Abstract: A method of manufacturing an emissions treatment device for an internal combustion engine includes disposing washcoated fibers between layers of a porous substrate to form multiple substantially parallel layers with a first group of layers at least partially open along the entire length of the layer. The porous substrate may be a stainless steel mesh with the method further including washcoating the substrate prior to disposing the washcoated fibers between the layers.

Abstract: A method of manufacturing an emissions treatment device for an internal combustion engine includes disposing washcoated fibers between layers of a porous substrate to form multiple substantially parallel layers with a first group of layers at least partially open along the entire length of the layer. The porous substrate may be a stainless steel mesh with the method further including washcoating the substrate prior to disposing the washcoated fibers between the layers.

Abstract: An emissions treatment device includes a substrate having multiple parallel channels/layers of a porous material, the channels/layers including a first group of channels/layers at least partially open along their length from an upstream end to a downstream end, and a second group of channels/layers that are at least partially open at the downstream end and may be substantially blocked at an upstream end, the parallel channels having complementary geometries and/or sizes. Coated metallic fibers or fleece facilitates flow of exhaust through walls of the first group into the second group of channels. Flow diverters or scoops may be formed in the walls between the first and second groups of channels to divert exhaust flow from the first group to the second group of channels. Catalyzed mesh sheets may be supported by perforated stainless steel sheets containing small passages and/or scoops to complement the useful wallflow by structure and flow design.

Abstract: An emissions treatment device includes a substrate having multiple parallel channels/layers of a porous material, the channels/layers including a first group of channels/layers at least partially open along their length from an upstream end to a downstream end, and a second group of channels/layers that are at least partially open at the downstream end and may be substantially blocked at an upstream end, the parallel channels having complementary geometries and/or sizes. Coated metallic fibers or fleece facilitates flow of exhaust through walls of the first group into the second group of channels. Flow diverters or scoops may be formed in the walls between the first and second groups of channels to divert exhaust flow from the first group to the second group of channels. Catalyzed mesh sheets may be supported by perforated stainless steel sheets containing small passages and/or scoops to complement the useful wallflow by structure and flow design.

Abstract: An exhaust aftertreatment device for an internal combustion engine is disclosed which contains multiple, parallel channels of a porous material, such as cordierite or silicon carbide, in which about some of the channels are plugged at an upstream end and other channels remain unplugged. In one embodiment, the substrate has an SCR coating and the engine has a urea supply system. Other embodiments include using TWC and LNT formulations. Several washcoat configurations and other specific geometries and dimensions to encourage crossflow, diffusion, and adsorption are disclosed herein.