Current Assignee: Isuzu Motors Limited
• Original Assignee: Isuzu Ceramics Research Institute Co., Ltd. (Isuzu Motors Limited)
• Inventors: Kawamura, Hideo, Higashino, Akira, Matsuoka, Hiroshi, Sakaguchi, Toshiaki
• Primary Examiner(s): SPITZER, ROBERT H
• Application Number:
  US08/556,269
• Time in Patent Office: 491 Days
• Field of Search: 55/484, 55/486, 55/487, 55/497, 55/501, 55/521, 55/523, 55/527, 55/DIG. 10, 55/DIG. 30
• US Class Current: 55/486
• CPC Class Codes: B01D 2275/10 Multiple layers
• CPC Class Codes: B01D 2279/30 for treatment of exhaust gases from IC Engines
• CPC Class Codes: B01D 39/2003 Glass or glassy material
• CPC Class Codes: B01D 39/2017 the material being filamentary or fibrous
• CPC Class Codes: B01D 39/2082 the material being filamentary or fibrous
• CPC Class Codes: B01D 46/0087 Bypass or safety valves
• CPC Class Codes: B01D 46/2414 End caps including additional functions or special forms
• CPC Class Codes: B01D 46/2425 characterized by parameters related to the physical properties of the honeycomb structure material
• CPC Class Codes: B01D 46/2444 of the outer peripheral sealing
• CPC Class Codes: B01D 46/24494 Thermal expansion coefficient, heat capacity or thermal conductivity
• CPC Class Codes: B01D 46/24495 Young's modulus
• CPC Class Codes: B01D 46/2455 of the whole honeycomb or segments
• CPC Class Codes: B01D 46/2486 characterised by the shapes or configurations
• CPC Class Codes: B01D 46/2498 The honeycomb filter being defined by mathematical relationships
• CPC Class Codes: B01D 46/52 Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
• CPC Class Codes: B01D 46/521 using folded, pleated material
• CPC Class Codes: B01D 46/84 by heating only
• CPC Class Codes: F01N 2330/10 Fibrous material, e.g. mineral or metallic wool
• CPC Class Codes: F01N 2330/12 Metallic wire mesh fabric or knitting
• CPC Class Codes: F01N 3/022 characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
• CPC Class Codes: F01N 3/0226 : the structure being fibrous
• CPC Class Codes: F01N 3/027 : using electric or magnetic heating means
• CPC Class Codes: F01N 3/032 : during filter regeneration only
• CPC Class Codes: F01N 3/18 : characterised by methods of operation; Control
• CPC Class Codes: F02B 3/06 : with compression ignition compression ignition engines using air or gas for blowing fuel into compressed air in cylinder F02B13/02
• CPC Class Codes: Y10S 55/30 : Exhaust treatment

Abstract

A diesel particulate filter apparatus comprises filter structures bent in a wavy profile, formed in a tubular form, and comprising ceramic fiber laminate materials formed by randomly laminating a ceramic fiber and wire nets laminated on the ceramic fiber laminate materials. First rigid members and second rigid members are fitted in and on both end portions of the filter structures. Tubular clamping members for clamping the filter structures in the thickness-wise direction thereof are provided on the outer sides of the second rigid members. Woven fabrics may be interposed between nonwoven fabrics of the ceramic fiber and the wire nets constituting the filter structures. Filter members comprise ceramic fiber laminate materials formed by laminating a ceramic fiber, and glass layers covering the outer peripheral surfaces of the ceramic fiber laminate materials and having a low Young'"'"'s modulus and a coefficient of linear thermal expansion substantially the same as that of the ceramic fiber, whereby breakage of the fiber laminate materials can be prevented while enabling forming thereof.

Claims

1. A diesel particulate filter apparatus comprising filter structures comprising ceramic fiber laminate materials formed by randomly laminating a ceramic fiber, and nets laminated on said ceramic fiber laminate materials for collecting particulates contained in exhaust gas from an engine with said filter structures;

wherein said filter structures are each bent in a wavy profile and formed in a tubular form, and

wherein both end portions of said filter structures further comprise first rigid members having a form fitting in said wavy profile on the inner sides of said filter structures, second rigid members having a form fitting on said wavy profile on the outer sides of said filter structures, and tubular clamping members for clamping said filter structures in the thickness-wise direction thereof on the outer sides of said second rigid members.

2. A diesel particulate filter apparatus as claimed in claim 1, wherein said first rigid members are made of a material selected from the group consisting of metals, ceramics and porous substances, and have the surfaces thereof covered with insulating layers.

3. A diesel particulate filter apparatus as claimed in claim 1, wherein said second rigid members are made of a material selected from the group consisting of metals, ceramics and porous substances, and have the surfaces thereof covered with insulating layers.

4. A diesel particulate filter apparatus as claimed in claim 1, wherein said first rigid members and said second rigid members each comprise segmented members respectively fitting in and on the wavy profiles of said filter structures.

5. A diesel particulate filter apparatus as claimed in claim 1, wherein said clamping members are constituted of tubular metal bands having a coefficient of linear thermal expansion not exceeding the coefficient of linear thermal expansion of a material constituting said first rigid members and said second rigid members.

6. A diesel particulate filter apparatus as claimed in claim 1, wherein said nets constituting said filter structures are wire nets, portions of said wire nets located on both end portions of said filter structures have a network structure of metal wires mutually crossed in directions oblique to the axial direction of said filter structures, and the portions of said wire nets other than said portions located on both end portions of said filter structures have a network structure of metal wires mutually crossed in the axial and peripheral directions of said filter structures.

7. A diesel particulate filter apparatus as claimed in claim 1, wherein said ceramic fiber laminate materials comprise nonwoven fabrics made of a ceramic fiber and woven fabrics made of a ceramic fiber and laminated on said nonwoven fabrics in both end portions of said filter structures, and wherein said woven fabrics are interposed between said nonwoven fabrics and said nets.

8. A diesel particulate filter apparatus as claimed in claim 7, wherein said ceramic fiber constituting said woven fabrics comprises 2 to 98% of SiO₂, and the balance of Al₂ O₃.

9. A diesel particulate filter apparatus as claimed in claim 7, wherein said ceramic fiber constituting said woven fabrics comprises Si, and at least one element selected from the group consisting of C, O and Ti.

10. A diesel particulate filter apparatus as claimed in claim 7, wherein said woven fabrics made of said ceramic fiber have a thickness of at least 0.6 mm.

11. A diesel particulate filter apparatus comprising filter members for collecting particulates contained in exhaust gas from an engine with said filter members;

wherein said filter members comprise ceramic fiber laminate materials formed by randomly laminating a ceramic fiber, and glass layers covering the outer peripheral surfaces of said ceramic fiber laminate materials, said glass layers being made of a glass material low in Young'"'"'s modulus and substantially the same in coefficient of linear thermal expansion as said ceramic fiber.

12. A diesel particulate filter apparatus as claimed in claim 11, wherein said ceramic fiber is an SiC ceramic fiber.

13. A diesel particulate filter apparatus as claimed in claim 11, wherein said glass layers are made of an oxynitride glass material.

14. A diesel particulate filter apparatus as claimed in claim 13, wherein said oxynitride glass material is any one selected from the group consisting of Mg--Al--Si--O--N, Y--Al--Si--O--N, and Li--Al--Si--O--N.

15. A diesel particulate filter apparatus as claimed in claim 11, wherein said ceramic fiber is used in the form of a multiple twist yarn of small-diameter SiC ceramic fibers twisted and drawn in the form of a yarn.

16. A diesel particulate filter apparatus as claimed in claim 11, wherein said outer peripheral surfaces of said ceramic fiber laminate materials are covered with said glass layers by coating said ceramic fiber laminate materials with a sol-gel slurry of an oxide glass capable of being converted into said glass layers, and heating the resulting coated ceramic fiber laminate materials in NH₃ for nitriding of said oxide glass to cover said outer peripheral surfaces of said ceramic fiber laminate materials with said glass layers.

17. A diesel particulate filter apparatus as claimed in claim 11, wherein said outer peripheral surfaces of said ceramic fiber laminate materials are covered with said glass layers by coating said ceramic fiber laminate materials with a sol-gel slurry of LiO₂, Al₂ O₃, AlF₃, SiO₂ and SiO₄ capable of being converted into said glass layers, blended together in predetermined amounts and pulverized, and heating the resulting coated ceramic fiber laminate materials in N₂ to cover said outer peripheral surfaces of said ceramic fiber laminate materials with said glass layers.