Thin & Ultra Thin Wall Substrates

The application trend in ceramic substrates is increase the efficiency of the converter by manufacturing the internal walls thinner and increasing the number of channels / cells (cell density).

The advantage of thin / ultra thin wall substrates are a greater geometric surface area (active surface area) for catalytic conversion so less catalyst can be used (base metal prices for catalyst are US $ 300 – 700 / oz) or you can have a more efficient converter to meet future regulations.

The systematic reduction in ceramic substrate cell wall thickness from 6mil to thin (4mil) and ultra thin wall (2-3mil) results in a much more fragile structure which, together with increased vibration so close to the engine, makes selection of the substrate support system critically important.

Exhaust systems globally are moving toward thin and ultra thin-walled substrates to ensure compliance with current and future emissions regulations.

Ecoflex products are an Enabling Technology for the use of Thin and Ultra Thin Wall substrates.

Substrates can be categorised as follows:

Ecoflex is Ideal for Ultra Thin Wall Substrates:

Feature: Non Intumescent

Benefit:  Holding pressure does not exceed Isostatic Strength of Substrate

Enables: Increased goemetric surface area which increases catalyst efficiency
Enables: Reduced precious metal content
Enables: Faster light-off due to lower thermal mass
Enables: Reduced package space