Gasoline particulate filter

Patent metadata

Field	Value
Publication number	US-2025091004-A1
Application number	US-202318832413-A
Country	US
Kind code	A1
Filing date	Jan 28, 2023
Priority date	Jan 28, 2022
Publication date	Mar 20, 2025
Grant date	—

Abstract

The present invention relates to a particulate filter, which comprises —a substrate, comprising a plurality of porous walls extending longitudinally to form a plurality of parallel channels extending from an inlet end to an outlet end, wherein a quantity of the channels are inlet channels that are open at the inlet end and closed at the outlet end, and a quantity of channels are outlet channels that are closed at the inlet end and open at the outlet end; and —a layer of inorganic particles loaded on surfaces of the porous walls in the inlet channels and/or outlet channels, preferably in at least the inlet channels, wherein the inorganic particles have a D90 in the range of 5.0 to 14.0 microns.

First claim

1 . A particulate filter, which comprises:
a substrate, comprising a plurality of porous walls extending longitudinally to form a plurality of parallel channels extending from an inlet end to an outlet end, wherein a quantity of the channels are inlet channels that are open at the inlet end and closed at the outlet end, and a quantity of channels are outlet channels that are closed at the inlet end and open at the outlet end; and a layer of inorganic particles loaded on surfaces of the porous walls in the inlet channels and/or outlet channels, preferably in at least the inlet channels, wherein the inorganic particles have a D 90 in the range of 5.0 to 14.0 microns.

2 . The particulate filter according to claim 1 , wherein the inorganic particles comprise one or more non-PGM components, for example alumina, zirconia, ceria, silica, titania, magnesium oxide, zinc oxide, zinc carbonate, calcium oxide, calcium carbonate, silicate zeolite, alumina silicate zeolite, or a combination or composite thereof.

3 . The particulate filter according to claim 2 , wherein the inorganic particles comprises alumina, zinc oxide, zirconia, or a combination or composite thereof.

4 . The particulate filter according to claim 3 , wherein the inorganic particles comprises alumina.

5 . The particulate filter according to claim 1 , wherein the layer of inorganic particles exhibits no three-way conversion catalytic activity.

6 . The particulate filter according to claim 1 , wherein the layer of inorganic particles does not comprise a PGM component.

7 . The particulate filter according to claim 1 , wherein the inorganic particles have a D 90 in the range of 5.5 to 9.5 microns.

8 . The particulate filter according to claim 7 , wherein the inorganic particles have a D 90 in the range of 5.8 to 9.0 microns.

9 . The particulate filter according to claim 1 , which further comprises a three-way conversion catalyst (TWC) coat, preferably a washcoat comprising a TWC composition.

10 . The particulate filter according to claim 9 , wherein the three-way conversion catalyst coat is in at least a portion of the inlet channels and/or outlet channels of the substrate.

11 . The particulate filter according to claim 1 , which comprises the layer of inorganic particles at a loading of from 0.005 to 0.83 g/in 3 (i.e., about 0.3 to 50 g/L), or 0.01 to 0.33 g/in 3 (i.e., about 0.6 to 20 g/L), or from 0.02 to 0.17 g/in 3 (i.e., about 1.2 to 10 g/L), or from 0.025 to 0.1 g/in 3 (i.e., about 1.5 to 6 g/L).

12 . The particulate filter according to claim 1 , which is a gasoline particulate filter.

13 . A method for producing a particulate filter as defined in claim 1 , which includes:
providing a substrate comprising a plurality of porous walls extending longitudinally to form a plurality of parallel channels extending from an inlet end to an outlet end, wherein a quantity of the channels are inlet channels that are open at the inlet end and closed at the outlet end, and a quantity of channels are outlet channels that are closed at the inlet end and open at the outlet end; and applying inorganic particles on surfaces of the porous walls in the inlet channels and/or outlet channels, wherein the inorganic particles have a D 90 in the range of 5.0 to 14.0 microns, preferably 5.5 to 9.5 μm, more preferably 5.8 to 9.0 μm.

14 . The method according to claim 13 , wherein the inorganic particles are applied by a dry coating process or washcoating process, preferably by a dry coating process.

15 . The method according to claim 14 , wherein the inorganic particles are applied by using the inorganic particles or precursors thereof.

16 . An exhaust treatment system, which comprises a particulate filter according to claim 1 or a particulate filter obtainable or obtained from the method comprising the steps of:
providing a substrate comprising a plurality of porous walls extending longitudinally to form a plurality of parallel channels extending from an inlet end to an outlet end, wherein a quantity of the channels are inlet channels that are open at the inlet end and closed at the outlet end, and a quantity of channels are outlet channels that are closed at the inlet end and open at the outlet end, and,
applying inorganic particles on surfaces of the porous walls in the inlet channels and/or outlet channels, wherein the inorganic particles have a D 90 in the range of 5.0 to 14.0 microns, preferably 5.5 to 9.5 μm, more preferably 5.8 to 9.0 μm, and located downstream of a gasoline engine.

17 . A method for treating an exhaust stream from a gasoline engine, which includes contacting the exhaust stream with a particulate filter as described as defined in claim 1 , or an exhaust treatment system, which comprises the particulate filter according to or a particulate filter obtainable or obtained from the method comprising the steps of:
providing a substrate comprising a plurality of porous walls extending longitudinally to form a plurality of parallel channels extending from an inlet end to an outlet end, wherein a quantity of the channels are inlet channels that are open at the inlet end and closed at the outlet end, and a quantity of channels are outlet channels that are closed at the inlet end and open at the outlet end; and, applying inorganic particles on surfaces of the porous walls in the inlet channels and/or outlet channels, wherein the inorganic particles have a D 90 in the range of 5.0 to 14.0 microns, preferably 5.5 to 9.5 μm, more preferably 5.8 to 9.0 μm, and located downstream of a gasoline engine.

Assignees

• Basf Corp

Inventors

• Siani Attilio
• Chen Chunyu
• Wu Yehui
• Deng Chenghao

Classifications

• F01N2510/068

  characterised by the distribution of the catalytic coatings · CPC title

• F01N2510/063

  zeolites · CPC title

• F01N2370/04

  Zeolitic material · CPC title

• F01N3/2803

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

• F01N3/101

  Three-way catalysts · CPC title