Methods and systems for a diesel oxidation catalyst

Patent metadata

Field	Value
Publication number	US-10598061-B2
Application number	US-201715466678-A
Country	US
Kind code	B2
Filing date	Mar 22, 2017
Priority date	Mar 22, 2017
Publication date	Mar 24, 2020
Grant date	Mar 24, 2020

Abstract

Methods and systems are provided for a diesel oxidation catalyst. In one example, the diesel oxidation catalyst comprises a washcoat with different catalytically active portions for reacting with one or more of carbon containing compounds and NOx. The diesel oxidation catalyst is located upstream of a particulate filter in an exhaust passage.

First claim

The invention claimed is:

1. A method, comprising:
generating NO 2 in a catalyst comprising a washcoat with zirconium, one or more base metal oxides, and a palladium oxide, with an exhaust gas flow rate being between lower and upper threshold flow rates; and
facilitating a regeneration of a particulate filter located downstream of the catalyst via NO 2 when an exhaust gas temperature is greater than a threshold temperature; where
the palladium oxide is contained in an upstream portion of the catalyst relative to a direction of exhaust gas flow; and
the one or more base metal oxides are contained in a downstream portion of the catalyst relative to the direction of exhaust gas flow.

2. The method of claim 1 , wherein the threshold temperature is a threshold NO 2 facilitated regeneration temperature, and where the threshold NO 2 facilitated regeneration temperature corresponds to the regeneration occurring in a presence of an amount of NO 2 greater than a threshold NO 2 regeneration amount.

3. The method of claim 1 , further including regenerating the particulate filter in response to the exhaust gas temperature being less than the threshold temperature by initiating active controls to adjust engine operating parameters to increase the exhaust gas temperature.

4. The method of claim 3 , wherein the active controls include one or more of decreasing an EGR flow rate, increasing a fuel injection pressure, increasing a fuel injection volume, decreasing an air/fuel ratio, increasing an intake manifold pressure, and retarding a fuel injection.

5. The method of claim 1 , wherein the regeneration is facilitated by NO 2 when an amount of NO 2 produced by an engine and the catalyst is greater than a threshold NO 2 regeneration amount.

6. The method of claim 1 , wherein the one or more base metal oxides are in a range of 15 to 75 weight percent of the washcoat.

7. The method of claim 1 , wherein generating NO 2 includes flowing exhaust gas through the catalyst and where the exhaust gas temperature is greater than 200° C.

8. A method for an engine driven vehicle, comprising:
regenerating a particulate filter without adjusting engine operating parameters during a first mode;
facilitating the particulate filter regeneration with oxygen by adjusting the engine operating parameters to increase an exhaust gas temperature by a first magnitude during a second mode, where an exhaust gas flow rate is lower than a lower threshold flow rate; and
facilitating the particulate filter regeneration with NO 2 by adjusting the engine operating parameters to increase the exhaust gas temperature by a second magnitude during a third mode, where the NO 2 is produced by at least a diesel oxidation catalyst located upstream of the particulate filter, where the diesel oxidation catalyst comprises a washcoat having a zirconium oxide substrate and at least a manganese oxide and a palladium oxide, and where the exhaust gas flow rate is within a range between the lower threshold flow rate and an upper threshold flow rate; where
the first magnitude is greater than the second magnitude.

9. The method of claim 8 , wherein the particulate filter regeneration is passively facilitated by oxygen when the exhaust gas temperature is greater than a threshold oxygen facilitated regeneration temperature, an amount of NO 2 at the particulate filter is less than a threshold NO 2 regeneration amount, and the exhaust gas flow rate is outside of the range between the lower and upper threshold flow rates during the first mode.

10. The method of claim 8 , wherein the particulate filter regeneration is passively facilitated by NO 2 when the exhaust gas temperature is greater than a threshold NO 2 facilitated regeneration temperature, an amount of NO 2 at the particulate filter is greater than a threshold NO 2 regeneration amount, and the exhaust gas flow rate is within the range between the lower and upper threshold flow rates during the first mode.

11. The method of claim 8 , wherein the particulate filter regeneration during the second mode includes initiating active controls configured to adjust the engine operating parameters to increase the exhaust gas temperature by the first magnitude, wherein increasing the exhaust gas temperature by the first magnitude corresponds to increasing the exhaust gas temperature to a temperature greater than a threshold oxygen facilitated regeneration temperature, and where the threshold oxygen facilitated regeneration temperature is equal to 600° C., and where an amount of NO 2 at the particulate filter is less than a threshold NO 2 regeneration amount.

12. The method of claim 8 , wherein the particulate filter regeneration during the third mode includes initiating active controls configured to adjust the engine operating parameters to increase the exhaust gas temperature by the second magnitude, wherein increasing the exhaust gas temperature by the second magnitude corresponds to increasing the exhaust gas temperature to a temperature greater than a threshold NO 2 facilitated regeneration temperature, and where the threshold NO 2 facilitated regeneration temperature is equal to 300° C., and where an amount of NO 2 at the particulate filter is greater than a threshold NO 2 regeneration amount.

13. The method of claim 12 , wherein the threshold NO 2 regeneration amount corresponds to an amount of NO 2 sufficient to promote burning of soot stored on the particulate filter.

14. The method of claim 8 , wherein the diesel oxidation catalyst is hermetically sealed along an outer circumference of the diesel oxidation catalyst to an exhaust pipe of an exhaust passage.

15. The method of claim 14 , wherein the diesel oxidation catalyst receives exhaust gas through the exhaust passage before the particulate filter.

16. The method of claim 8 , where the palladium oxide is applied to an upstream portion of the zirconium oxide substrate relative to a direction of exhaust gas flow, and the manganese oxide is applied to a downstream portion of the zirconium oxide substrate relative to the direction of exhaust gas flow.

Assignees

• Ford Global Tech Llc

Inventors

• Dobson Douglas Allen
• Chanko Timothy Brian
• Lambert Christine Kay

Classifications

• F01N3/0231 Primary

  using special exhaust apparatus upstream of the filter for producing nitrogen dioxide, e.g. for continuous filter regeneration systems [CRT] · CPC title

• F01N2900/1606

  Particle filter loading or soot amount · CPC title

• F02D2200/0802

  Temperature of the exhaust gas treatment apparatus · CPC title

• F02D41/1454

  the characteristics being an oxygen content or concentration or the air-fuel ratio · CPC title

• B01D53/9477

  with catalysts positioned on separate bricks, e.g. exhaust systems · CPC title