Gasoline engine emissions treatment systems having particulate filters
First Claim
1. An emission treatment system downstream of a gasoline direct injection engine for treatment of an exhaust stream comprising hydrocarbons, carbon monoxide, nitrogen oxides, and particulates, the emission treatment system comprising a catalyzed particulate filter comprising:
- a three-way conversion (TWC) catalytic material that is coated onto or within a particulate filter having an uncoated porosity;
wherein the catalyzed particulate filter has a coated porosity that is substantially the same as the uncoated porosity of the particulate filter.
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Accused Products
Abstract
Exhaust systems and components are suitable for use with gasoline engines to capture particulates and to reduce gaseous emissions, where three-way conversion (TWC) catalysts located on a particulate filters are provided. Coated particle filters having washcoat loadings in the range of 1 to 4 g/ft3 result in minimal impact on back pressure while simultaneously providing TWC catalytic activity and particle trapping functionality to meet increasingly stringent regulations such as Euro 6. Sufficient to high levels of oxygen storage components (OSC) are also delivered on and/or within the filter. The filters can have a coated porosity that is substantially the same as its uncoated porosity. The TWC catalytic material can comprise a particle size distribution such that a first set of particles has a first d90 particle size of 7.5 μm or less and a second set of particles has a second d90 particle size of more than 7.5 μm.
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Citations
26 Claims
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1. An emission treatment system downstream of a gasoline direct injection engine for treatment of an exhaust stream comprising hydrocarbons, carbon monoxide, nitrogen oxides, and particulates, the emission treatment system comprising a catalyzed particulate filter comprising:
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a three-way conversion (TWC) catalytic material that is coated onto or within a particulate filter having an uncoated porosity; wherein the catalyzed particulate filter has a coated porosity that is substantially the same as the uncoated porosity of the particulate filter. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A catalyzed particulate filter located in an emission treatment system downstream of a gasoline direct injection engine for treatment of an exhaust stream comprising hydrocarbons, carbon monoxide, nitrogen oxides, and particulates, the catalyzed particulate filter comprising:
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a three-way conversion (TWC) catalytic material that is coated onto or within a particulate filter in an amount in the range of 1.0 to 4 g/in3 (122 to 244 g/L); wherein the TWC catalytic material stores at least 100 mg/L of oxygen after a full useful life aging and comprises an oxygen storage component in an amount in the range of 1.0 to 4.0 g/in3 (122 g/L to 244 g/L); wherein the particulate filter comprises a pore size distribution such that a first set of pores has a first mean pore size of 30 μ
m or less and second set of pores has a second mean pore size of more than 30 μ
m; andwherein the TWC catalytic material comprises a particle size distribution such that a first set of particles has a first d90 particle size of 7.5 μ
m or less and a second set of particles has a second d90 particle size of more than 7.5 μ
m. - View Dependent Claims (19, 20, 23)
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21. A method of treating an exhaust gas comprising hydrocarbons, carbon monoxide, nitrogen oxides, and particulates, the method comprising:
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providing a catalyzed particulate filter comprising a three-way conversion (TWC) catalytic material coated onto or within a particulate filter in an amount of effective to provide a particulate emissions number of no more than 6×
1011 per kilometer;locating the catalyzed particulate filter downstream of a gasoline direct injection engine; and contacting exhaust gas from the gasoline direct injection engine with the catalyzed particulate filter. - View Dependent Claims (22, 24, 25)
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26. A method of making a catalyzed particulate filter, the method comprising:
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providing a particulate filter; providing a three-way conversion (TWC) catalytic material; and coating the TWC catalytic material onto or into the particulate filter in an amount of at least 1.0 g/in3 (61 g/L) to form the catalyzed particulate filter such that the catalyzed particulate filter has a coated porosity that is substantially the same as an uncoated porosity of the particulate filter.
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Specification