Regenerable diesel particulate trap

Claim 2

An electrically regenerable particulate trap (10) comprising a gas permeable support (11) and a plurality of alternately layered ceramic fiber filter materials (12, 14, 16, 18, 20) and electrical heater elements (13, 15, 17, 19), said filter materials (12, 14, 16, 18, 20) together with said heater elements (13, 15, 17, 19) forming variable-sized open spaces extending radially from the permeable support (11) requiring exhaust gases to pass through said spaces so that particulates in said exhaust gases are collected adjacent a heater element (13, 15, 17, 19) portion and subsequently vaporized upon application of electrical energy to said heater elements (13, 15, 17, 19).

Claim 3

An electrically regenerable particulate trap (10) according to claim 1 wherein said filter layer (12) adjacent said gas permeable support (11) is woven ceramic fiber fabric having uniform gas permeability of less than 1.5 L/M/cm², said fabric being capable of maintaining its integrity for prolonged periods at temperatures of about 1150°C., and said fabric having essentially no visible spaces or openings present between the yarns at magnification of 7.5 times.

Claim 4

An electrically regenerable particulate trap (10) according to claim 2 wherein said ceramic fibers are selected from the group consisting of continuous fused silica, leached fiberglass, alumina-silica, zirconia-­silica, alumina-chromia-metal (IV) oxide, titania, graphite, silicon carbide, and alumina-boria-silica fibers.

Claim 5

An electrically regenerable particulate trap (10) according to claim 2 wherein said ceramic fibers are alumina-boria-silica ceramic fibers.

Claim 6

An electrically regenerable particulate trap (10) according to claim 2 wherein said ceramic fibers are alumina-silica.

Claim 7

An electrically regenerable particulate trap (10) according to claim 1 wherein the gas permeable support (11) is selected from stainless steel tube, stainless steel wire woven cloth, or stainless steel welded wire mesh.

Claim 8

An electrically regenerable particulate trap (10) according to claim 1 wherein the layered ceramic fiber filter materials (12, 14, 16, 18, 20) are selected from the group consisting of continuous fused silica, leached fiberglass, aluminasilica, zirconia-silica, alumina-chromia-metal (IV) oxide, titania, graphic, silicon carbide, and alumina-boriasilica fibers.

Claim 9

An electrically regenerable particulate trap (10) according to claim 7 wherein said ceramic fibers are alumina-boria-silica ceramic fibers.

Claim 10

An electrically regenerable particulate trap (10) according to claim 1 wherein said layered ceramic fiber filter materials (12, 14, 16, 18, 20) and electrical heater elements form diamond shaped openings such that particulate is collected adjacent a heater element (13, 15, 17, 19) portion.

Claim 11

An electrically regenerable particulate trap (10) according to claim 1 wherein the electrical heater elements (13, 15, 17, 19) are electrical resistance metallic wire.

Claim 12

An electrically regenerable particulate trap (10) according to claim 1 wherein said ceramic fiber filter materials (12, 14, 16, 18, 20) are formed by braiding or winding ceramic strands directly on said permeable support (11) or said heater elements (13, 15, 17, 19).

Claim 13

An exhaust gas, electrically regenerable cleaning device (10) for an internal combustion engine comprising: a canister (32) including an inlet (33) for receiving exhaust gas from said engine and an outlet (34); at least one filter element (10) within said canister (32) including a plurality of alternately layered ceramic fiber filter materials (12, 14, 16, 18, 20) and electrical heater elements (13, 15, 17, 19), said filter materials (12, 14, 16, 18, 20) being effective to remove particulates from said exhaust gas; means within said canister (32) for directing said exhaust gases from said inlet (33), through said filter element (10) and to said outlet (34), means extending through said canister (32) for electrically energizing said heater elements (13, 15, 17, 19) to burn said exhaust gas particulates.

Claim 14

An exhaust gas, electrically regenerable cleaning device (10) for an internal combustion engine comprising: a canister (32) including an inlet (33) for receiving exhaust gas from said engine and an outlet (34); at least one filter element (10) within said canister (32) including a plurality of alternately layered ceramic fiber filter materials (12, 14, 16, 18, 20) and electrical heater elements (13, 15, 17, 19), said filter materials (12, 14, 16, 18, 20) being effective to remove particulates from said exhaust gas; means within said canister (32) for directing said exhaust gases from said inlet (33), through said filter element (10) and to said outlet (34), means extending through said canister (32) for electrically energizing said heater elements (13, 15, 17, 19) to burn said exhaust gas particulates.