A diesel engine emissions catalyst which may be used to fill a niche between standard oxidation catalyst and diesel particulate filters for control of diesel particulate matter. The catalyst includes a structure (substrate) comprising one or more coated, corrugated micro-expanded metal foil layers. The coated surface may be a high surface area, stabilized, and promoted washcoat layer. The corrugated pattern may include a herringbone-style pattern that, when in use, is oriented in a longitudinal direction of the diesel engine exhaust flow. The micro-expanded metal foil provides small openings or eyes that, as the exhaust flow passes through the catalyst (transverse to the eye opening), particulates in the flow impinge on the surface and becomes trapped in the eyes. The catalyst may be used to treat a locomotive engine exhaust stream and may be used with a selective catalyst reduction system.

A honeycomb body comprises a matrix of intersecting porous walls forming channels. Plugs are disposed in a percentage of the channels having the second hydraulic diameter, wherein the percentage of the channels of the second diameter having a plug is less than or equal to 15%. In some embodiments, some of the channels have a first hydraulic diameter and others have a second hydraulic diameter that is smaller than the first hydraulic diameter, and may be unplugged for plugged. The porous walls can further comprise a transverse thickness of the walls Tw less than or equal to 0.20 mm, a channel density CD greater than or equal to 62 channels per cm.sup.2, an average bulk porosity % P greater than or equal to 50%, and a median pore diameter d.sub.50 ranging from between 4.0 μm and 30.0 μm.

A particulate filter having a honeycomb structure of a matrix of interconnected porous walls including inlet cells and outlet cells defining a plurality of inlet channels and outlet channels, respectively, wherein at least a portion of the outlet cells are larger than any of the inlet cells, and a cross-sectional shape of at least some of the outlet channels is rectangular. Honeycomb extrusion dies, honeycomb bodies, honeycomb structures, and methods of manufacture are described, as are other aspects.

A honeycomb body having intersecting porous walls which includes first through fourth cells, wherein the cells extend from inlet to outlet face and are plugged to define a repeating structural unit with three inlets and one outlet channel. Repeating structural unit includes a first channel including length L.sub.1, width W.sub.2, and area A.sub.1, a second channel including length L.sub.2, the width W.sub.2, and area A.sub.2, a third channel including the length L.sub.1, width W.sub.1, and area A.sub.3, and a fourth channel including the length L.sub.2, the width W.sub.1, and A.sub.4, wherein the first through third channels are inlets and the fourth channel is a rectangular outlet and at least one of W.sub.1≥W.sub.2 and L.sub.1≠L.sub.2, i.e. W.sub.1≥W.sub.2, or L.sub.1≠L.sub.2, or W.sub.1≥W.sub.2 and L.sub.1≠L.sub.2. Repeating structural unit has a quadrilateral outer perimeter. Particulate filters including the honeycomb body, honeycomb extrusion dies, and methods of manufacturing the honeycomb body are provided.

A particulate filter having a honeycomb structure of a matrix of interconnected porous walls including inlet cells and outlet cells defining a plurality of inlet channels and outlet channels, respectively, wherein at least a portion of the outlet cells are larger than any of the inlet cells, and a cross-sectional shape of at least some of the outlet channels is rectangular. Honeycomb extrusion dies, honeycomb bodies, honeycomb structures, and methods of manufacture are described, as are other aspects.

A particulate trap filter body has asymmetrical channels. The cross-sectional shape of the asymmetrical channel structure includes a combination of hexagonal, square and triangular shapes. The hexagonal channel and the triangular channel act as inlet channel, and the square channel acts as outlet channel. Compared with the traditional symmetrical filter body structure, the inlet channel volume and filter body wall area can be effectively increased by more than 30%, which means that with capturing the same amount of particles, the particle cake layer formed on the wall surface is thinner. The limiting carbon load of the new channel structure is increased by more than 30%, having a very positive effect on reducing the regeneration frequency and prolonging the service life of the trap.

A honeycomb filter includes a pillar-shaped honeycomb structure body having a porous partition wall disposed to surround a plurality of cells and a plugging portion, wherein the partition wall defining inflow cells includes partition wall parts making up sides of polygon that is sectional shape of each cell, the partition wall parts each having a surface that is a face defining the inflow cell, the partition wall part is either a first partition wall part loaded with the exhaust-gas purifying catalyst on the surface so that a percentage of the area loaded therewith exceeds 10%, or a second partition wall part loaded with the exhaust-gas purifying catalyst so that a percentage of the area loaded therewith is 10% or less, and the partition wall is configured to include one or more the first partition wall parts and one or more the second partition wall parts as the partition wall parts.

A diesel engine emissions catalyst which may be used to fill a niche between standard oxidation catalyst and diesel particulate filters for control of diesel particulate matter. The catalyst includes a structure (substrate) comprising one or more coated, corrugated micro-expanded metal foil layers. The coated surface may be a high surface area, stabilized, and promoted washcoat layer. The corrugated pattern may include a herringbone-style pattern that, when in use, is oriented in a longitudinal direction of the diesel engine exhaust flow. The micro-expanded metal foil provides small openings or eyes that, as the exhaust flow passes through the catalyst (transverse to the eye opening), particulates in the flow impinge on the surface and becomes trapped in the eyes. The catalyst may be used to treat a locomotive engine exhaust stream and may be used with a selective catalyst reduction system.

A honeycomb substrate with an electrode includes a conductive ceramic honeycomb substrate that generates heat by energization and a pair of electrodes that is provided to face an outer periphery of the honeycomb substrate. A coefficient of thermal expansion of the electrode is higher than a coefficient of thermal expansion of the honeycomb substrate.

An exhaust gas purification catalyst device having a substrate and one or more catalytic noble metals supported on the substrate. The substrate has a plurality of cells partitioned by a porous wall 1 and includes ceria-zirconia compound oxide particles. A specific noble metal that is one of the one or more catalytic noble metals satisfies both the following requirements (1) and (2): (1) the noble metal 50% support depth for the specific noble metal is 30% or less of the distance from the surface of the porous wall 1 to the center of the interior of the porous wall 1, and (2) the noble metal 90% support depth for the specific noble metal is 35% or more of the distance from the surface of the porous wall 1 to the center of the interior of the porous wall 1.