Segregated catalyzed metallic wire filter for diesel soot filtration

Abstract

A filter for removing soot particles from the exhaust gas of a diesel engine comprises a plurality of hollow channels which contain therein a metal mesh. The metal mesh can be coated with an oxidation catalyst to promote ignition of the soot particles and regeneration of the metal mesh for filtering the soot particles. The metal mesh can optionally be removed from the hollow channels and replaced with regenerated or new metal mesh if desired.

1 . A filter for removing soot particles from the exhaust of a diesel engine comprising: an enclosed area, a plurality of channels disposed within said enclosed area and disposed longitudinally in the same direction as gas flow through the filter, each of said channels having a hollow interior and containing opposed open ends, disposed within each of said channels and substantially filling said hollow interior is an optionally removable metal mesh.  
   
   
       2 . The filter of  claim 1  including a void space between said plurality of channels, said void space being open to said exhaust.  
   
   
       3 . The filter of  claim 2  wherein the volume of said void space is less than 25% of the volume of said enclosed area.  
   
   
       4 . The filter of  claim 1  wherein said metal mesh is a woven metal mesh.  
   
   
       5 . The filter of  claim 1  wherein said metal mesh is non-woven.  
   
   
       6 . The filter of  claim 1  wherein said metal mesh contained in said channels is of a single mass.  
   
   
       7 . The filter of  claim 1  wherein said channels are hollow cylinders.  
   
   
       8 . The filter of  claim 1  wherein said metal mesh is coated with an oxidation catalyst.  
   
   
       9 . The filter of  claim 8  wherein said oxidation catalyst is a platinum group metal.  
   
   
       10 . The filter of  claim 8  containing a metal anchor coat disposed between said metal mesh and said catalyst.  
   
   
       11 . The filter of  claim 10  wherein said anchor coat is applied by electric arc spraying.  
   
   
       12 . The filter of  claim 8  wherein at least a portion of the interior surfaces of said channels are coated with an oxidation catalyst.  
   
   
       13 . The filter of  claim 2  wherein said void space is defined by a plurality of void spaces between each of said channels.  
   
   
       14 . The filter of  claim 13  wherein said channels are supported by opposed upstream and downstream end plates, said endplates containing a plurality of orifices to direct exhaust gas to said plurality of void spaces.  
   
   
       15 . A method of removing soot from the exhaust gas of a diesel engine comprising directing said exhaust gas through a diesel filter comprising an enclosed area, a plurality of channels disposed within said enclosed area and disposed longitudinally in the same direction as gas flow through the filter, each of said channels having a hollow interior end containing opposed open ends, disposed within each of said channels and substantially filling said hollow interior is an optionally removable metal mesh, whereby soot particles contained in said exhaust gas are trapped on said metal mesh.  
   
   
       16 . The method of  claim 15  including a void space between said plurality of channels, said void space being open to said exhaust gas flow.  
   
   
       17 . The method of  claim 16  wherein the volume of said void space is less than 25% of the volume of said enclosed area.  
   
   
       18 . The method of  claim 15  wherein said channels are hollow cylinders.  
   
   
       19 . The method of  claim 15  wherein said metal mesh is coated with an oxidation catalyst, and said trapped soot particles are continuously or periodically ignited and burned to regenerate the filter.  
   
   
       20 . The method of  claim 19  wherein said oxidation catalyst is a platinum group metal.