# US 11,439,987 B2 · Multi-region TWC for treatment of exhaust gas from gasoline engine

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- Number: US 11,439,987 B2
- Document ID: US11439987B2
- Status: Granted
- Kind: B2
- Application number: 15/733,193
- Filed: 2018-12-07
- Published: 2020-12-17
- Granted: 2022-09-13
- Earliest claimed: 2017-12-08
- Assignees: Johonson Matthey (Shanghai) Chemicals Co., Ltd
- Applicants: Johnson Matthey (Shanghai) Chemicals LTD.
- Inventors: Hongyu Ji; Dongsheng Qiao; Xiang Zheng
- Web page: https://patentgrep.com/patent/US11439987B2

## CPC

- B01J 23/002: {Mixed oxides other than spinels, e.g. perovskite}
- B01J 23/58: with alkali- or alkaline earth metals
- B01D 53/945: {characterised by a specific catalyst}
- B01D 53/9472: {in different zones}
- B01J 23/10: of rare earths
- B01J 23/44: Palladium
- B01J 23/464: {Rhodium}
- B01J 23/63: with rare earths or actinides
- B01J 35/19: {Catalysts containing parts with different compositions}
- B01J 35/56: Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths
- B01J 37/0228: {in several steps}
- B01J 37/0244: {Coatings comprising several layers}
- B01J 37/08: Heat treatment {(B01J37/0009, B01J37/0018 take precedence)}
- F01N 3/101: {Three-way catalysts}
- F01N 3/2839: {Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration}
- B01D 2255/1023: Palladium
- B01D 2255/1025: Rhodium
- B01D 2255/2042: Barium
- B01D 2255/9022: Two layers
- B01D 2255/9032: Two zones
- B01D 2255/9035: Three zones
- B01D 2255/908: O2-storage component incorporated in the catalyst
- B01D 2255/9155: Wall flow filters
- B01D 2258/014: Stoichiometric gasoline engines
- B01J 2523/00: Constitutive chemical elements of heterogeneous catalysts
- F01N 2330/02: Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
- F01N 2330/06: Ceramic, e.g. monoliths
- F01N 2370/02: used in catalytic reactors
- F01N 2510/06: for exhaust purification, e.g. catalytic reaction
- Y02T 10/12: Improving ICE efficiencies
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- 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)
- F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16)
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A three-way catalyst article, and its use in an exhaust system for internal combustion engines, is disclosed. The catalyst article for treating exhaust gas comprising: a substrate comprising an inlet end, an outlet end with an axial length L; a first catalytic region beginning at the inlet end and extending for less than the axial length L, wherein the first catalytic region comprises a first palladium component; a second catalytic region beginning at the outlet end and extending for less than the axial length L, wherein the second catalytic region comprises a second palladium component; a third catalytic region beginning at the outlet end and extending for less than the axial length L, wherein the third catalytic region comprises a third rhodium component; and wherein the third catalytic region overlies the second catalytic region.

## Claims

### Claim 1

A catalyst article for treating exhaust gas comprising:
a substrate comprising an inlet end, an outlet end with an axial length L;
a first catalytic region beginning at the inlet end and extending for 30 to 70 percent of the axial length L, wherein the first catalytic region comprises a first palladium component and a first oxygen storage capacity (OSC) material;
a second catalytic region beginning at the outlet end and extending for 30 to 70 percent of the axial length L, wherein the second catalytic region comprises a second palladium component and a second OSC material;
a third catalytic region beginning at the outlet end and extending for 50 to 95 percent of the axial length L, wherein the third catalytic region comprises a third rhodium component;
wherein the third catalytic region overlies the second catalytic region; and
wherein the first palladium component and the second palladium component have a weight ratio of greater than 1:1.

### Claim 2 (depends on 1)

The catalyst article of claim 1, wherein the second catalytic region overlaps with the first catalytic region for 1 to 15 percent of the axial length L.

### Claim 3 (depends on 1)

The catalyst article of claim 1, wherein the total length of the second catalytic region and the first catalytic region equals to the axial length L.

### Claim 4 (depends on 1)

The catalyst article of claim 1, wherein the total length of the second catalytic region and the first catalytic region is less than the axial length L.

### Claim 5 (depends on 1)

The catalyst article of claim 1, wherein the third catalytic region extends for 60 to 95 percent of the axial length L.

### Claim 6 (depends on 1)

The catalyst article of claim 1, wherein the first catalytic region is essentially free of PGM metals other than the first palladium component.

### Claim 7 (depends on 1)

The catalyst article of claim 1 wherein the first catalytic region comprises 50-250 g/ft3 of the first palladium component.

### Claim 8 (depends on 1)

The catalyst article of claim 1, wherein the first catalytic region further comprises a first alkali or alkaline-earth metal component and/or a first inorganic oxide.

### Claim 9 (depends on 1)

The catalyst article of claim 1, wherein the second catalytic region is essentially free of PGM metals other than the second palladium component.

### Claim 10 (depends on 1)

The catalyst article of claim 1, wherein the second catalytic region comprises 5-60 g/ft3 of the second palladium component.

### Claim 11 (depends on 10)

The catalyst article of claim 10, wherein the second catalytic region comprises 10-50 g/ft3 of the second palladium component.

### Claim 12 (depends on 1)

The catalyst article of claim 1, wherein the second catalytic region further comprises a second alkali or alkaline-earth metal component and/or a second inorganic oxide.

### Claim 13 (depends on 1)

The catalyst article of claim 1, wherein the third catalytic region comprises 0.1-20 g/ft3 of the third rhodium component.

### Claim 14 (depends on 1)

The catalyst article of claim 1, wherein the third catalytic region further comprises a third oxygen storage capacity (OSC) material, a third alkali or alkaline-earth metal component, and/or a third inorganic oxide.

### Claim 15 (depends on 1)

The catalyst article of claim 1, wherein the substrate is a flow-through monolith.

### Claim 16 (depends on 1)

The catalyst article of claim 1, wherein the substrate is more than 90 mm in length.

### Claim 17 (depends on 1)

The catalyst article of claim 1, wherein the first catalytic region is supported/deposited directly on the substrate.

### Claim 18 (depends on 1)

The catalyst article of claim 1, wherein the second catalytic region is supported/deposited directly on the substrate.

### Claim 19 (depends on 1)

The catalyst article of claim 1, wherein the first palladium component and the second palladium component have a weight ratio of at least 3:1.

### Claim 20 (depends on 1)

An emission treatment system for treating a flow of a combustion exhaust gas comprising the catalyst article of claim 1.