Bi-metallic oxidation catalyst materials and appurtenant devices and systems

Patent metadata

Field	Value
Publication number	US-10753247-B2
Application number	US-201815902464-A
Country	US
Kind code	B2
Filing date	Feb 22, 2018
Priority date	Feb 22, 2018
Publication date	Aug 25, 2020
Grant date	Aug 25, 2020

Abstract

Bimetallic oxidation catalyst devices include a support body, one or more metal A bulk deposits disposed on the support body, and a plurality of metal B atomic clusters disposed on the surface of each of the metal A bulk deposits. Metal A and metal B are different metals each selected from the group consisting of platinum group metals (PGM), Ag, Au, Ni, Co, and Cu, and substantially no metal B is deposited on the support body. At least 85% by weight of the metal B atomic clusters comprise up to 10 atoms and the maximum metal B atomic cluster size is 200 metal B atoms. The combined loading of metal A and metal B can be less than 1.5% by weight relative to the weight of the support body. Metal A can include Pd, Rh, Rh, or Pd, and metal B can include Pt, Pt, Ag, or Ag.

First claim

What is claimed is:

1. A catalytic device, the device comprising:
a support body;
one or more metal A bulk deposits disposed on the support body, and
a plurality of metal B atomic clusters disposed on the surface of at least one of the metal A bulk deposits, wherein less than 10% by weight of metal B atomic clusters are disposed directly on the support body;
wherein metal A and metal B are different metals each selected from the group consisting of platinum group metals (PGM), Ag, Au, Ni, Co, and Cu.

2. The catalytic device of claim 1 , wherein metal A and metal B are different metals each selected from the group consisting of PGM, Ag, and Au.

3. The catalytic device of claim 1 , wherein metal A comprises Pd and metal B comprises Pt or Ag.

4. The catalytic device of claim 1 , wherein metal A is selected from the group consisting of Ni, Co, and Cu, and metal B is selected from the group consisting of Pt, Pd, and Rh.

5. The catalytic device of claim 1 , wherein the metal B atomic clusters are deposited onto the surface of the one or more metal A bulk deposits by contacting the support body and the one or more metal A bulk deposits with a solution or slurry comprising complexed metal B ions.

6. The catalytic device of claim 5 , wherein prior to the deposition of metal B atomic clusters on to the surface of the one or more metal A bulk deposits, the support body is pH-adjusted to exhibit a charge which is repulsive to the metal B ions in the slurry or solution.

7. The catalytic device of claim 1 , wherein the one or more metal A bulk deposits comprises diameters of about 0.2 nanometers to about 3 nanometers.

8. The catalytic device of claim 1 , wherein at least 85% by weight of the metal B atomic clusters comprise up to 10 atoms.

9. The catalytic device of claim 1 , wherein the support body consists of a metal oxide and/or a ceramic material.

10. A catalytic device, the device comprising:
a support body;
one or more metal A bulk deposits disposed on the support body, and
a plurality of metal B atomic clusters disposed on at least one of the metal A bulk deposits, wherein at least 85% by weight of the metal B atomic clusters comprise up to 10 metal B atoms, and the maximum metal B atomic cluster size is 200 metal B atoms;
wherein metal A and metal B are different metals each selected from the group consisting of platinum group metals (PGM), Ag, Au, Ni, Co, and Cu.

11. The catalytic device of claim 10 , wherein at least 85% by weight of the metal B atomic clusters comprise up to 5 metal B atoms.

12. The catalytic device of claim 10 , wherein the maximum metal B atomic cluster size is 50 atoms.

13. The catalytic device of claim 10 , wherein less than 10% by weight of metal B atomic clusters are disposed directly on the support body.

14. The catalytic device of claim 10 , wherein metal A and metal B are different metals each selected from the group consisting of PGM, Ag, and Au.

15. A bimetallic oxidation catalyst device configured to treat exhaust gas generated by a gasoline internal combustion engine, the device comprising:
a canister;
a non-metal support body disposed within the canister;
a plurality of metal A bulk deposits disposed on the support body; and
a plurality of metal B atomic clusters disposed on at least one of the metal A bulk deposits, wherein at least 85% by weight of the metal B atomic clusters comprise up to 10 metal B atoms, and the maximum metal B atomic cluster size is 200 metal B atoms;
wherein metal A and metal B are different metals each selected from the group consisting of platinum group metals (PGM), Ag, Au, Ni, Co, and Cu.

16. The bimetallic oxidation catalyst device of claim 15 , wherein the combined loading of metal A and metal B is less than 1 . 5 % by weight relative to the weight of the support body.

17. The bimetallic oxidation catalyst device of claim 15 , wherein the gasoline internal combustion engine powers a vehicle.

18. The bimetallic oxidation catalyst device of claim 15 , wherein the support body comprises one or more of alumina, silica, ceria, zirconia, titania, lanthana, and zeolite.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Yang Ming
• Day Ryan J
• Xiao Xingcheng
• Qi Gongshin
• Li Wei

Classifications

• F01N3/10 Primary

  by thermal or catalytic conversion of noxious components of exhaust · CPC title

• F01N3/2803

  characterised by structure, by material or by manufacturing of catalyst support · CPC title

• F01N3/2066

  Selective catalytic reduction [SCR] · CPC title

• C01B32/40

  Carbon monoxide · CPC title

• C01B21/0422

  by reduction · CPC title