Exhaust system for a vehicle having a “stop-start” compression ignition engine

Patent metadata

Field	Value
Publication number	US-9273583-B2
Application number	US-97455610-A
Country	US
Kind code	B2
Filing date	Dec 21, 2010
Priority date	Dec 21, 2009
Publication date	Mar 1, 2016
Grant date	Mar 1, 2016

Abstract

A vehicle comprises a compression ignition engine provided with engine management means and having a catalyst for exhaust gas aftertreatment, wherein the engine management means is configured, when in use, to detect idle conditions and upon determining that idle conditions exist, stops the engine entirely, wherein the catalyst comprises a honeycomb substrate monolith coated with a catalytic washcoat comprising one or more precious metal, which catalytic washcoat being arranged between a first, upstream washcoat zone and a second, downstream washcoat zone, wherein a thermal mass in the first washcoat zone is different from a thermal mass in the second washcoat zone and wherein a washcoat layer in the first, upstream washcoat zone is substantially contiguous with a washcoat layer in the second, downstream washcoat zone.

First claim

The invention claimed is:

1. A vehicle comprising a diesel engine provided with engine management means and having a catalyst for exhaust gas aftertreatment, wherein the engine management means is configured, when in use, to detect idle conditions and upon determining that idle conditions exist, stops the engine entirely, wherein the catalyst comprises a honeycomb substrate monolith coated with a catalytic washcoat comprising one or more precious metal and a washcoat component, wherein the one or more precious metal is selected from the group consisting of (i) platinum, (ii) palladium, (iii) a mixture of platinum and palladium, and (iv) a combination of palladium and gold; wherein:
the catalytic washcoat is arranged between an upstream washcoat zone and a downstream washcoat zone;
a washcoat layer in the upstream washcoat zone is substantially contiguous with a washcoat layer in the downstream washcoat zone;
a thermal mass in the upstream washcoat zone is less than a thermal mass in the downstream washcoat zone;
a total precious metal loading in the upstream washcoat zone comprises 55 to 90% of the total precious metal loading of the honeycomb substrate monolith, measured as a unit weight of precious metal per unit volume of washcoat; and
the honeycomb substrate monolith has a total length, and the upstream washcoat zone is defined at an upstream end by an inlet end of the honeycomb substrate monolith and at a downstream end by a point between 20% and 40% of the total length of the substrate monolith measured from the inlet end.

2. A vehicle according to claim 1 , wherein a greater thermal mass in the downstream washcoat zone relative to the upstream washcoat zone is provided by a thicker washcoat layer in the downstream washcoat zone compared to the upstream washcoat zone.

3. A vehicle according to claim 2 , wherein the thicker washcoat layer is provided by a washcoat loading of from 4 to 10 gin −3 .

4. A vehicle according to claim 2 , wherein the upstream washcoat zone has a thinner washcoat layer than the downstream washcoat zone, and wherein the thinner washcoat layer has a washcoat loading of from 1 to 3.5 gin −3 .

5. A vehicle according to claim 1 , wherein a greater thermal mass in the downstream washcoat zone relative to the upstream washcoat zone is provided by a washcoat component having a density of at least 3.50 gcm −3 .

6. A vehicle according to claim 5 , wherein the washcoat component is selected from the group consisting of densified alpha alumina, densified lanthana, densified cerium II oxide, densified cerium III oxide and densified zirconia.

7. A vehicle according to claim 1 , wherein the upstream washcoat zone comprises 60 to 80% of a total precious metal loading of the honeycomb substrate monolith.

8. A vehicle according to claim 1 , wherein the total precious metal loading on the honeycomb substrate monolith is from 15 to 300 gft −3 .

9. A vehicle according to claim 1 , wherein the precious metal or combination of precious metals in the upstream washcoat zone is different from the precious metal or combination of precious metals in the downstream washcoat zone.

10. A vehicle according to claim 1 , wherein the one or more precious metal is a combination of palladium and gold, wherein the combination of palladium and gold is a mixture of palladium and gold, an alloy of palladium and gold, or both a mixture and an alloy of palladium and gold.

Assignees

• Bergeal David
• Phillips Paul Richard
• Johnson Matthey Plc

Inventors

• Bergeal David
• Phillips Paul Richard

Classifications

• B01J23/66

  Silver or gold · CPC title

• B01J23/54

  combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 · CPC title

• F01N2510/0682

  having a discontinuous, uneven or partially overlapping coating of catalytic material, e.g. higher amount of material upstream than downstream or vice versa · CPC title

• F02N11/0814

  comprising means for controlling automatic idle-start-stop · CPC title

• B01J23/40

  of the platinum group metals · CPC title