PGM nanoparticles TWC catalysts for gasoline exhaust gas applications

Patent metadata

Field	Value
Publication number	US-10875010-B2
Application number	US-202016864314-A
Country	US
Kind code	B2
Filing date	May 1, 2020
Priority date	May 6, 2019
Publication date	Dec 29, 2020
Grant date	Dec 29, 2020

Abstract

A three-way catalyst article, and its use in an exhaust system for internal combustion engines, is disclosed. The catalyst article for treating exhaust gas comprising: a substrate; and a first catalytic region on the substrate; wherein the first catalytic region comprises a first platinum group metal (PGM) component and a first inorganic oxide, wherein the first PGM component comprises PGM nanoparticles, wherein the PGM nanoparticles have no more than 100 PGM atoms, and wherein the PGM nanoparticles have a mean particle size of 1 nm to 10 nm with a standard deviation (SD) no more than 1 nm.

First claim

I claim:

1. A catalyst article for treating exhaust gas comprising:
a substrate; and
a first catalytic region on the substrate;
wherein the first catalytic region comprises a first platinum group metal (PGM) component and a first inorganic oxide, wherein the first PGM component comprises PGM nanoparticles, wherein the PGM nanoparticles have no more than 100 PGM atoms, and wherein the PGM nanoparticles have a mean particle size of 1 nm to 10 nm with a standard deviation (SD) no more than 1 nm.

2. The catalyst article of claim 1 , wherein the PGM nanoparticles have an average particle size of about 1 to about 5 nm.

3. The catalyst article of claim 1 , wherein the PGM nanoparticles are Pt.

4. The catalyst article of claim 3 , wherein the Pt nanoparticles have a mean particle size of no more than 15 nm after hydrothermal redox aging at 600° C. for 4 hours, wherein the mean particle size is measured by TEM.

5. The catalyst article of claim 3 , wherein the Pt nanoparticles have a mean particle size of no more than 20 nm after hydrothermal redox aging at 700° C. for 4 hours, wherein the mean particle size is measured by TEM.

6. The catalyst article of claim 3 , wherein the Pt nanoparticles have a mean particle size of no more than 25 nm after hydrothermal redox aging at 800° C. for 4 hours, wherein the mean particle size is measured by TEM.

7. The catalyst article of claim 3 , wherein the Pt nanoparticles have 2 to 100 Pt atoms.

8. The catalyst article of claim 7 , wherein the Pt nanoparticles have 30 to 100 Pt atoms.

9. The catalyst article of claim 3 , wherein the Pt nanoparticles have a mean particle size of no more than 50 nm after aging at 1000° C. for 4 hours, wherein the mean particle size is measured by TEM.

10. The catalyst article of claim 3 , wherein the Pt nanoparticles have a mean particle size of no more than 30 nm after hydrothermal redox aging at 800° C. for 4 hours, wherein the mean particle size is measured by CO-pulse method.

11. The catalyst article of claim 3 , wherein the Pt nanoparticles have a mean particle size of no more than 60 nm after hydrothermal redox aging at 900° C. for 4 hours, wherein the mean particle size is measured by CO-pulse method.

12. The catalyst article of claim 3 , wherein the Pt nanoparticles have a mean particle size of no more than 80 nm after aging at 1000° C. for 4 hours, wherein the mean particle size is measured by CO-pulse method.

13. The catalyst article of claim 3 , wherein the Pt nanoparticles are atomically resolved.

14. The catalyst article of claim 13 , wherein the Pt nanoparticles have 12 to 28 Pt atoms.

15. The catalyst article of claim 3 , wherein frequency of adsorbed CO molecule is lower than 2080 cm −1 at 200° C. by IR spectroscopy.

16. The catalyst article of claim 3 , wherein frequency of adsorbed CO molecule is lower than 2070 cm −1 at 200° C. by IR spectroscopy.

17. An emission treatment system for treating a flow of a combustion exhaust gas comprising the catalyst article of claim 1 .

18. The emission treatment system of claim 17 further comprising a second catalyst article.

19. The emission treatment system of claim 18 , wherein the second catalyst article comprises Three-Way Catalyst (TWC) component.

20. The emission treatment system of claim 18 , wherein the second catalyst article is downstream of the catalyst article.

Assignees

• Johnson Matthey Plc

Inventors

• Nagaoka Shuhei

Classifications

• B01J2235/00

  Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties · CPC title

• B01J35/45

  Nanoparticles · CPC title

• B01J35/393

  Metal or metal oxide crystallite size · CPC title

• B01J35/56

  Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths · CPC title

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title