Corning Incorporated

Achim Karl-Erich Heibel

Douglas Munroe Beall

Pushkar Tandon

Suhao He

David John Thompson

Sam George

Kenneth Richard Miller

Wenbin Qiu

Min Shen

Dana Craig Bookbinder

Todd Parrish St Clair

Robert John Locker

Izhar Zahoor Ahmed

Thomas Adam Collins

Seth Thomas Nickerson

Kunal Upendra Sakekar

Vishwanath Deshmane

Konstantin Vladimirovich Khodosevich

Prashanth Abraham Vanniamparambil

Joshua Adam Jamison

Paul Michael Schelling

Hrushikesh Govindrao Pimpalgaonkar

Sandeep Viswanathan

Krishna Sastry Aravelli

Mitchell E Smith

Mahesh Govindareddy

An exhaust treatment method and apparatus for treating an exhaust stream flowing through an exhaust line housing in a downstream direction, the apparatus comprising a first particulate filter, an SCR unit, and a second particulate filter downstream of the SCR unit, all serially positioned in the exhaust line.

Exhaust treatment method and apparatus having particulate filters and SCR

A method of manufacturing a ceramic honeycomb structure by mixing a ceramic precursor batch composition having a median particle diameter less than or equal to about 10 μm and at least one starch-based pore former having a median particle diameter greater than or equal to about 10 μm. The method also includes forming a mixture of ceramic precursor batch composition and a starch-based pore former into a green ceramic structure having a web structure, and firing the green ceramic structure to yield a ceramic honeycomb structure.

High porosity ceramic honeycomb structure and method of manufacturing

An exhaust treatment apparatus for treating exhaust gas flowing through an exhaust line housing from an upstream location to a downstream location in a downstream direction, the exhaust treatment apparatus comprising a ceramic filter body having a honeycomb structure of a plurality of intersecting porous ceramic walls extending from a first end to a second end in an axial direction and defining a plurality of channels extending in the axial direction, wherein a first transverse face at the first end comprises metal oxide particles affixed to a portion of the intersecting walls. The metal oxide particles may be affixed to the upstream end, or the downstream end, or both the upstream and downstream ends. Preferably the metal oxide particles provide reinforcement to the underlying portion of the walls, and of the honeycomb structure itself.

Reinforced exhaust treatment article, exhaust line, and methods

A particulate filter having a honeycomb structure of a matrix of interconnected porous walls including inlet cells and outlet cells defining a plurality of inlet channels and outlet channels, respectively, wherein at least a portion of the outlet cells are larger than any of the inlet cells, and a cross-sectional shape of at least some of the outlet channels is rectangular. Honeycomb extrusion dies, honeycomb bodies, honeycomb structures, and methods of manufacture are described, as are other aspects.

Rectangular outlet honeycomb structures, particulate filters, extrusion dies, and method of manufacture thereof

An apparatus and methods for evaluating the radial compressive strength of ceramic honeycomb samples. The apparatus includes a housing defining a testing compartment. A pressure subsystem is configured to introduce a pressurizing fluid into the testing compartment. A flexible member is in fluid communication with the pressure subsystem. The flexible member defines a testing area within the testing compartment configured to receive the ceramic honeycomb sample. The flexible member expands inwardly and subjects the honeycomb sample to a compressive force by engaging against the outer surface of the honeycomb sample when pressurized by the pressurizing fluid. An end cap covers an end face of the ceramic honeycomb sample when the ceramic honeycomb sample is positioned in the testing compartment. An acoustic sensor disposed on the end cap is configured to translate acoustic waveforms propagating through the acoustic sensor to a signal representative of the acoustic waveforms.

Apparatus and method for evaluating radial compressive strength of a ceramic honeycomb sample

A coated ceramic honeycomb body comprising a honeycomb structure comprising a matrix of intersecting porous walls forming a plurality of axially-extending channels, at least some of the plurality of axially-extending channels being plugged to form inlet channels and outlet channels, wherein a total surface area of the outlet channels is greater than a total surface area of the inlet channels, and wherein a catalyst is preferentially located within the outlet channels, and preferentially disposed on non-filtration walls of the outlet channels. Methods and apparatus configured to preferentially apply a catalyst-containing slurry to the outlet channels and non-filtration walls are provided, as are other aspects.

Outlet-coated ceramic honeycomb bodies and methods of manufacturing same

A ceramic honeycomb structure having a web structure including a plurality of intersecting channel walls forming channels. The ceramic honeycomb structure has a total porosity greater than or equal to about 55%, an average channel wall thickness less than or equal to about 150 &#x3bc;m, a median pore diameter greater than or equal to about 10 &#x3bc;m, a dless than or equal to about 0.45, where d=(d&#x2212;d)/d, and a strength (MOR/CFA) greater than or equal to about 900 psi. A method of manufacturing a ceramic honeycomb structure by mixing a ceramic precursor batch composition having a median particle diameter less than or equal to about 10 &#x3bc;m and at least one starch-based pore former having a median particle diameter greater than or equal to about 10 &#x3bc;m. The method also includes forming a mixture of ceramic precursor batch composition and a starch-based pore former into a green ceramic structure having a web structure, and firing the green ceramic structure to yield a ceramic honeycomb structure.

A ceramic honeycomb body, suitable for use in exhaust gas processing, includes a honeycomb structure having a plurality of through-channels, a first portion of the plurality of through-channels have a first hydraulic diameter dh1, a second portion of the plurality of through-channels have a second hydraulic diameter that is smaller than the first hydraulic diameter dh1, the first hydraulic diameter dh1 is equal to or greater than 1.1 mm, and the first and second portions of through-channels, taken together, have a geometric surface area GSA greater than 2.9 mm. Diesel oxidation catalysts and methods of soot removal are also provided, as are other aspects.

Honeycomb bodies having an array of through channels with a range of hydraulic diameters

A honeycomb body having intersecting porous walls and repeating structural units. Each repeating structural unit has a plurality of inlet channels and outlet channels that extend parallel to each other in an axial direction from an inlet face to an outlet face. Each of the repeating structural units has 2.0&#x3c;I/O&#x3c;3.0, wherein I/O is a ratio of a number of inlet channels to a number of the outlet channels, each of the inlet and outlet channels have a same cross-sectional size and shape, and each inlet channel of a particular repeating structural unit directly abuts an outlet channel of the particular repeating structural unit or an outlet channel of an adjacent repeating structural unit. Particulate filters including the honeycomb body, honeycomb extrusion dies, and methods of capturing soot in the honeycomb body are provided, as are other aspects.

High ash storage, pattern-plugged, honeycomb bodies and particulate filters

A partial wall-flow filter has an inlet end, an outlet end, and a plurality of parallel channels disposed and configured to flow fluid from the inlet end to the outlet end. The channels are defined by a plurality of porous walls. A first portion of the channels have a first hydraulic diameter Dh1, a second portion of the channels have a second hydraulic diameter Dh2 smaller than the first hydraulic diameter Dh1, and the ratio of Dh1:Dh2 is in the range of 1.1 to 1.6. At least a portion of channels having hydraulic diameter Dh1 are plugged at the outlet end, and channels having hydraulic diameter Dh2 are flow-through channels.

Partial wall-flow filter and method

Method, apparatus, and system to control ammonia slip in a selective catalytic reduction (SCR) system. The method includes detecting an engine operation transition event, increasing NOx to the SCR catalyst, and decreasing a reductant dose. The system includes a controller to receive an engine transition signal, anticipate a temperature transition at the SCR catalyst in response to the engine transition signal, and cause a NOx increase in the exhaust gas stream to the SCR catalyst and a decrease of reductant to the SCR catalyst coinciding with the temperature transition at the SCR catalyst. The apparatus includes a NOx increase module to cause the NOx increase in the exhaust gas stream to the SCR catalyst in response to the engine transition signal. The apparatus also includes a reductant shut-off module configured to cause the reductant addition to the exhaust gas stream to turn off in response to the engine transition signal.

Method, apparatus, and system to control selective catalytic reduction (SCR) catalyst ammonia slip during high temperature transitions

A thin-walled porous ceramic wall-flow filter is disclosed. The filter produces a relatively lower pressure drop coupled with relatively high initial filtration efficiency (FE), and may enable packaging the filter in a smaller volume. The filter includes a plurality of porous ceramic walls forming cell channels. At least some of the cells are plugged forcing some exhaust gases through the walls, thereby filtering out entrained particulates. The walls have a wall thickness (T) wherein 102 &#x3bc;m&#x2266;T&#x3c;279 &#x3bc;m, and a median pore diameter (MPD), and wherein 10&#x3c;T/MPD, and may also be &#x3c;40. The relatively small median pore diameter (MPD) in comparison to the wall thickness (T) allows the use of thinner ceramic walls that provide less flow resistance than thicker walls while maintaining sufficient initial filtration efficiency (FE). Furthermore, such thin-walled filter structure coupled with unequal inlet/outlet area ratio (Ai/Ao) may allow filter lengths to be additionally shortened.

Thin-walled porous ceramic wall-flow filter

Systems and methods for controlling temperature and total hydrocarbon slip in an exhaust system are provided. Control systems can comprise an oxidation catalyst, a particulate filter, a fuel injector, and a processor for controlling a fuel injection based on an oxidation catalyst model. Example system includes a virtual sensor comprising a controller for calculating and providing the total hydrocarbon slip to subsystems for after-treatment management based on modeling the oxidation catalyst. Example methods for controlling the temperature and the total hydrocarbon slip in an exhaust system include the steps of providing an oxidation catalyst model, monitoring a condition of the exhaust system, calculating a hydrocarbon fuel injection flow rate and controlling a fuel injection. The example methods further include the steps of determining an error in the oxidation catalyst model based on the monitored condition and changing the oxidation catalyst model to reduce the error.

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Corning, NY, United States of America

Achim Karl-Erich Heibel