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Kafe 바로가기국가/구분 | United States(US) Patent 등록 |
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국제특허분류(IPC7판) |
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출원번호 | US-0521334 (2014-10-22) |
등록번호 | US-9517448 (2016-12-13) |
발명자 / 주소 |
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출원인 / 주소 |
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대리인 / 주소 |
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인용정보 | 피인용 횟수 : 8 인용 특허 : 362 |
The present disclosure relates to a substrate comprising nanoparticle catalysts and NOx storage materials for treatment of gases, and washcoats for use in preparing such a substrate. Also provided are methods of preparation of the nanoparticle catalysts and NOx storage materials, as well as methods
The present disclosure relates to a substrate comprising nanoparticle catalysts and NOx storage materials for treatment of gases, and washcoats for use in preparing such a substrate. Also provided are methods of preparation of the nanoparticle catalysts and NOx storage materials, as well as methods of preparation of the substrate comprising the nanoparticle catalysts and NOx storage materials. More specifically, the present disclosure relates to a coated substrate comprising nanoparticle catalysts and NOx storage materials for lean NOx trap (LNT) systems, useful in the treatment of exhaust gases.
1. A coated substrate comprising: a substrate;a washcoat layer comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles bonded to a first micron-sized carrier particle, the oxidative composite nanopar
1. A coated substrate comprising: a substrate;a washcoat layer comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles bonded to a first micron-sized carrier particle, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle;a washcoat layer comprising reductive catalytically active micron-particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles bonded to a second micron-sized carrier particle, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle; anda washcoat layer comprising NOx trapping particles, the NOx trapping particles comprising a micron-sized cerium oxide-containing material. 2. The coated substrate of claim 1, wherein the micron-sized cerium oxide-containing material comprises cerium oxide, cerium-zirconium oxide, cerium-lanthanum oxide, cerium-yttrium oxide, cerium-zirconium-lanthanum oxide, cerium-zirconium-yttrium oxide, cerium-lanthanum-yttrium oxide, or cerium-zirconium-lanthanum-yttrium oxide. 3. The coated substrate of claim 2, wherein the micron-sized cerium oxide-containing material comprises cerium-zirconium-lanthanum oxide or cerium-zirconium-lanthanum-yttrium oxide. 4. The coated substrate of claim 1, wherein the washcoat layer comprising reductive catalytically active micron-particles is located closer to the substrate than the washcoat layer comprising oxidative catalytically active micron-particles. 5. The coated substrate of claim 4, wherein the washcoat layer comprising oxidative catalytically active micron-particles is located closer to the substrate than the washcoat layer comprising NOx trapping particles. 6. The coated substrate of claim 1, wherein the NOx trapping particles further comprise barium oxide impregnated in the micron-sized cerium oxide-containing material. 7. The coated substrate of claim 6, wherein the barium oxide is impregnated in the micron-sized cerium oxide or the micron-sized cerium oxide-containing material by wet chemistry. 8. The coated substrate of claim 1, wherein the NOx trapping particles further comprise platinum or palladium impregnated in the micron-sized cerium oxide-containing material. 9. The coated substrate of claim 8, wherein the platinum or palladium is plasma-generated. 10. The coated substrate of claim 8, wherein the platinum or palladium is impregnated in the micron-sized cerium oxide-containing material by wet chemistry. 11. The coated substrate of claim 1, wherein the NOx trapping particles further comprise the perovskite FeBaO3 impregnated in the micron-sized cerium oxide-containing material. 12. The coated substrate of claim 1, wherein the NOx trapping particles further comprise metal oxides selected from the group consisting of samarium, zinc, copper, iron, and silver oxides impregnated in the micron-sized cerium oxide-containing material. 13. The coated substrate of claim 1, wherein the washcoat layer comprising NOx trapping particles further comprises micron-sized aluminum oxide particles. 14. The coated substrate claim 1, wherein the oxidative catalytically active micron-particles comprise a material selected from the group comprising platinum, palladium, or a platinum-palladium alloy. 15. The coated substrate of claim 1, wherein the NOx trapping particles further comprise zirconium oxide. 16. The coated substrate of claim 1, wherein the first micron-sized carrier particle, first micron-sized porous carrier, or first support particle comprises aluminum oxide. 17. The coated substrate of claim 1, wherein the second micron-sized carrier particle, second micron-sized porous carrier, or second support particle comprises cerium oxide. 18. The coated substrate of claim 1, wherein the washcoat layer comprising oxidative catalytically active micron-particles or the washcoat layer comprising reductive catalytically active micron-particles further comprises filler particles or boehmite particles; wherein the filler particles are metal oxide particles. 19. The coated substrate according to claim 1, wherein the micron-sized cerium oxide-containing material comprises cerium oxide. 20. A catalytic converter comprising a coated substrate of claim 1. 21. An exhaust treatment system comprising a conduit for exhaust gas and a catalytic converter according to claim 20. 22. A vehicle comprising an exhaust treatment system according to claim 21. 23. A vehicle comprising a catalytic converter according to claim 20. 24. A method of treating an exhaust gas, comprising contacting the coated substrate of claim 1 with the exhaust gas. 25. A method of treating an exhaust gas, comprising contacting the coated substrate of claim 1 with the exhaust gas, wherein the substrate is housed within a catalytic converter configured to receive the exhaust gas. 26. A coated substrate comprising: a substrate;a washcoat layer comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles embedded in a first micron-sized porous carrier, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle;a washcoat layer comprising reductive catalytically active micron-particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles embedded in a second micron-sized porous carrier, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle; anda washcoat layer comprising NOx trapping particles, and the NOx trapping particles comprising a micron-sized cerium oxide-containing material. 27. The coated substrate of claim 26, wherein the micron-sized cerium oxide-containing material comprises cerium oxide, cerium-zirconium oxide, cerium-lanthanum oxide, cerium-yttrium oxide, cerium-zirconium-lanthanum oxide, cerium-zirconium-yttrium oxide, cerium-lanthanum-yttrium oxide, or cerium-zirconium-lanthanum-yttrium oxide. 28. The coated substrate of claim 27, wherein the micron-sized cerium oxide-containing material comprises cerium-zirconium-lanthanum oxide or cerium-zirconium-lanthanum-yttrium oxide. 29. The coated substrate of claim 26, wherein the washcoat layer comprising reductive catalytically active micron-particles is located closer to the substrate than the washcoat layer comprising oxidative catalytically active micron-particles. 30. The coated substrate of claim 29, wherein the washcoat layer comprising oxidative catalytically active micron-particles is located closer to the substrate than the washcoat layer comprising NOx trapping particles. 31. The coated substrate of claim 26, wherein the NOx trapping particles further comprise barium oxide impregnated in the micron-sized cerium oxide-containing material. 32. The coated substrate of claim 31, wherein the barium oxide is impregnated in the micron-sized cerium oxide or the micron-sized cerium oxide-containing material by wet chemistry. 33. The coated substrate of claim 26, wherein the NOx trapping particles further comprise platinum or palladium impregnated in the micron-sized cerium oxide-containing material. 34. The coated substrate of claim 33, wherein the platinum or palladium is plasma-generated. 35. The coated substrate of claim 33, wherein the platinum or palladium is impregnated in the micron-sized cerium oxide-containing material by wet chemistry. 36. The coated substrate of claim 26, wherein the NOx trapping particles further comprise the perovskite FeBaO3 impregnated in the micron-sized cerium oxide-containing material. 37. The coated substrate of claim 26, wherein the NOx trapping particles further comprise metal oxides selected from the group consisting of samarium, zinc, copper, iron, and silver oxides impregnated in the micron-sized cerium oxide-containing material. 38. The coated substrate of claim 26, wherein the washcoat layer comprising NOx trapping particles further comprises micron-sized aluminum oxide particles. 39. The coated substrate claim 26, wherein the oxidative catalytically active micron-particles comprise a material selected from the group comprising platinum, palladium, or a platinum-palladium alloy. 40. The coated substrate of claim 26, wherein the NOx trapping particles further comprise zirconium oxide. 41. The coated substrate of claim 26, wherein the first micron-sized carrier particle, first micron-sized porous carrier, or first support particle comprises aluminum oxide. 42. The coated substrate of claim 26, wherein the second micron-sized carrier particle, second micron-sized porous carrier, or second support particle comprises cerium oxide. 43. The coated substrate of claim 26, wherein the washcoat layer comprising oxidative catalytically active micron-particles or the washcoat layer comprising reductive catalytically active micron- particles further comprises filler particles or boehmite particles; wherein the filler particles are metal oxide particles. 44. The coated substrate according to claim 26, wherein the micron-sized cerium oxide-containing material comprises cerium oxide. 45. A catalytic converter comprising a coated substrate of claim 26. 46. An exhaust treatment system comprising a conduit for exhaust gas and a catalytic converter according to claim 45. 47. A vehicle comprising a catalytic converter according to claim 46. 48. A vehicle comprising an exhaust treatment system according to claim 47. 49. A method of treating an exhaust gas, comprising contacting the coated substrate of claim 26 with the exhaust gas. 50. A method of treating an exhaust gas, comprising contacting the coated substrate of claim 26 with the exhaust gas, wherein the substrate is housed within a catalytic converter configured to receive the exhaust gas. 51. A coated substrate comprising: a substrate;a washcoat layer comprising oxidative catalytically active composite nanoparticles attached to a first micron-sized support particle, the oxidative catalytically active composite nanoparticles being plasma-generated and comprising a first support nanoparticle and an oxidative catalytic nanoparticle;a washcoat layer comprising reductive catalytically active composite nanoparticles attached to a second micron-sized support particle, the reductive catalytically active composite nanoparticles being plasma-generated and comprising a second support nanoparticle and a reductive catalytic nanoparticle; anda washcoat layer comprising NOx trapping particles, and the NOx trapping particles comprising a micron-sized cerium oxide-containing material. 52. The coated substrate according to claim 51, wherein the micron-sized cerium oxide-containing material comprises cerium oxide. 53. A method of forming a coated substrate, the method comprising: a) coating a substrate with a washcoat composition comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising composite oxidative nanoparticles bonded to a first micron-sized carrier particle, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle;b) coating the substrate with a washcoat composition comprising reductive catalytically active micron-particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles bonded to a second micron-sized carrier particle, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle; andc) coating the substrate with a washcoat composition comprising NOx trapping particles, the NOx trapping particles comprising a micron-sized cerium oxide-containing material. 54. A method of forming a coated substrate, the method comprising: a) coating a substrate with a washcoat composition comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles embedded in a first micron-sized porous carrier, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle;b) coating the substrate with a washcoat composition comprising reductive catalytically active micron-particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles embedded in a second micron-sized porous carrier, the reductive composite nanoparticles comprising a second support nanoparticle and reductive catalytic nanoparticle; andc) coating the substrate with a washcoat composition comprising NOx trapping particles, the NOx trapping particles comprising a micron-sized cerium oxide-containing material. 55. A method of forming a coated substrate, the method comprising: a) coating a substrate with a washcoat composition comprising oxidative catalytically active composite nanoparticles attached to a first micron-sized support particle, the oxidative catalytically active composite nanoparticles being plasma-generated and comprising a first support nanoparticle and an oxidative catalytic nanoparticle;b) coating the substrate with a washcoat composition comprising reductive catalytically active composite nanoparticles attached to a second micron-sized support particle, the reductive catalytically active composite nanoparticles being plasma-generated and comprising a second support nanoparticle and a reductive catalytic nanoparticle; andc) coating the substrate with a washcoat composition comprising NOx trapping particles, the NOx trapping particles comprising a micron-sized cerium oxide-containing material. 56. A coated substrate comprising: a substrate;a first washcoat layer comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles bonded to a first micron-sized carrier particle, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle; anda second washcoat layer comprising reductive catalytically active micron-particles and NOx trapping particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles bonded to a second micron-sized carrier particle, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NOx trapping particles comprising a micron-sized cerium oxide-containing material. 57. A coated substrate comprising: a substrate;a washcoat layer comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles embedded in a first micron-sized porous carrier, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle; anda washcoat layer comprising reductive catalytically active micron- particles and NOx trapping particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles embedded in a second micron-sized porous carrier, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NOx trapping particles comprising a micron-sized cerium oxide-containing material. 58. A coated substrate comprising: a substrate;a washcoat layer comprising oxidative catalytically active composite nanoparticles attached to a first micron-sized support particle, the oxidative catalytically active composite nanoparticles being plasma-generated and comprising a first support nanoparticle and an oxidative catalytic nanoparticle;and a washcoat layer comprising NOx trapping particles and reductive catalytically active composite nanoparticles attached to a second micron-sized support particle, the reductive catalytically active composite nanoparticles being plasma-generated and comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NOx trapping particles comprising a micron-sized cerium oxide-containing material. 59. A method of forming a coated substrate, the method comprising: a) coating a substrate with a washcoat composition comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles bonded to a first micron-sized carrier particle, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle; andb) coating the substrate with a washcoat composition comprising reductive catalytically active micron-particles and NOx trapping particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles bonded to second micron-sized carrier particle, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NOx trapping particles comprising a micron-sized cerium oxide-containing material. 60. A method of forming a coated substrate, the method comprising: a) coating a substrate with a washcoat composition comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles embedded in a first micron-sized porous carrier, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle; andb) coating the substrate with a washcoat composition comprising reductive catalytically active micron-particles and NOx trapping particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles embedded in a second micron-sized porous carrier, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NOx trapping particles comprising a micron-sized cerium oxide-containing material. 61. A method of forming a coated substrate, the method comprising: a) coating a substrate with a washcoat composition comprising oxidative catalytically active composite nanoparticles attached to a first micron-sized support particle, the oxidative catalytically active composite nanoparticles being plasma-generated and comprising a first support nanoparticle and an oxidative catalytic nanoparticle; andb) coating the substrate with a washcoat composition comprising NOx trapping particles and reductive catalytically active composite nanoparticles attached to a second micron-sized support particle, the reductive catalytically active composite nanoparticles being plasma-generated and comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NOx trapping particles comprising a micron-sized cerium oxide-containing material.
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