Three-way catalytic converter

Patent metadata

Field	Value
Publication number	US-10071342-B2
Application number	US-201414895304-A
Country	US
Kind code	B2
Filing date	May 28, 2014
Priority date	Jun 3, 2013
Publication date	Sep 11, 2018
Grant date	Sep 11, 2018

Abstract

The present invention relates to a three-way catalytic converter for reducing harmful exhaust components of gasoline-powered internal combustion engines, and to a corresponding method for exhaust gas purification. The catalytic converter is characterized by a particularly inhomogeneous distribution of the oxygen-storing material present.

First claim

The invention claimed is:

1. A three-way catalytic converter for the reduction of harmful exhaust components in gasoline-operated internal combustion engines: comprising:
one body, or a plurality of adjacent supporting bodies, with a catalytically active coating, wherein the catalytically active coating has an inhomogeneous distribution of oxygen storing capacity in the flow direction, wherein
on the downstream side of the three-way catalytic converter, no oxygen storing material is present, and this area comprises a relative volume of the entire three-way catalytic converter of 5-50%, and
the three-way catalytic convertor is free of platinum.

2. The catalytic converter according to claim 1 , wherein the catalytically active coating on the supporting body or bodies is zoned and/or applied in one or more layers onto the supporting body or bodies.

3. The catalytic converter according to claim 1 , wherein the material with oxygen-storing capacity that is used is chosen from the group of cerium oxides, of cerium-zirconium oxides or doped cerium-zirconium oxides and mixtures thereof.

4. The catalytic converter according to claim 1 , wherein the oxygen capacity inside the catalytic converter rises in steps or continually from the downstream end to the upstream end.

5. The catalytic converter according to claim 1 , wherein the catalytically active coating comprises precious metals, the precious metals being selected from a group consisting of palladium, rhodium, and mixtures thereof.

6. The catalytic converter of claim 1 wherein the three-way catalytic converter has peak performance in a stoichiometric level in the exhaust.

7. The catalytic converter of claim 1 wherein the upstream side has, with respect to precious metal content, only palladium, rhodium or both together with the oxygen storage material, and the downstream side, which is free of oxygen storing material, has, with respect to precious metal content, only palladium, rhodium or both together.

8. The catalytic converter of claim 7 wherein the upstream side has two layers with an upper layer of those two layers having both palladium and rhodium as precious metals and a lower layer of those two layers having only palladium as the precious metal.

9. The catalytic converter of claim 8 wherein the downstream side has a single layer with that single layer having both palladium and rhodium as precious metals.

10. A method for reducing the harmful exhaust components of a gasoline-driven internal combustion engine by means of conducting the exhaust gas over a three-way catalytic converter according to claim 1 .

11. A three-way catalytic converter for the reduction of harmful exhaust components in gasoline-operated internal combustion engines: comprising:
one body, or a plurality of adjacent supporting bodies, with a catalytically active coating, wherein the catalytically active coating has an inhomogeneous distribution of oxygen storing capacity in the flow direction, wherein
on the downstream side of the three-way catalytic converter, no oxygen storing material is present, and this area comprises a relative volume of the entire three-way catalytic converter of 5-50%, and
the catalytic converter includes not less than 2 connected supporting bodies, the supporting body on the downstream end having a catalytically active coating that comprises deposits of palladium, rhodium and barium oxide on aluminum oxide with a large surface.

12. A three-way catalytic converter for the reduction of harmful exhaust components in a gasoline-operated internal combustion engine: comprising:
one body, or a plurality of adjacent supporting bodies, with a catalytically active coating, wherein the catalytically active coating has an inhomogeneous distribution of oxygen storing capacity in the flow direction, wherein
on the downstream side of the three-way catalytic converter, no oxygen storing material is present, and this area comprises a relative volume of the entire three-way catalytic converter of 5-50%,
the three-way catalytic converter having a catalytic active coating that is directed towards a simultaneous reduction-oxidation in removing the harmful exhaust components, which simultaneous reduction-oxidation involves the reduction of NOx and, at the same time as that reduction, an oxidation of hydrocarbons and CO, and
the three-way catalytic converter is free of platinum.

13. The catalytic converter according to claim 12 , wherein the catalytically active coating on the supporting body or bodies is zoned and/or applied in one or more layers onto the supporting body or bodies.

14. The catalytic converter according to claim 12 , wherein the material with oxygen-storing capacity that is used is chosen from the group of cerium oxides, of cerium-zirconium oxides or doped cerium-zirconium oxides and mixtures thereof.

15. The catalytic converter according to claim 12 , wherein the catalytic converter comprises precious metals, the precious metals being selected from a group consisting of palladium, rhodium, and mixtures thereof.

16. The catalytic converter of claim 12 wherein the three-way catalytic converter has peak performance in a stoichiometric in the exhaust.

17. A method for reducing the harmful exhaust components of a gasoline-driven internal combustion engine by means of conducting the exhaust gas over a three-way catalytic converter according to claim 12 .

18. A three-way catalytic converter for the reduction of harmful exhaust components in a gasoline-operated internal combustion engine: comprising:
one body, or a plurality of adjacent supporting bodies, with a catalytically active coating, wherein the catalytically active coating has an inhomogeneous distribution of oxygen storing capacity in the flow direction, wherein
on the downstream side of the three-way catalytic converter, no oxygen storing material is present, and this area comprises a relative volume of the entire three-way catalytic converter of 5-50%,
the three-way catalytic converter having catalytic active coating that is directed towards a simultaneous reduction-oxidation in removing the harmful exhaust components, which simultaneous reduction-oxidation involves the reduction of NOx and, at the same time as that reduction, an oxidation of hydrocarbons and CO, and
the catalytic converter includes not less than 2 connected supporting bodies, the supporting body on the downstream end having a catalytically active coating that comprises deposits of palladium, rhodium and barium oxide on aluminum oxide.

Assignees

• Umicore Ag & Co Kg

Inventors

• Schoenhaber Jan
• Despres Joel
• Richter Joerg-Michael
• Roesch Martin

Classifications

• Y02A50/2324

  Cross-Sectional Technologies · mapped topic

• B01D2255/9032

  Two zones · CPC title

• F01N2510/0682

  having a discontinuous, uneven or partially overlapping coating of catalytic material, e.g. higher amount of material upstream than downstream or vice versa · CPC title

• B01D2255/908

  O2-storage component incorporated in the catalyst · CPC title

• B01D2255/2042

  Barium · CPC title