Advanced catalysts for automotive applications

• US 9,533,289 B2
• Filed: 08/04/2015
• Issued: 01/03/2017
• Est. Priority Date: 12/15/2009
• Status: Active Grant

• Current Assignee: Umicore AG & Company KG (Umicore S.A.)
• Original Assignee: SDC Materials,Inc.
• Inventors: Yin, Qinghua, Qi, Xiwang, Biberger, Maximilian A.
• Primary Examiner(s): Nguyen, Cam N.
• Application Number:
  US14/818,164
• Publication Number:
  US 20160067679A1
• Time in Patent Office: 518 Days
• Field of Search: 502261-263, 502/327, 502332-334, 502/339, 502/355, 502/415, 502/439, 502/527.12, 502/527.13, 502/527.19, 977/773, 977/775
• US Class Current: 1/1
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 23/42 Platinum
• CPC Class Codes: B01J 23/44 Palladium
• CPC Class Codes: B01J 23/464 Rhodium
• CPC Class Codes: B01J 23/8926 Copper and noble metals
• CPC Class Codes: B01J 35/23 in a colloidal state
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 37/00 Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
• CPC Class Codes: B01J 37/009 Preparation by separation, e.g. by filtration, decantation, screening
• CPC Class Codes: B01J 37/0211 using a colloidal suspension
• CPC Class Codes: B01J 37/32 Freeze drying, i.e. lyophilisation
• CPC Class Codes: B01J 37/349 making use of flames, plasmas or lasers
• CPC Class Codes: B28B 23/0087 Lightweight aggregates for making lightweight articles
• CPC Class Codes: B32B 37/14 characterised by the properties of the layers
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: B82Y 40/00 Manufacture or treatment of nanostructures
• CPC Class Codes: C23C 4/134 Plasma spraying
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Embodiments of present inventions are directed to an advanced catalyst. The advanced catalyst includes a honeycomb structure with an at least one nano-particle on the honeycomb structure. The advanced catalyst used in diesel engines is a two-way catalyst. The advanced catalyst used in gas engines is a three-way catalyst. In both the two-way catalyst and the three-way catalyst, the at least one nano-particle includes nano-active material and nano-support. The nano-support is typically alumina. In the two-way catalyst, the nano-active material is platinum. In the three-way catalyst, the nano-active material is platinum, palladium, rhodium, or an alloy. The alloy is of platinum, palladium, and rhodium.

Claims

1. A catalytic converter comprising;

a honeycomb structure; and

a washcoat layer on the honeycomb structure comprising micron-sized oxide particles and plasma-generated nano-particles, the nano-particles comprising nano-active material and a nano-support; and

wherein the nano-support comprises a partially reduced alumina surface configured to limit movement of the nano-active material and limit conglomeration of the nano-active material.

2. The catalytic converter of claim 1, wherein the nano-active material comprises platinum.

3. The catalytic converter of claim 1, wherein the nano-active material comprises palladium.

4. The catalytic converter of claim 1, wherein the nano-active material comprises rhodium.

5. The catalytic converter of claim 1, wherein the nano-active material comprises an alloy.

6. A cordierite substrate in a catalytic converter comprising:

a. a first type of nano-particles comprising a first nano-active material and a first nano-support, wherein the first nano-support comprises a partially reduced alumina surface configured to limit movement of the first nano-active material and limit conglomeration of the first nano-active material; and

b. a second type of nano-particles comprising a second nano-active material and a second nano-support.

7. The cordierite substrate of claim 6, wherein the first nano-active material comprises platinum.

8. The cordierite substrate of claim 6, wherein the second nano-active material comprises palladium.

9. The cordierite substrate of claim 6, wherein the second nano-active material comprises rhodium.

10. The cordierite substrate of claim 6, wherein the second nano-support is configured to limit movement of the second nano-active material and limit conglomeration of the second nano-active material.

11. The cordierite substrate of claim 10, wherein the second nano-support comprises alumina.

12. The cordierite substrate of claim 10, wherein second nano-support comprises a partially reduced alumina surface.

13. The cordierite substrate of claim 6, further comprising a third type of nano-particles comprising a third nano-active material and a third nano-support.

14. The cordierite substrate of claim 13, wherein the third nano-support is configured to limit movement of the third nano-active material and limit conglomeration of the third nano-active material.

15. The cordierite substrate of claim 13, wherein the third nano-support comprises alumina.

16. The cordierite substrate of claim 13, wherein the third nano-support comprises a partially reduced alumina surface.