How It Works
The Science of
Cleaner Air
Decades of materials science and precision manufacturing engineering packed into every ceramic honeycomb cell — enabling global compliance with the most stringent emissions regulations.
Material Science
Cordierite: The Material That Changed Emissions Control
Cordierite (2MgO · 2Al₂O₃ · 5SiO₂) is the engineered ceramic that makes catalytic converters possible. Its exceptionally low coefficient of thermal expansion (CTE ≈ 0.5×10⁻⁶/K) allows the substrate to survive thousands of thermal cycles — from cold start at -40°C to full operating temperature above 900°C — without cracking.
Thermal Exp. (CTE)
~0.5×10⁻⁶/K
Max Temperature
1400°C
Open Frontal Area
up to 89%
Geo. Surface Area
up to 46 cm²/cm³
Heat Capacity
166–340 J/K·L
Filter Material
Aluminum Titanate: Purpose-Built for DPF
Aluminum titanate (Al₂TiO₅) was specifically developed for diesel particulate filter applications requiring extreme thermal shock resistance during active regeneration events (600–900°C+). Unlike silicon carbide (SiC), AT's ultra-low CTE enables monolithic — not segmented — construction, eliminating the risk of cement joint failure.
CTE
<1.0×10⁻⁶/K
Peak Regen
1000–1050°C
Structure
Monolithic
Porosity
40–60%
Manufacturing
From Raw Material to Finished Product
Batch Preparation
Raw ceramic powders (MgO, Al₂O₃, SiO₂) are precisely weighed, mixed with organic binders and plasticizers, and milled to a uniform particle size distribution.
Extrusion
The ceramic batch is forced through a precision die to form the honeycomb channel structure. Wall thickness and cell density are set by the die geometry.
Drying & Firing
Green extrudates are carefully dried to remove moisture, then fired in continuous tunnel kilns at 1200–1450°C to develop the final ceramic microstructure.
Inspection & Testing
Every substrate is inspected for dimensional accuracy, isostatic strength, MOR, and CTE. Samples are tested for thermal shock resistance and backpressure.
Understanding Substrate Specifications
Every parameter in a substrate specification directly affects emissions performance, backpressure, and system cost.
Cell Density (CPSI)
Number of channels per square inch of frontal area. Higher CPSI = more geometric surface area for catalyst coating, but higher backpressure.
Wall Thickness
Thickness of ceramic walls between channels. Thinner walls = lower backpressure and thermal mass, enabling faster light-off.
Open Frontal Area
Percentage of the frontal face that is open (not ceramic wall). Higher OFA correlates with lower flow restriction and backpressure.
Geometric Surface Area
Total catalyst-exposed surface area per unit volume. Key parameter for catalyst mass activity and conversion efficiency.
Hydraulic Diameter
Effective diameter of each channel, derived from cell geometry. Determines gas velocity, heat/mass transfer coefficients.
Heat Capacity
Thermal mass of the substrate per unit volume. Lower heat capacity enables faster catalyst light-off from cold start.