High entropy rare earth oxides for emissions control

Patent metadata

Field	Value
Publication number	US-12427477-B2
Application number	US-202217648520-A
Country	US
Kind code	B2
Filing date	Jan 20, 2022
Priority date	Jan 20, 2022
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

Methods and systems are provided for an emissions aftertreatment device. In one example, the emissions aftertreatment device may include a catalyst and a high entropy oxygen storage material formed of at least five metal oxides in equal molar proportions. The at least five metal oxides includes one or more rare earth metals as well as other metals with similar chemical properties as the rare earth metals.

First claim

The invention claimed is:

1. An emissions aftertreatment device, comprising:
a catalyst, wherein the catalyst is a three-way catalyst configured to chemically interact CO, NOx, and hydrocarbons (HC) in exhaust gas;
a high entropy oxygen storage material in addition to the catalyst, wherein the high entropy oxygen storage material is formed of metal oxides including a 1:1:1:1:1:1 molar ratio of La, Ce, Pr, Nd, Tb, and Yb.

2. The emissions aftertreatment device of claim 1 , wherein the high entropy oxygen storage material further includes one or more of samarium, europium, gadolinium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, scandium, yttrium, hafnium, and zirconium.

3. The emissions aftertreatment device of claim 1 , wherein the equal molar ratios includes variations between each of the equal molar ratios up to 10%.

4. The emissions aftertreatment device of claim 1 , wherein the metal oxides are incorporated into the high entropy oxygen storage material as ceramic materials.

5. The emissions aftertreatment device of claim 1 , wherein the metal oxides form a single crystalline phase.

6. The emissions aftertreatment device of claim 1 , wherein the catalyst is a precious metal catalyst.

7. The emissions aftertreatment device of claim 1 , wherein the high entropy oxygen storage material has an internal entropy between 1.5 to 3 times higher than an oxygen storage material formed of fewer than the metal oxides, the fewer than the metal oxides including ceria and zirconia as majority constituents.

8. The emissions aftertreatment device of claim 1 , wherein the high entropy oxygen storage material is incorporated into at least one washcoat of the emissions aftertreatment device.

9. An oxygen storage material for an emissions aftertreatment device, comprising:
a single phase ceramic material formed of at least five metal oxides in equal molar proportions, the single phase ceramic material is an oxide comprising a 1:1:1:1:1:1 molar ratio of La, Ce, Pr, Nd, Tb, and Yb.

10. The oxygen storage material of claim 9 , wherein the single phase ceramic material further includes one or more rare earth metals including samarium, europium, gadolinium, dysprosium, holmium, erbium, thulium, and lutetium.

11. The oxygen storage material of claim 10 , wherein the single phase ceramic material further includes one or more metals having similar chemical properties to the one or more rare earth metals, including scandium, yttrium, hafnium, and zirconium.

12. The oxygen storage material of claim 9 , wherein more than 50% of NOx in exhaust gas is reduced by the emissions aftertreatment device when the single phase ceramic material is combined with a catalyst.

13. The oxygen storage material of claim 9 , wherein the single phase ceramic material provides oxygen for oxidation of hydrocarbons and CO when an air-to-fuel ratio of an engine is rich, the engine flowing exhaust gas to the emissions aftertreatment device.

14. The oxygen storage material of claim 9 , wherein the single phase ceramic material stores oxygen when an air-to-fuel ratio of an engine is lean, the engine flowing exhaust gas to the emissions aftertreatment device.

15. A three-way catalytic converter for a vehicle, comprising:
a washcoat supported on a substrate, the washcoat including:
a first zone and a second zone, wherein exhaust gas flows through the first zone before flowing through the second zone, wherein a composition of the first zone and the second zone is different, and wherein the first zone and/or the second zone include:
at least one catalyst; and
a high entropy oxygen storage material formed of a single phase of equal molar amounts of metal oxides, the metal oxides including a 1:1:1:1:1:1 molar ratio of La, Ce, Pr, Nd, Tb, and Yb.

16. The three-way catalytic converter of claim 15 , wherein the washcoat further includes alumina and/or ceria-zirconia, and wherein the washcoat is a first washcoat and the first zone is upstream of the second zone relative to a direction of exhaust gas flow, further comprising a second washcoat layered over each of the first zone and the second zone of the first washcoat.

17. The three-way catalytic converter of claim 15 , wherein the substrate is formed of one of cordierite, aluminum titanate, or a metal.

Assignees

• Ford Global Tech Llc

Inventors

• Getsoian Andrew
• Wu Jason

Classifications

• B01J2523/49

  Hafnium · CPC title

• B01J2523/48

  Zirconium · CPC title

• B01J2523/3793

  Lutetium · CPC title

• B01J2523/3787

  Ytterbium · CPC title

• B01J2523/3775

  Erbium · CPC title