Particulate filter

• US 8,092,565 B2
• Filed: 03/02/2009
• Issued: 01/10/2012
• Est. Priority Date: 03/28/2008
• Status: Expired due to Fees

• Current Assignee: Mazda Motor Corporation
• Original Assignee: Mazda Motor Corporation
• Inventors: Yamada, Hiroshi, Harada, Koichiro, Okamoto, Kenji, Takami, Akihide, Suzuki, Kenji
• Primary Examiner(s): CLEMENTE, ROBERT ARTHUR
• Application Number:
  US12/396,117
• Publication Number:
  US 20090241495A1
• Time in Patent Office: 1,044 Days
• Field of Search: 552/823, 554/83, 554/84, 555/23, 55D/IG.30, 422/177, 422/180, 428/116
• US Class Current: 55/483
• CPC Class Codes: B01D 2279/30 for treatment of exhaust gases from IC Engines
• CPC Class Codes: B01D 46/2455 of the whole honeycomb or segments
• CPC Class Codes: B01D 46/247 of the cells
• CPC Class Codes: B01D 46/2478 Structures comprising honeycomb segments
• CPC Class Codes: B01D 46/2484 Cell density, area or aspect ratio
• CPC Class Codes: B01D 46/2498 The honeycomb filter being defined by mathematical relationships
• CPC Class Codes: F01N 3/0222 the structure being monolithic, e.g. honeycombs
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10S 55/30 Exhaust treatment
• CPC Class Codes: Y10T 428/24149 Honeycomb-like

Abstract

Disclosed is a particulate filter 10, which comprises a filter body 8 including a plurality of filter segments F1, F2 joined to each other by a joining material 7, wherein each of the filter segments includes a plurality of inflow cells each having a closed end on a downstream side in an exhaust-gas flow direction, and a plurality of outflow cells each having a closed end on an upstream side in the exhaust-gas flow direction. The filter segments include a first filter segment located in a central region of the particulate filter and designed to form each of the inflow cells to have an opening area approximately equal to that of each of the outflow cells, and a second filer segment located in at least a part of an outer peripheral region of the particulate filter and designed to form each of the inflow cells to have an opening area greater than that of each of the outflow cells. The present invention can keep the central region of the particulate filter from becoming overheated during a particulate-filter regeneration process, while suppressing a pressure loss.

Claims

1. A particulate filter comprising:

a filter body including a plurality of filter segments joined to each other by a joining material, each of the filter segments including a plurality of inflow cells each having a closed end on a downstream side in an exhaust-gas flow direction, a plurality of outflow cells each having a closed end on an upstream side in the exhaust-gas flow direction, and a cell wall having communication pores for passage of exhaust gas and defining the inflow cells and the outflow cells; and

an outer peripheral coating covering an outer peripheral surface of the filter body,

wherein the filter segments include;

a first filter segment located in a central region of the particulate filter and designed to form each of the inflow cells to have an opening area approximately equal to that of each of the outflow cells; and

a second filer segment located in at least a part of an outer peripheral region of the particulate filter and designed to form each of the inflow cells to have an opening area greater than that of each of the outflow cells.

2. The particulate filter as defined in claim 1, wherein a percentage occupied by the second filter segment designed to form each of the inflow cells to have an opening area greater than that of each of the outflow cells, in the particulate filter, is in the range of 25 to 70%.

3. The particulate filter as defined in claim 1, wherein the number of the second filter segments each designed to form each of the inflow cells to have an opening area greater than that of each of the outflow cells is two or more, wherein the second filter segments are arranged symmetrically with respect to a point defined by a center of the particulate filter.

4. The particulate filter as defined in claim 1 which carries a catalyst material comprising:

a composite oxide containing Ce and Zr, alumina, and Pt as a catalyst metal.

5. The particulate filter as defined in claim 2, wherein the number of the second filter segments each designed to form each of the inflow cells to have an opening area greater than that of each of the outflow cells is two or more, wherein the second filter segments are arranged symmetrically with respect to a point defined by a center of the particulate filter.

6. The particulate filter as defined in claim 2, which carries a catalyst material comprising:

a composite oxide containing Ce and Zr;

alumina; and

Pt as a catalyst metal.