# US 2023/0191379 A1 · Emissions control device

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- Number: US 2023/0191379 A1
- Document ID: US20230191379A1
- Status: Published application
- Kind: A1
- Application number: 18/171,124
- Filed: 2023-02-17
- Published: 2023-06-22
- Earliest claimed: 2016-04-11
- Assignees: Johnson Matthey Public Limited Company
- Applicants: Johnson Matthey Public Limited Company
- Inventors: Cecilia BERNARDINI; Thomas CAMPBELL; Guy Richard CHANDLER; Christopher DALY; Katharine Ann HARDSTONE; Thomas HOTCHKISS; David THOMPSETT
- Web page: https://patentgrep.com/patent/US20230191379A1

## CPC

- B01J 29/763: {CHA-type, e.g. Chabazite, LZ-218}
- B01D 53/9418: {for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas}
- B01J 21/04: Alumina
- B01J 23/42: Platinum
- B01J 35/19: {Catalysts containing parts with different compositions}
- B01J 35/50: characterised by their shape or configuration
- B01J 35/56: Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths
- B01J 35/657: {larger than 1000 nm}
- B01J 37/0215: {Coating}
- B01J 37/0236: {Drying, e.g. preparing a suspension, adding a soluble salt and drying}
- B01J 37/08: Heat treatment {(B01J37/0009, B01J37/0018 take precedence)}
- B05D 7/22: to internal surfaces, e.g. of tubes
- F01N 3/035: with catalytic reactors
- F01N 3/106: {Auxiliary oxidation catalysts}
- F01N 3/2066: {Selective catalytic reduction [SCR]}
- F01N 3/2803: {characterised by structure, by material or by manufacturing of catalyst support}
- F01N 3/2828: {Ceramic multi-channel monoliths, e.g. honeycombs}
- F01N 13/009: {having two or more separate purifying devices arranged in series}
- B01D 2255/20761: Copper
- B01D 2255/2092: Aluminium
- B01D 2255/50: Zeolites
- B01J 2235/30: Scanning electron microscopy; Transmission electron microscopy
- F01N 2250/02: filtering and catalytic conversion
- F01N 2330/00: Structure of catalyst support or particle filter
- F01N 2330/06: Ceramic, e.g. monoliths
- F01N 2330/22: Metal foam
- F01N 2370/04: Zeolitic material
- 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)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- 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

An emissions control device for treating or removing pollutants from an exhaust gas produced by an internal combustion engine is disclosed. The emissions control device comprises a solid foam layer disposed on a substrate, wherein the solid foam layer disposed on a substrate has an open cell structure and comprises a particulate material which is a catalytic material comprising a catalytically active metal supported on a support material.

## Claims

### Claim 1

An emissions control device for treating or removing pollutants from an exhaust gas produced by an internal combustion engine, wherein the emissions control device comprises a solid foam layer disposed on a substrate, and wherein the solid foam layer disposed on a substrate has an open cell structure and comprises a particulate material which is a catalytic material comprising a catalytically active metal supported on a support material.

### Claim 2 (depends on 1)

The emissions control device according to claim 1, the solid foam layer has a cell volume, wherein more than 20% of the cell volume is interconnected.

### Claim 3 (depends on 1)

The emissions control device according to claim 1, wherein the solid foam layer has a median pore diameter of 1-100 µm.

### Claim 4 (depends on 1)

The emissions control device according to claim 1, wherein the solid foam layer comprises bubble like structures having a size distribution in the range of 5 µm-500 µm.

### Claim 5 (depends on 1)

The emissions control device according to claim 1, wherein the solid foam layer comprises a partially collapsed structure.

### Claim 6 (depends on 1)

The emissions control device according to claim 1, wherein the thickness of the solid foam layer is no more than 500 µm.

### Claim 7 (depends on 1)

The emissions control device according to claim 1, wherein the solid foam layer is substantially localized on the walls of the channels.

### Claim 8 (depends on 1)

The emissions control device according to claim 1, wherein the substrate is a porous monolith.

### Claim 9 (depends on 1)

The emissions control device according to claim 1, wherein the catalytically active metal is at least one transition metal selected from iron, copper, nickel, gold, platinum, palladium, rhodium, and ruthenium.

### Claim 10 (depends on 1)

The emissions control device according to claim 1, wherein the support material is a refractory oxide, a metal aluminate or a zeolite.

### Claim 11 (depends on 1)

The emissions control device according to claim 1, wherein the support material is a refractory oxide, which is selected from the group consisting of alumina, silica, titania, magnesia, zirconia, ceria, lanthana and a mixed or composite oxide of two or more thereof, such as silica-alumina, titania-alumina, zirconia-alumina, ceria-alumina, titania-silica, zirconia-silica, zirconia-titania, ceria zirconia, ceria-zirconia-alumina or alumina-magnesium oxide.

### Claim 12 (depends on 1)

The emissions control device according to claim 1, wherein the particulate material is a metal oxide based SCR catalyst formulation, a molecular sieve based SCR catalyst formulation or a mixture thereof.

### Claim 13 (depends on 12)

The emissions control device according to claim 12, wherein the particulate material is a molecular sieve based SCR catalyst formulation, preferably the molecular sieve based SCR catalyst formulation comprises a transition metal exchanged molecular sieve.

### Claim 14 (depends on 13)

The emissions control device according to claim 13, wherein the molecular sieve based SCR catalyst formulation comprises a transition metal exchanged molecular sieve.

### Claim 15 (depends on 14)

The emissions control device according to claim 14, wherein the transition metal of the transition metal exchanged molecular sieve is copper and the molecular sieve is a zeolite having a framework structure represented by a Framework Type Code CHA.