초록 ▼

An improved, efficient, and regenerable exhaust emission filter and filter system are provided which incorporate the use of an inorganic, non-woven fiber filter element. The filter is able to capture exhaust pollutants and particulates through the interwoven nature of the filter element and due to a

An improved, efficient, and regenerable exhaust emission filter and filter system are provided which incorporate the use of an inorganic, non-woven fiber filter element. The filter is able to capture exhaust pollutants and particulates through the interwoven nature of the filter element and due to area enhancements applied to the filter element including microscopic enhancements. The filter has an improved life and is able to combust a greater percentage of trapped particulates due to the high temperatures the filter element can withstand. The filter element if formed from a non-woven fiber block which is machined or shaped into a filter foundation. The filter element can have a multitude of coatings and catalysts applied and can be wrapped in insulation and a casing. The improved exhaust emission filter is particularly useful for diesel engine exhausts.

대표청구항 ▼

1. An engine exhaust filter element comprising:a filter foundation comprising a plurality of non-woven inorganic fibers; at least one zone formed within said filter foundation; and at least one area enhancement applied to an interior portion of said filter foundation; wherein said plurality of nonwo

1. An engine exhaust filter element comprising:a filter foundation comprising a plurality of non-woven inorganic fibers; at least one zone formed within said filter foundation; and at least one area enhancement applied to an interior portion of said filter foundation; wherein said plurality of nonwoven fibers comprises about 50% to about 90% fibrous glass; about 5% to about 50% alumina fiber; and about 10% to about 25% aluminoborosilicate fiber; and wherein said percentages are based on total fiber content. 2. The engine exhaust filter element according to claim 1, wherein said filter foundation has a porosity of about 90%.3. The engine exhaust filter element according to claim 2, further comprising a catalyst applied to said engine exhaust filter element.4. The engine exhaust filter element according to claim 3, wherein said catalyst is a platinum-based catalyst.5. The engine exhaust filter element according to claim 3, wherein said catalyst is a palladium-based catalyst.6. The engine exhaust filter element according to claim 3, wherein said catalyst is a rhodium-based catalyst.7. The engine exhaust filter element according to claim 1, further comprising a catalyst applied to said engine exhaust filter element.8. The engine exhaust filter element according to claim 7, wherein said catalyst is a platinum-based catalyst.9. The engine exhaust filter element according to claim 7, wherein said catalyst is a palladium-based catalyst.10. The engine exhaust filter element according to claim 7, wherein said catalyst is a rhodium-based catalyst.11. The engine exhaust filter element according to claim 1, wherein said filter foundation has a density of about 8 pounds per cubic foot.12. An engine exhaust filter element comprising:a filter foundation comprising a plurality of non-woven inorganic fibers; at least one zone formed within said filter foundation; at least one area enhancement applied to an interior portion of said filter foundation; and a platinum-based catalyst applied to said engine exhaust filter element. 13. The engine exhaust filter element according to claim 12, wherein said plurality of non-woven inorganic fibers comprises alumina-boria-silica fibers.14. The engine exhaust filter element according to claim 12, wherein said plurality of non-woven inorganic fibers comprises alumina-oxide fibers.15. The engine exhaust filter element according to claim 12, wherein said plurality of non-woven inorganic fibers comprises alumina-zirconia fibers.16. The engine exhaust filter element according to claim 12, wherein said plurality of non-woven inorganic fibers comprises silica-oxide fibers.17. An engine exhaust filter element comprising:a filter foundation comprising a plurality of non-woven inorganic fibers; at least one zone formed within said filter foundation; at least one area enhancement applied to an interior portion of said filter foundation; and a palladium-based catalyst applied to said engine exhaust filter element. 18. The engine exhaust filter element according to claim 17, wherein said plurality of non-woven inorganic fibers comprises alumina-boria-silica fibers.19. The engine exhaust filter element according to claim 17, wherein said plurality of non-woven inorganic fibers comprises alumina-oxide fibers.20. The engine exhaust filter element according to claim 17, wherein said plurality of non-woven inorganic fibers comprises alumina-zirconia fibers.21. The engine exhaust filter element according to claim 17, wherein said plurality of non-woven inorganic fibers comprises silica-oxide fibers.22. An engine exhaust filter element comprising:a filter foundation comprising a plurality of non-woven inorganic fibers; at least one zone formed within said filter foundation; at least one area enhancement applied to an interior portion of said filter foundation; and a rhodium-based catalyst applied to said engine exhaust filter element. 23. The engine exhaust filter element according to claim 22, wherein said plurality of non-woven inorganic fibers comprises alumina-boria-silica fibers.24. The engine exhaust filter element according to claim 22, wherein said plurality of non-woven inorganic fibers comprises alumina-oxide fibers.25. The engine exhaust filter element according to claim 22, wherein said plurality of non-woven inorganic fibers comprises alumina-zirconia fibers.26. The engine exhaust filter element according to claim 22, wherein said plurality of non-woven inorganic fibers comprises silica-oxide fibers.27. An engine exhaust filter system comprising:a casing having an inlet end and an outlet end for connecting to an engine exhaust; a filtering element contained within said casing comprising: a filter foundation comprising a plurality of non-woven inorganic fibers; at least one zone formed within said filter foundation; at least one area enhancement applied to an interior portion of said filter foundation; and wherein said plurality of nonwoven fibers comprises about 50% to about 90% fibrous glass; about 5% to about 50% alumina fiber; and about 10% to about 25% aluminoborosilicate fiber; and wherein said percentages are based on total fiber content. 28. The engine exhaust filter system according to claim 27, wherein said filter foundation has a porosity of about 90%.29. The engine exhaust filter element according to claim 28, further comprising a catalyst applied to said filtering element.30. The engine exhaust filter system according to claim 29, wherein said catalyst is a platinum-based catalyst.31. The engine exhaust filter system according to claim 29, wherein said catalyst is a palladium-based catalyst.32. The engine exhaust filter system according to claim 29, wherein said catalyst is a rhodium-based catalyst.33. The engine exhaust filter system according to claim 27, further comprising a catalyst applied to said filtering element.34. The engine exhaust filter system according to claim 33, wherein said catalyst is a platinum-based catalyst.35. The engine exhaust filter system according to claim 33, wherein said catalyst is a palladium-based catalyst.36. The engine exhaust filter system according to claim 33, wherein said catalyst is a rhodium-based catalyst.37. The engine exhaust filter system according to claim 27, wherein said filter foundation has a density of about 8 pounds per cubic foot.38. An engine exhaust filter system comprising:a casing having an inlet end and an outlet end for connecting to an engine exhaust; a filtering element contained within said casing comprising: a filter foundation comprising a plurality of non-woven inorganic fibers; at least one zone formed within said filter foundation; at least one area enhancement applied to an interior portion of said filter foundation; and a platinum-based catalyst applied to said filtering element. 39. An engine exhaust filter system comprising:a casing having an inlet end and an outlet end for connecting to an engine exhaust; a filtering element contained within said casing comprising: a filter foundation comprising a plurality of non-woven inorganic fibers; at least one zone formed within said filter foundation; at least one area enhancement applied to an interior portion of said filter foundation; and a palladium-based catalyst applied to said filtering element. 40. An engine exhaust filter system comprising:a casing having an inlet end and an outlet end for connecting to an engine exhaust; a filtering element contained within said casing comprising: a filter foundation comprising a plurality of non-woven inorganic fibers; at least one zone formed within said filter foundation; at least one area enhancement applied to an interior portion of said filter foundation; and a rhodium-based catalyst applied to said filtering element. 41. The engine exhaust filter system of claim 38, wherein said filter foundation has a density of about 8 pounds per cubic foot.42. An engine exhaust filter element comprising:a filter foundation comprising a plurality of non-woven inorganic fibers; at least one zone formed within said filter foundation, wherein said at least one zone comprises a plurality of zones each with a different density; and at least one area enhancement applied to an interior portion of said filter foundation. 43. An engine exhaust filter system comprising:a casing having an inlet end and an outlet end for connecting to an engine exhaust; a filtering element contained within said casing comprising: a filter foundation comprising a plurality of non-woven inorganic fibers; at least one zone formed within said filter foundation, wherein said at least one zone comprises a plurality of zones each with a different density; and at least one area enhancement applied to an interior portion of said filter foundation. 44. A method of making an engine exhaust filter element comprising the steps of:mixing a plurality of inorganic non-woven fibers with a colloidal solution to form at least one slurry solution; vacuuming said at least one slurry solution into a mold to form a fiber block; curing said fiber block; machining said fiber block into a filter foundation; and applying a microscopic enhancement to an interior portion of said filter foundation. 45. The method of claim 44, further comprising the step of applying a coating to an exterior surface of said filter element.46. The method of claim 44, further comprising the step of applying a catalyst to said filter element.47. The method of claim 44, further comprising the step of applying a heating element to said filter element.48. The method of claim 44, further comprising the step of forming said fiber block in an oxygen free chamber.49. The method of claim 44, further comprising the step of exposing said fiber block to hydrogen during said formation of said fiber block.50. The method of claim 44, further comprising the step of exposing said fiber block to nitrogen during said formation of said fiber block.51. The method of claim 44, further comprising the step of applying a binder to slurry recipe.52. The method of claim 44, further comprising the step of curing said fiber block at a temperature above 500 degrees Celsius.53. The method of claim 44, further comprising the step of curing said fiber block at a temperature of about 1000 degrees Celsius.54. The method of claim 44, further comprising the step of quenching said fiber block after said curing.55. The method of claim 44, wherein said area enhancement is at a microscopic level.56. The method of claim 44, further comprising the step of piercing said interior portion of said filter foundation to form said at least one area enhancement.57. The method of claim 44, further comprising the step of drilling said interior portion of said filter foundation to form said at least one area enhancement.58. A method of making an engine exhaust filter element comprising the steps of:mixing a plurality of inorganic non-woven fibers with a colloidal solution to form at least one slurry solution; applying a binder to said slurry recipe; vacuuming said at least one slurry solution into a mold to form a fiber block; forming said fiber blank in an oxygen free chamber; exposing said fiber blank to hydrogen during said formation; curing said fiber block by baking said fiber block at a temperature above 500 degrees Celsius and then quenching said fiber blank; machining said fiber block into a filter foundation; and applying an area enhancement to an interior portion of said filter foundation.