Zoned catalytic converters for gasoline engines with reduced rhodium content
AssigneeSDCmaterials, Inc.
InventorsQinghua YIN, Xiwang QI, Bryant KEARL, Maximilian A. BIBERGER
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Abstract
Zoned substrates and catalytic converters comprising zoned substrates for use in treating exhaust gases from gasoline engines are disclosed, along with materials for use in providing high oxygen storage capacity for the catalytic converters. Methods of making the zoned substrates, catalytic converters, and the oxygen storage material are also disclosed.
Claims29
A coated substrate for use in a catalytic converter for treatment of gasoline engine exhaust, comprising:
- a) a substrate;
- b) a first washcoat layer disposed in a first zone of the substrate, the first washcoat layer comprising:
- b.i) first composite nanoparticles comprising a first catalytic nanoparticle bonded to a first support nanoparticle;
- and
- either b.ii) first metal oxide particles impregnated with barium oxide, or b.ii′) first metal oxide particles and barium oxide;
- c) a second washcoat layer disposed in a second zone of the substrate, the second washcoat layer comprising:
- c.i) second composite nanoparticles comprising a second catalytic nanoparticle bonded to a second support nanoparticle;
- and
- c.ii) oxygen storage particles;
- wherein the first zone and second zone on the substrate do not overlap.
2-5. (canceled)
23-42. (canceled)
A method of making a coated substrate for use in a catalytic converter for treatment of gasoline engine exhaust, comprising:
- coating a substrate with a first washcoat formulation in a first zone of the substrate, the first washcoat formulation comprising first composite nanoparticles comprising a first catalytic nanoparticle bonded to a first support nanoparticle;
- and first metal oxide particles impregnated with barium oxide or a barium oxide precursor;
- coating the substrate with a second washcoat formulation in a second zone of the substrate, the second washcoat formulation comprising second composite nanoparticles comprising a second catalytic nanoparticle bonded to a second support nanoparticle;
- and oxygen storage particles;
- wherein the first zone and second zone on the substrate do not overlap.
44-86. (canceled)
(canceled)
93-116. (canceled)
Dependencies are inferred from the claim text.