Catalyst design for heavy-duty diesel combustion engines

Patent metadata

Field	Value
Publication number	US-9950316-B2
Application number	US-201615387445-A
Country	US
Kind code	B2
Filing date	Dec 21, 2016
Priority date	Oct 22, 2013
Publication date	Apr 24, 2018
Grant date	Apr 24, 2018

Abstract

Disclosed are washcoats, coated substrates formed from such washcoats, and catalytic converters for use in diesel applications, such as heavy duty diesel applications. Methods of preparing the coated substrates are also disclosed.

First claim

What is claimed is:

1. A method of forming a coated substrate, comprising:
coating a substrate with a first washcoat layer comprising zeolites;
coating the first washcoat layer with a second washcoat layer comprising a first catalytically active material comprising first composite nanoparticles embedded within porous micron-sized carrier particles, wherein the first composite nanoparticles comprise a first support nanoparticle and a first catalytic nanoparticle, and wherein the first catalytic nanoparticle comprises a platinum-palladium alloy; and
coating the second washcoat layer with a third washcoat layer comprising a second catalytically active material comprising second composite nanoparticles embedded within porous micron-sized carrier particles, wherein the second composite nanoparticles comprise a second support nanoparticle and a second catalytic nanoparticle, and wherein the second catalytic nanoparticle comprises a platinum-palladium alloy.

2. The method of claim 1 , wherein the platinum-palladium alloy of the first catalytic nanoparticle comprises a platinum:palladium ratio of less than about 4:1 Pt:Pd.

3. The method of claim 2 , wherein the platinum-palladium alloy of the first catalytic nanoparticle comprises a platinum:palladium ratio of about 1:1 to about 4:1 Pt:Pd.

4. The method of claim 1 , wherein the platinum-palladium alloy of the second catalytic nanoparticle comprises a platinum:palladium ratio of greater than about 4:1 Pt:Pd.

5. The method of claim 4 , wherein the platinum palladium alloy of the second catalytic nanoparticle comprises a platinum:palladium ratio of about 10:1 to about 100:1 Pt:Pd.

6. The method of claim 5 , wherein the platinum-palladium alloy of the first catalytic nanoparticle comprises a platinum:palladium ratio of less than about 4:1 Pt:Pd.

7. The method of claim 6 , wherein the platinum-palladium alloy of the first catalytic nanoparticle comprises a platinum:palladium ratio of about 1:1 to about 4:1 Pt:Pd.

8. The method of claim 4 , wherein the platinum-palladium alloy of the first catalytic nanoparticle comprises a platinum:palladium ratio of less than about 4:1 Pt:Pd.

9. The method of claim 8 , wherein the platinum-palladium alloy of the first catalytic nanoparticle comprises a platinum:palladium ratio of about 1:1 to about 4:1 Pt:Pd.

10. The method of claim 1 , wherein the first composite nanoparticle and the second composite nanoparticle are plasma-created.

11. The method of claim 1 , wherein the first support nanoparticle or the second support nanoparticle comprises aluminum oxide.

12. The method of claim 1 , wherein the first support nanoparticle and the second support nanoparticle comprise aluminum oxide.

13. The method of claim 1 , wherein the first washcoat layer is coated onto the substrate at a thickness of about 30 g/l to about 100 g/l.

14. The method of claim 1 , wherein the second washcoat layer is coated onto the first washcoat layer at a thickness of about 50 g/l to about 140 g/l.

15. The method of claim 1 , wherein the third washcoat layer is coated onto the second washcoat layer at a thickness of about 50 g/l to about 140 g/l.

16. The method of claim 1 , wherein the first washcoat layer is coated onto the substrate at a thickness of about 30 g/l to about 100 g/l, the second washcoat layer is coated onto the first washcoat layer at a thickness of about 50 g/l to about 140 g/l, and the third washcoat layer is coated onto the second washcoat layer at a thickness of about 50 g/l to about 140 g/l.

17. The method of claim 1 , further comprising:
drying and calcining the substrate after coating the substrate with the first washcoat layer;
drying and calcining the substrate after coating the first washcoat layer with the second washcoat layer; and
drying and calcining the substrate after coating the second washcoat layer with the third washcoat layer.

Assignees

• Umicore Ag & Co Kg

Inventors

• Yin Qinghua
• Qi Xiwang
• Biberger Maximilian A

Classifications

• Y02A50/20

  Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters · CPC title

• B01D2255/50

  Zeolites · CPC title

• B01D2255/2092

  Aluminium · CPC title

• B01D2255/9202

  Linear dimensions · CPC title

• B01D2255/9022

  Two layers · CPC title