Provided are an exhaust treatment catalyst and an exhaust article containing the catalyst. The catalyst comprises a carrier; a first layer deposited on the carrier, said first layer comprising substantially only at least one refractory metal oxide; a second layer deposited on the first layer, said s
Provided are an exhaust treatment catalyst and an exhaust article containing the catalyst. The catalyst comprises a carrier; a first layer deposited on the carrier, said first layer comprising substantially only at least one refractory metal oxide; a second layer deposited on the first layer, said second layer comprising substantially only at least one oxygen storage component and at least one binder therefore; and a third layer deposited on the second layer, said third layer comprising at least one layer of one or more platinum group metal components supported on a refractory metal oxide support.
대표청구항▼
What is claimed is: 1. An exhaust gas treatment article comprising: a catalyst, an upstream EGO or air/fuel ratio sensor and a downstream EGO sensor, wherein the catalyst comprises: (a) a carrier; (b) a first washcoat layer deposited on the carrier, said first washcoat layer comprising substantiall
What is claimed is: 1. An exhaust gas treatment article comprising: a catalyst, an upstream EGO or air/fuel ratio sensor and a downstream EGO sensor, wherein the catalyst comprises: (a) a carrier; (b) a first washcoat layer deposited on the carrier, said first washcoat layer comprising substantially only at least one refractory metal oxide; (c) a second washcoat layer deposited on the first washcoat layer, said second washcoat layer comprising substantially only at least one oxygen storage component and at least one binder therefor; and (d) a third washcoat layer deposited on the second washcoat layer, said third washcoat layer comprising at least one washcoat layer of one or more platinum group metal components supported on a refractory metal oxide support, wherein the amount of oxygen storage component in the second layer is present in an amount sufficient so that deterioration of its oxygen storage capacity can be correlated with deterioration of the catalyst's ability to reduce hydrocarbons, carbon monoxides or nitrogen oxides in the exhaust gas. 2. The article of claim 1 wherein the third washcoat layer further comprises at least one oxygen storage component and at least one binder therefor. 3. The article of claim 2 further comprising a fourth washcoat layer deposited on the third washcoat layer, said fourth washcoat layer comprising one or more platinum group components supported on a refractory metal oxide support. 4. The article of claim 3 wherein the fourth washcoat layer further comprises at least one oxygen storage component and at least one binder therefor. 5. The article of claim 3 wherein the refractory metal oxide employed in the first washcoat layer, third washcoat layer and the fourth washcoat layer is independently selected from the group consisting of alumina; titania; zirconia; mixtures of alumina with one or more of titania, zirconia, and ceria; ceria coated on alumina; and titania coated on alumina. 6. The article of claim 3 further comprising an overcoat washcoat layer deposited on the third or the fourth washcoat layer, said overcoat washcoat layer comprising a catalyst poisons sorbent. 7. The article of claim 6 wherein the carrier comprises a ceramic or metal having a honeycomb cellular structure comprising hexagonal or square cells. 8. The article of claim 7 wherein the first, second, third, fourth and overcoat washcoat layers have thicknesses at their respective edges and corners of the rectangular or square cells are as follows: Washcoat layer Edge Thickness, μ Corner Thickness, μ First about 3 to about 15 about 30 to about 200 Second about 5 to about 15 about 30 to about 100 Third about 5 to about 15 about 30 to about 100 Fourth about 5 to about 15 about 30 to about 100 Overcoat about 5 to about 15 about 30 to about 100. 9. The article of claim 1 wherein the oxygen storage component is selected from the group consisting of ceria, praseodymia, a ceria-zirconia composite, a ceria-praseodymia-zirconia composite and a ceria-praseodymia-zirconia-neodymia composite, and the binder comprises zirconia. 10. The article of claim 1 wherein the catalyst comprises at least two catalytic zones. 11. The article of claim 1, wherein the first layer comprises at least 76 weight % of one refractory metal oxide. 12. The article of claim 1, wherein the first layer comprises active ingredients in a quantity not exceeding approximately 12 weight %. 13. The article of claim 12, wherein the first layer comprises stabilizers in a quantity not exceeding approximately 12 weight %. 14. The article of claim 13, wherein the second layer comprises at least 76 weight % of one refractory metal oxide. 15. The article of claim 14, wherein the second layer comprises active ingredients other than stabilizers in a quantity not exceeding approximately 12 weight %. 16. The article of claim 15, wherein the second layer comprises stabilizers in a quantity not exceeding approximately 12 weight %. 17. The article of claim 1, further comprising a vehicle on board diagnostic (OBD) system in communication with the upstream EGO sensor and downstream EGO sensor, the OBD system configured to detect deterioration of the performance of the oxygen storage capacity of the oxygen storage component and the deterioration of the catalyst's ability to reduce hydrocarbons, carbon monoxides or nitrogen oxides in the exhaust gas and to provide a signal to an operator of the vehicle indicating a need for exhaust system maintenance. 18. The article of claim 1, wherein, the oxygen storage component is present in the second layer in an amount of about 0.05 to about 2.5 g/in3 of the finished second layer.
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이 특허에 인용된 특허 (12)
Shelef Mordecai (Bloomfield Village MI) Usmen Rengin K. (Troy MI) Graham George W. (Ann Arbor MI) Watkins William L. H. (Toledo OH) McCabe Robert W. (Lathrup Village MI), Automotive catalysts with improved oxygen storage and metal dispersion.
Morikawa, Akira; Hatanaka, Miho; Imagawa, Haruo; Suda, Akihiko; Takahashi, Naoki, Composite oxide, process for producing the same, catalyst for purifying exhaust gas, and process for producing the same.
Dieter Lindner DE; Renee Van Yperen DE; Lothar Mussmann DE; Egbert Lox DE; Thomas Kreuzer DE, Exhaust gas treatment catalyst for internal combustion engines with two catalytically active layers on a carrier structure.
Muhammed,Mamoun; Adamopoulos,Othan; Bog,Tassilo; Mussmann,Lothar; Lindner,Dieter; Votsmeier,Martin; Feger,Matthias; Lox,Egbert; Kreuzer,Thomas, Oxygen storage material, process for its preparation and its application in a catalyst.
Nunan, John G.; Klingmann, Raoul; Andersen, Ryan J.; Clark, Davion Onuga; Moser, David Henry, Three-way catalyst having an upstream single-layer catalyst.
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