# US 10,864,508 B2 · Nano-sized functional binder

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- Number: US 10,864,508 B2
- Document ID: US10864508B2
- Status: Granted
- Kind: B2
- Application number: 15/543,404
- Filed: 2016-01-15
- Published: 2018-01-11
- Granted: 2020-12-15
- Earliest claimed: 2015-01-16
- Assignees: BASF SE
- Applicants: BASF Corporation
- Inventors: Gary A. Gramiccioni; Jaya L. Mohanan; John K. Hochmuth; Kenneth R. Brown; Brian Todd Jones
- Web page: https://patentgrep.com/patent/US10864508B2

## CPC

- B01D 53/945: {characterised by a specific catalyst}
- B01D 53/9418: {for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas}
- B01D 53/944: {Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts (three-way-catalysts [TWC] B01D53/9445)}
- B01J 23/002: {Mixed oxides other than spinels, e.g. perovskite}
- B01J 23/005: {Spinels}
- B01J 23/10: of rare earths
- B01J 23/63: with rare earths or actinides
- B01J 23/83: with rare earths or actinides
- B01J 29/763: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 35/40: characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77)
- B01J 35/56: Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths
- B01J 35/60: characterised by their surface properties or porosity
- B01J 37/0009: {Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst}
- B01J 37/0246: {Coatings comprising a zeolite}
- B01D 2255/102: Platinum group metals
- B01D 2255/206: Rare earth metals
- B01D 2255/207: Transition metals
- B01D 2255/20715: Zirconium
- B01D 2255/2073: Manganese
- B01D 2255/20738: Iron
- B01D 2255/20753: Nickel
- B01D 2255/20761: Copper
- B01D 2255/402: Perovskites
- B01D 2255/405: Spinels
- B01D 2255/407: Zr-Ce mixed oxides
- B01D 2255/50: Zeolites
- B01D 2255/908: O2-storage component incorporated in the catalyst
- B01D 2255/9155: Wall flow filters
- B01D 2255/9202: Linear dimensions
- B01D 2255/9205: Porosity
- B01D 2257/404: Nitrogen oxides other than dinitrogen oxide
- B01D 2257/502: Carbon monoxide
- B01D 2257/702: Hydrocarbons
- B01D 2258/01: Engine exhaust gases
- B01J 35/23: in a colloidal state
- B01J 2229/42: Addition of matrix or binder particles
- Y02T 10/00: Road transport of goods or passengers
- Y02T 10/12: Improving ICE efficiencies
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

Described are catalytic articles comprising a substrate having a washcoat on the substrate, the washcoat containing a catalytic component having a first average (D50) particle size and a functional binder component having a second average (D50) particle size in the range of about 10 nm to about 1000 nm, wherein the ratio of the first average (D50) particle size to the second average (D50) particle size is greater than about 10:1. The catalytic articles are useful in methods and systems to purify exhaust gas streams from an engine.

## Claims

### Claim 1

A catalytic article for purification of exhaust gases of combustion engines comprising a substrate having a washcoat on the substrate, the washcoat containing a catalytic component having a first average (D50) particle size and a functional binder component having a second average (D50) particle size of about 10 nm to about 1000 nm,
wherein the ratio of the first average (D50) particle size to the second average (D50) particle size is greater than about 10:1, and
wherein the washcoat has a porosity in the range of about 10% to about 50% as measured by scanning electron microscopy (SEM).

### Claim 2 (depends on 1)

The catalytic article of claim 1, wherein the functional binder component has a structure selected from the group consisting of zeolite, Perovskite, spinel, composite, and combinations thereof.

### Claim 3 (depends on 1)

The catalytic article of claim 1, wherein the functional binder comprises an oxide selected from the group consisting of transition metal oxide, a rare-earth metal oxide, and combinations thereof.

### Claim 4 (depends on 3)

The catalytic article of claim 3, wherein the transition metal oxide comprises an oxide selected from the group consisting of zirconium oxide, copper oxide, nickel oxide, iron oxide, manganese oxide, and combinations thereof.

### Claim 5 (depends on 3)

The catalytic article of claim 3, wherein the rare-earth metal oxide comprises an oxide selected from the group consisting of cerium oxide, lanthanum oxide, neodymium oxide, yttrium oxide, praseodymium oxide, and combinations thereof.

### Claim 6 (depends on 2)

The catalytic article of claim 2, wherein the composite comprises a solid solution ceria/zirconia having the general formula Ce0.5Zr0.5O2.

### Claim 7 (depends on 1)

The catalytic article of claim 1, wherein the washcoat has porosity in the range of about 20% to about 30%.

### Claim 8 (depends on 1)

The catalytic article of claim 1, wherein the catalytic component comprises a particle size distribution of d10>1.0 μm, d50 is about 3 μm to about 5 μm, and d90 is about 9 μm to about 13 μm.

### Claim 9 (depends on 1)

The catalytic article of claim 1, wherein the catalytic component is selected from the group consisting of an SCR catalyst, a TWC catalyst, a diesel oxidation catalyst (DOC), or a catalyzed soot filter (CSF).

### Claim 10 (depends on 1)

The catalytic article of claim 1, wherein the catalytic component comprises a high surface area metal oxide support and a component selected from the group consisting of a platinum group metal (PGM), a base metal (BM), an oxygen storage component (OSC), a molecular sieve, and combinations thereof.

### Claim 11 (depends on 10)

The catalytic article of claim 10, wherein the high surface area metal oxide support comprises alumina and the functional binder comprises a ceria-containing oxygen storage component (OSC), wherein the alumina to OSC ratio by weight is about 0.5 to about 10.0.

### Claim 12 (depends on 1)

The catalytic article of claim 1, wherein the functional binder component comprises less than about 5% of platinum group metal by weight.

### Claim 13 (depends on 1)

The catalytic article of claim 1, wherein the substrate is a honeycomb substrate.

### Claim 14 (depends on 13)

The catalytic article of claim 13, wherein the honeycomb substrate comprises a wall flow filter.

### Claim 15 (depends on 13)

The catalytic article of claim 13, wherein the honeycomb substrate comprises a flow through substrate.

### Claim 16 (depends on 1)

The catalytic article of claim 1, wherein the functional binder component comprises about 0.5 wt. % to about 40 wt. %, on a solids basis, of the washcoat.

### Claim 17 (depends on 16)

The catalytic article of claim 16, wherein the second average (D50) particle size is about 10 to about 40 nm.