EP3946692A1

EP3946692A1 - Catalytically active particulate filter

Info

Publication number: EP3946692A1
Application number: EP19716102.9A
Authority: EP
Inventors: Jan Schoenhaber; Naina DEIBEL; Martin Roesch; Joerg-Michael Richter
Original assignee: Umicore AG and Co KG
Current assignee: Umicore AG and Co KG
Priority date: 2019-03-29
Filing date: 2019-03-29
Publication date: 2022-02-09
Also published as: CN113412145A; WO2020200394A1; US20220176364A1

Abstract

The invention relates to a particulate filter which comprises a wall flow filter of length L and two catalytically active coatings Y and Z, wherein the wall flow filter comprises channels E and A that extend in parallel between a first and a second end of the wall flow filter and are separated by porous walls which form surfaces O_E and O_A, respectively, and wherein the channels E are closed at the second end and the channels A are closed at the first end, and the coatings Y and Z have the same oxygen storage components and the same carrier materials for noble metals. The invention is characterised in that the coating Y is located in the channels E on the surfaces O_E and the coating Z is located in the channels A on the surfaces O_A.

Description

Catalytically active particle filter

The present invention relates to a catalytically active particle filter which is particularly suitable for the removal of particles, carbon monoxide, hydrocarbons and nitrogen oxides from the exhaust gas of internal combustion engines operated with a stoichiometric air / fuel mixture.

Exhaust gases from internal combustion engines operated with a stoichiometric air / fuel mixture, ie gasoline engines, are cleaned in conventional processes with the aid of three-way catalytic converters. These are able to convert the three essential gaseous pollutants of the engine, namely hydrocarbons, carbon monoxide and nitrogen oxides, into harmless components at the same time.

In addition to these gaseous pollutants, the exhaust gas from gasoline engines also contains extremely fine particles (PM), which result from the incomplete combustion of the fuel and which essentially consist of soot. In contrast to the particle emissions from diesel engines, the particles in the exhaust gas of stoichiometrically operated internal combustion engines are very small and have an average particle size of less than 1 μm. Typical particle sizes are in the range from 10 to 200 nm. In addition, the amount of particles emitted is very small and ranges from 2 to 4 mg / km.

The European emissions standard EU-6c is linked to a change in the limit value for such particles from the particulate mass limit value to a more critical particle number limit value of 6 x 10 ¹¹ / km (in the Worldwide Harmonized Light Vehicles Test Cycle - WLTP). This creates a need for exhaust gas cleaning concepts for stoichiometrically operated internal combustion engines that include effectively working devices for removing particles.

Wall-flow filters made of ceramic materials such as silicon carbide, aluminum titanate and cordierite have proven themselves in the area of cleaning exhaust gas from lean-burn engines, in particular diesel engines. These are made up of a large number of parallel channels that are formed by porous walls. The channels are mutually closed at one of the two ends of the filter, so that channels A are formed which are open on the first side of the filter and closed on the second side of the filter, and channels B which are closed on the first side of the filter and are open on the second side of the filter. The example Exhaust gas flowing into channels A can only leave the filter via channels B, and for this purpose must flow through the porous walls between channels A and B. When the exhaust gas passes through the wall, the particles are retained and the exhaust gas is cleaned.

The particles retained in this way must then be burned off or oxidized in order to prevent the filter from clogging or an unacceptable increase in the back pressure of the exhaust system. For this purpose, for example, the wall flow filter is provided with catalytically active coatings that lower the ignition temperature of soot.

It is already known to apply such coatings to the porous walls between the channels (so-called on-wall coating) or to introduce them into the porous walls (so-called in-wall coating). EP 1 657 410 A2 also already describes a combination of both types of coating, i.e. part of the catalytically active material is present in the porous walls and another part on the porous walls.

The concept of removing particles from the exhaust gas by means of wall flow filters has already been transferred to the cleaning of exhaust gas from internal combustion engines operated with a stoichiometric air / fuel mixture, see for example EP 2042226 A2. According to their teaching, a wall flow filter carries two layers arranged one above the other, one in the porous wall and the other on the porous wall can be arranged.

DE 10201 1050788 A1 follows a similar concept. There the porous filter walls contain a catalyst material of a three-way catalyst, while a catalyst material of a three-way catalyst is additionally applied to partial areas of the filter walls.

Further documents which describe filter substrates provided with catalytically active coatings are EP 3205388 A1, EP 3207977 A1, EP 3207978 A1, EP 3207987 A1, EP 3207989 A1, EP 3207990 A1 and EP 3162428 A1.

There is still a need for catalytically active particulate filters that combine the functionalities of a particulate filter and a three-way catalytic converter and allow future limit values to be adhered to. The present invention relates to a particle filter which comprises a wall flow filter of length L and two coatings Y and Z, which can preferably be completely identical, wherein the wall flow filter comprises channels E and A, which extend parallel between a first and a second end of the wall flow filter extend and which are separated by porous walls, the surfaces OE and OA form and wherein the channels E are closed at the second end and the channels A at the first end, and wherein the coatings Y and Z include the same oxygen storage components and the same carrier materials for precious metals , and the coating Y is located in the channels E on the surfaces OE and extends from the first end of the wall flow filter over 55 to 90% of the length L, and the coating Z is and is in the channels A on the surfaces OA extending from the second end of the wall flow filter over 55 to 90% of the length L, and wherein the coating gene Y and Z aluminum oxide in an amount of 20 to 70 wt .-%, based on the total weight of the coating Y or Z, rhodium, palladium or palladium and rhodium and one or more oxygen storage components in an amount of 30 to 80 wt. -%, based on the total weight of the coating Y or Z contains ..

The coatings Y and Z are three-way catalytically active, especially at operating temperatures of 250 to 1,100 ° C. They usually contain one or more precious metals that are fixed on one or more carrier materials, as well as one or more oxygen storage components. The coatings Y and Z comprise the same oxygen storage components and the same carrier materials for noble metals in different, but preferably in the same, amounts. The coatings Y and Z also contain the same or different precious metals in the same or different amounts. Coatings Y and Z are particularly preferably completely identical.

Particularly suitable noble metals are platinum, palladium and rhodium, palladium, rhodium or palladium and rhodium being preferred and palladium and rhodium being particularly preferred. In relation to the particle filter according to the invention, the proportion of rhodium in the total precious metal content is in particular greater than or equal to 10% by weight. The porous walls of the particle filter according to the invention are preferably free of noble metals. The noble metals are usually used in amounts of 0.15 to 5 g / l, based on the volume of the wall flow filter. Suitable carrier materials for the noble metals are all materials familiar to the person skilled in the art for this purpose. Such materials are in particular metal oxides with a BET surface area of 30 to 250 m ² / g, preferably 100 to 200 m ² / g (determined according to DIN 66132).

Particularly suitable support materials for the noble metals are selected from the series consisting of aluminum oxide, doped aluminum oxide, silicon oxide, titanium dioxide and mixed oxides of one or more thereof.

Doped aluminum oxides are, for example, lanthanum oxide, zirconium oxide and / or titanium oxide-doped aluminum oxides. Lanthanum-stabilized aluminum oxide is advantageously used, lanthanum being advantageously used in amounts of 1 to 10% by weight, preferably 3 to 6% by weight, calculated in each case as La ₂ O ₃ and based on the weight of the stabilized aluminum oxide . Another suitable carrier material is lanthanum-stabilized aluminum oxide, the surface of which is coated with lanthanum oxide, barium oxide or strontium oxide.

Cerium / zirconium / rare earth metal mixed oxides are particularly suitable as oxygen storage components. The term “cerium / zirconium / rare earth metal mixed oxide” in the context of the present invention excludes physical mixtures of cerium oxide, zirconium oxide and rare earth oxide. Rather, “cerium / zirconium / rare earth metal mixed oxides” are characterized by a largely homogeneous, three-dimensional crystal structure that is ideally free of phases of pure cerium oxide, zirconium oxide or rare earth oxide. Depending on the manufacturing process, however, products that are not completely homogeneous can also arise, which can usually be used without any disadvantage. Furthermore, the term rare earth metal or rare earth metal oxide in the context of the present invention does not include cerium or cerium oxide.

As rare earth metal oxides in the cerium / zirconium / rare earth metal mixed oxides, for example, lanthanum oxide, yttrium oxide, praseodymium oxide, neodymium oxide and / or Sa marium oxide come into consideration. Lanthanum oxide, yttrium oxide and / or praseody oxide are preferred. Lanthanum oxide and / or yttrium oxide are particularly preferred and lanthanum oxide and yttrium oxide, yttrium oxide and praseodymium oxide, such as lanthanum oxide and praseodymium oxide, are very particularly preferred. In embodiments of the present invention, the oxygen storage components are particularly preferably free from neodymium oxide. According to the invention, the mass ratio of cerium oxide to zirconium oxide in the cerium / zirconium / rare earth metal mixed oxides can vary within wide limits. It is, for example, 0.1 to 1.5, preferably 0.2 to 1 or 0.3 to 0.5.

If the cerium / zirconium / rare earth metal mixed oxides contain yttrium oxide as the rare earth metal, its proportion in the mixed oxide is in particular 2 to 15% by weight, preferably 3 to 10% by weight.

If the cerium / zirconium / rare earth metal mixed oxides contain praseodic oxide as rare earth metal, its proportion is in particular 2 to 15% by weight, preferably 3 to 10% by weight.

If the cerium / zirconium / rare earth metal mixed oxides contain lanthanum oxide and yttrium oxide as rare earth metal, its mass ratio is in particular between 0.1 and 1, preferably 0.3 to 1.

If the cerium / zirconium / rare earth metal mixed oxides contain lanthanum oxide and praseodymium oxide as rare earth metal, its mass ratio is in particular 0.1 to 1, preferably 0.3 to 1.

The coatings Y and Z usually contain oxygen storage components in amounts of 15 to 120 g / l, based on the volume of the wall-flow filter.

The mass ratio of carrier materials and oxygen storage components in coatings Y and Z is usually 0.3 to 1.5, for example 0.4 to 1.3.

In embodiments of the present invention, one or both of coatings Y and Z contain an alkaline earth compound such as e.g. Strontium oxide, barium oxide or barium sulfate. The amount of barium sulfate per coating is in particular 2 to 20 g / l volume of the wall-flow filter.

In further embodiments of the present invention, one or both of the coatings Y and Z contain additives such as rare earth compounds such as lanthanum oxide and / or binders such as aluminum compounds. These additives are used in amounts which can vary within wide limits and which the person skilled in the art can determine with simple means in the specific case. These may help to improve the rheology of the coating. In embodiments of the present invention, coatings Y and Z comprise lanthanum-stabilized aluminum oxide, rhodium, palladium or palladium and rhodium and an oxygen storage component comprising zirconium oxide, cerium oxide, yttrium oxide and lanthanum oxide.

In other embodiments of the present invention, the coatings Y and Z comprise lanthanum-stabilized aluminum oxide, rhodium, palladium or palladium and rhodium and an oxygen storage component comprising zirconium oxide, cerium oxide, praseodymium oxide and lanthanum oxide.

In other embodiments of the present invention, the coatings Y and Z comprise lanthanum-stabilized aluminum oxide, rhodium, palladium or palladium and rhodium, a first oxygen storage component comprising zirconium oxide, ceria, yttrium oxide and lanthanum oxide, and a second zirconium oxide, cerium oxide, yttrium oxide and praseodymium oxide comprehensive oxygen storage component.

In embodiments, the coatings Y and Z each comprise lanthanum-stabilized aluminum oxide in amounts of 20 to 70% by weight, particularly preferably 30 to 60% by weight, and the oxygen storage component in amounts of 30 to 80% by weight , particularly preferably 40 to 70% by weight, based in each case on the total weight of the coating Y or Z.

In embodiments of the present invention, the coating Y preferably extends from the first end of the wall flow filter over 55 to 90%, particularly preferably over 57 to 80%, but very particularly preferably over 57 to 65% of the length L of the wall flow filter. The loading of the wall-flow filter with coating Y is preferably 33 to 125 g / l, based on the volume of the wall-flow filter.

In embodiments of the present invention, the coating Z preferably extends from the second end of the wall flow filter over 55 to 90%, in particular over 57 to 80%, but very particularly preferably over 67 to 65% of the length L of the wall flow filter. The loading of the wall flow filter with coating Z is preferably 33 to 125 g / l, based on the volume of the wall flow filter.

A preferred embodiment relates to a wall flow filter with a coating Y with a length L of 57 to 80% starting from the first end of the wall flow filter and a coating Z with a length L of 57 to 80% starting from the second end of the wall flow filter.

In embodiments of the present invention, the sum of the lengths of coating Y and coating Z is 1 10 to 160% of the length L, preferably 1 15 to 140% of the length L.

In embodiments of the present invention, coatings Y and Z contain no zeolite and no molecular sieve.

The total loading of the particle filter according to the invention with the coatings Y and Z is in particular 40 to 150 g / l, based on the volume of the wall flow filter.

In a more preferred embodiment of the present invention, this relates to a particle filter comprising a wall flow filter of length L and two coatings Y and Z, the wall flow filter comprising channels E and A which extend in parallel between a first and a second end of the wall flow filter and which are separated by porous walls, which form the surfaces O _E and OA, respectively, and wherein the channels E are closed at the second end and the channels A at the first end, and the coatings Y and Z include identical oxygen storage components and identical carrier materials for precious metals, characterized in that

Coating Y is located in the channels E on the surfaces O _E and extends from the first end of the wall flow filter over 57 to 80% of the length L, coating Z is located in the channels A on the surfaces OA and starts from the second End of the wall flow filter over 57 to 80% of the length L it stretches, and the coatings Y and Z aluminum oxide in an amount of 20 to 70 wt .-%, based on the total weight of the coating Y or Z, rhodium, palladium or palladium and rhodium and an oxygen storage component in an amount of 30 to 80 wt .-%, based on the total weight of the coating Y or Z, the oxygen storage component zirconium oxide, cerium oxide, lanthanum oxide and yttrium oxide or zirconium oxide, cerium oxide, lanthanum oxide and Praseody oxide or comprises a mixture of two oxygen storage components, one oxygen storage component being zirconium oxide, cerium oxide, lanthanum oxide and yttri umoxide and the other contains zirconia, cerium oxide, lanthanum oxide and praseodymium oxide. Very preferably, both coatings Y and Z are completely the same. The embodiments explained above also apply in relation to those mentioned here.

Wall flow filters that can be used in accordance with the present invention are known and are available on the market. They consist, for example, of silicon carbide, aluminum titanate or cordierite, have a cellularity of 200 to 400 cells per inch and usually a wall thickness between 6 and 12 mils, or 0.1524 and 0.305 millimeters. In the uncoated state, for example, they have porosities of 50 to 80, in particular 55 to 75%. Their average pore size in the uncoated state be, for example, 10 to 25 micrometers. As a rule, the pores of the wall flow filter are so-called open pores, i.e. they are connected to the channels. Furthermore, the pores are usually connected to one another. This enables on the one hand the light coating of the inner pore surfaces and on the other hand an easy passage of the exhaust gas through the porous walls of the wall flow filter.

The particle filter according to the invention can be produced by methods familiar to those skilled in the art, for example by applying a coating suspension, usually called a washcoat, to the wall-flow filter using one of the usual dip-coating processes or pump and suction coating processes. Thermal aftertreatment or calcination usually follow. Coatings Y and Z are obtained in separate and consecutive coating steps.

The person skilled in the art knows that the average pore size of the wall flow filter and the average particle size of the catalytically active materials must be coordinated with one another in order to achieve an on-wall coating or an in-wall coating. In the case of in-wall coating, the mean particle size of the catalytically active materials must be small enough to penetrate into the pores of the wall flow filter. In contrast, in the case of the on-wall coating, the mean particle size of the catalytically active materials must be large enough not to penetrate into the pores of the wall flow filter. In embodiments of the present invention, the coating suspensions for producing the coatings Y and Z are ground up to a particle size distribution of d _ö o = 4 to 8 μm and dg9 = 22 to 16 μm.

The particle filter according to the invention is ideal for removing particles, carbon monoxide, hydrocarbons and nitrogen oxides from the exhaust gas of internal combustion engines operated with a stoichiometric air / fuel mixture.

The present invention thus also relates to a method for removing particles, carbon monoxide, hydrocarbons and nitrogen oxides from the exhaust gas of internal combustion engines operated with a stoichiometric air / fuel mixture, which is characterized in that the exhaust gas is passed through a particle filter according to the invention.

The exhaust gas can be passed through a particle filter according to the invention in such a way that it enters the particle filter through channels E and leaves it again through channels A. But it is also possible that the exhaust gas enters the particulate filter through channels A and leaves it again through channels E.

Surprisingly, it has been shown that it is advantageous to distribute the catalytic coating over the largest possible surface of the porous filter wall.

According to the experiments, the decisive factor for a low exhaust back pressure is not the degree of coverage of the filter walls, as originally assumed, but rather the layer thickness of the catalytic coating applied. By distributing the coating over a large area over at least 55% of the filter length per zone, the exhaust gas back pressure can be reduced and at the same time a high catalytic activity can be achieved. This was not to be expected based on the known state of the art.

Figure 1 shows a particle filter according to the invention, which comprises a wall flow filter of length L (1) with channels E (2) and channels A (3), which run parallel between a first end (4) and a second end (5) of the wall flow filter extend and which are separated by porous walls (6), the surfaces OE (7) and OA (8) and where the channels E (2) at the second end (5) and the channels A (3) at the first end ( 4) are closed. Coating Y (9) is located in channels E (2) on the Surfaces O _E (7) and coating Z (10) in channels A (3) on the surfaces

O _A (8). The invention is illustrated in more detail in the examples below.

Comparative example 1

Aluminum oxide stabilized with lanthanum oxide was used together with a first oxygen storage component, which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide, in Suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly for coating a commercially available wall-flow filter substrate, the coating being introduced into the porous filter wall over 100% of the substrate length. The total loading of this filter was 75 g / l, the total noble metal loading was 1.27 g / l with a ratio of palladium to rhodium of 5: 1. The coated filter thus obtained was dried and then calcined. It is hereinafter referred to as VGPF1.

example 1

Coating of the input and output channels:

Aluminum oxide stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide. The weight ratio of the alumina and the oxygen storage component was 56:44. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension thus obtained, with constant stirring. The resulting coating suspension was used directly for coating a commercially available wall-flow filter substrate. The coating suspension was coated onto the filter walls of the substrate, first in the inlet channels over a length of 60% of the filter length. The loading of the inlet channel was 62.5 g / l, the noble metal loading 1.06 g / l with a ratio of palladium to rhodium of 5: 1. The coated filter obtained in this way was dried and then calcined. The outlet channels of the filter were then coated with the same coating suspension over a length of 60% of the filter length. The coated filter thus obtained was dried again and then calcined. The total loading of this filter was thus 75 g / l, the total precious metal loading 1.27 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as GPF1.

Example 2

Aluminum oxide stabilized with lanthanum oxide was used together with a first oxygen storage component, which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide, suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate. The coating suspension was coated onto the filter walls of the substrate, initially in the inlet channels over a length of 60% of the filter length. The loading of the inlet channel was 62.5 g / l, the noble metal loading 1.06 g / l with a ratio of palladium to rhodium of 5: 1. The coated filter thus obtained was dried and then calcined. The outlet channels of the filter were then coated with the same coating suspension over a length of 60% of the filter length. The coated filter thus obtained was dried again and then calcined. The total loading of this filter was thus 75 g / l, the total precious metal loading was 1.27 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as GPF2.

Catalytic characterization

The particle filters VGPF1, GPF1 and GPF2 were aged together in an engine test bench aging process. This consists of an overrun fuel cut-off with an exhaust gas temperature of 950 ° C in front of the catalyst inlet (maximum bed temperature 1030 ° C). The aging time was 19 hours (see Motortechnische Zeitschrift, 1994, 55, 214-218). The aged catalytically active particulate filters were then tested on an engine test bench in the so-called “light-off test” and the “lambda sweep test”. In the light-off test, the light-off behavior is determined with a stoichiometric exhaust gas composition with a constant average air ratio l (l = 0.999 with ± 3.4% amplitude).

The following Table 1 shows the temperatures T o _5, in each of which 50% of the subject components are reacted.

Table 1

The dynamic turnover behavior of the particle filters in the lambda sweep test was determined in a range of l = 0.99 - 1.01 at a constant temperature of 510 ° C. The amplitude of l was ± 3.4%. Table 2 contains the conversion at the intersection of the CO and NOx conversion curves, as well as the associated HC conversion of the aged particle filters.

Table 2

The particle filters GPF1 and GPF2 according to the invention show, compared to VGPF1 in the aged state, a significant improvement in the light-off behavior and in the dynamic CO / NOx conversion. Comparative example 2:

a) Application of the inside wall coating:

Aluminum oxide stabilized with lanthanum oxide was used together with a first oxygen storage component, which comprised 40% by weight of ceria, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of ceria, zirconium oxide, lanthanum oxide and yttrium oxide , suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly for coating a commercially available wall-flow filter substrate, the coating being introduced into the porous filter wall over 100% of the substrate length. The total loading of this filter was 100 g / l, the noble metal loading 2.60 g / l with a ratio of palladium to rhodium of 60: 13.75. The coated filter thus obtained was dried and then calcined.

b) Coating of the input channels

Aluminum oxide stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praesodymium oxide. The weight ratio of aluminum oxide and oxygen storage component was 50:50. The suspension obtained in this way was then mixed with a palladium nitrate solution and a rhodium nitrate solution with constant stirring. The resulting coating suspension was used directly for coating the wall flow filter substrate obtained under a), the filter walls of the substrate being coated, specifically in the inlet channels over a length of 25% of the filter length. The loading of the inlet channel was 58 g / l, the noble metal loading 2.30 g / l with a ratio of palladium to rhodium of 10: 3. The coated filter thus obtained was dried and then calcined. c) Coating of the exit channels

Aluminum oxide stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide. The weight ratio of alumina and oxygen storage component was 56:44. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension thus obtained, with constant stirring. The resulting coating suspension was used directly for coating the wall flow filter substrate obtained under b), the filter walls of the substrate being coated over a length of 25% of the filter length in the outlet channels. The loading of the outlet channel was 59 g / l, the noble metal loading 1.06 g / l with a ratio of palladium to rhodium of 1: 2. The coated filter thus obtained was dried and then calcined. The total loading of this filter was thus 130 g / l, the total noble metal loading 3.44 g / l with a ratio of palladium to rhodium of 10: 3. It is referred to below as VGPF2.

Comparative example 3:

a) Application of the inside wall coating:

Aluminum oxide stabilized with lanthanum oxide was used together with a first oxygen storage component, which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide, suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate, the coating being introduced into the porous filter wall over 100% of the substrate length. The loading of this filter was 100 g / l, the noble metal loading 2.07 g / l with a ratio of palladium to rhodium of 45: 13.5. The coated filter obtained in this way was dried and then calcined. b) Coating of the input channels

Aluminum oxide stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praseous oxide. The weight ratio of aluminum oxide and oxygen storage component was 50:50. The suspension obtained in this way was then stirred with a palladium nitrate solution and a rhodium nitrate solution is added. The resulting coating suspension was used directly for coating the wall flow filter substrate obtained under a), the filter walls of the substrate being coated, specifically in the inlet channels over a length of 60% of the filter length. The loading of the inlet channel was 90 g / l, the noble metal loading 2.30 g / l with a ratio of palladium to rhodium of 10: 3. The coated filter thus obtained was dried and then calcined. The total loading of this filter was thus 154 g / l, the total noble metal loading 3.44 g / l with a ratio of palladium to rhodium of 10: 3. It is referred to below as VGPF3.

Example 3

Coating of the input channels

a) Aluminum oxide stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide. The weight ratio of the alumina and the oxygen storage component was 56:44. The suspension obtained in this way was then mixed with a palladium nitrate solution and a rhodium nitrate solution with constant stirring. The resulting coating suspension was used directly for coating a commercially available wall-flow filter substrate. The coating suspension was coated on the filter walls of the substrate in the inlet channels over a length of 60% of the filter length. The loading of the inlet channel was 83.33 g / l, the noble metal loading 2.87 g / l with a ratio of palladium to rhodium of 10: 3. The coated filter thus obtained was dried and then calcined. The outlet channels of the filter were then coated with the same coating suspension over a length of 60% of the filter length. The coated filter thus obtained was dried again and then calcined. The total loading of this filter was thus 100 g / l, the total precious metal loading 3.44 g / l with a ratio of palladium to rhodium of 10: 3. It is referred to below as GPF3.

Catalytic characterization

The particle filters VGPF2, VGF3 and GPF3 were aged together in an engine test bench aging process. This consists of an overrun fuel cut-off with an exhaust gas temperature of 950 ° C in front of the catalyst inlet (maximum bed temperature 1030 ° C). The aging time was 76 hours (see Motortechnische Zeitschrift, 1994, 55, 214-218). The aged catalytically active particulate filters were then tested on an engine test bench in the so-called “light-off test” and the “lambda sweep test”. In the light-off test, the light-off behavior is determined with a stoichiometric exhaust gas composition with a constant average air ratio l (l = 0.999 with ± 3.4% amplitude).

The following Table 3 contains the temperatures T o _5, in each of which 50% of the subject components are reacted.

Table 3

The dynamic turnover behavior of the particle filters in the lambda sweep test was determined in a range of l = 0.99 - 1.01 at a constant temperature of 510 ° C. The amplitude of l was ± 3.4%. Table 4 contains the conversion at the intersection of the CO and NOx conversion curves, as well as the associated HC conversion of the aged particle filters.

Table 4 The particle filter GPF3 according to the invention shows, compared to VGPF2 and VGPF3 in the aged state, a significant improvement in the light-off behavior and in the dynamic CO / NOx conversion. Comparative example 4:

Coating of the input channels

a) Alumina stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide. The weight ratio of alumina and oxygen storage component was 56/44. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate. Since the coating suspension was coated on the filter walls of the substrate in the inlet channels over a length of 50% of the filter length. The loading of the inlet channel was 100 g / l, the noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5:

1. The coated filter thus obtained was dried and then calcined. Coating of the exit channels

b) Aluminum oxide stabilized with lanthanum oxide, together with a first oxygen storage component, which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which contained 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and Comprised yttria suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly for coating the wall-flow filter substrate obtained under a), the filter walls of the substrate being coated over a length of 50% of the filter length in the outlet channels. The loading of the exhaust duct was 100 g / l, the noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5: 1. The coated filter thus obtained was dried and then calcined. The total loading of this filter was thus 100 g / l, the total noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as VGPF4.

Example 4

Coating of the input channels

a) Alumina stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide. The weight ratio of alumina and oxygen storage component was 56/44. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate. Since the coating suspension was coated on the filter walls of the substrate in the inlet channels over a length of 55% of the filter length. The loading of the inlet channel was 91 g / l, the noble metal loading 1.16 g / l with a ratio of palladium to rhodium of 5: 1. The coated filter thus obtained was dried and then calcined. Coating of the exit channels

b) Alumina stabilized with lanthanum oxide was combined with a first oxygen storage component, which comprised 40% by weight of ceria, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of ceria, zirconium oxide, lanthanum oxide and yttrium oxide, in Suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. The suspension obtained in this way was then with constant stirring a palladium nitrate solution and a rhodium nitrate solution are added. The resulting coating suspension was used directly for coating the wall-flow filter substrate obtained under a), the filter walls of the substrate being coated over a length of 55% of the filter length in the outlet channels. The loading of the outlet channel was 91 g / l, the noble metal loading 1.16 g / l with a ratio of palladium to rhodium of 5: 1. The coated filter thus obtained was dried and then calcined. The total loading of this filter was thus 100 g / l, the total noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as GPF3.

Example 5

Coating of the input channels

a) Alumina stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide. The weight ratio of alumina and oxygen storage component was 56/44. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate. Since the coating suspension was coated on the filter walls of the substrate, namely in the inlet channels over a length of 60% of the filter length. The loading of the inlet channel was 83.33 g / l, the noble metal loading 1.06 g / l with a ratio of palladium to rhodium of 5: 1. The coated filter obtained in this way was dried and then calcined. Coating of the exit channels

b) Aluminum oxide stabilized with lanthanum oxide was combined with a first oxygen storage component, which comprised 40% by weight of ceria, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of ceria, zirconium oxide, lanthanum oxide and yttrium oxide, suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly to coat the wall-flow filter substrate obtained under a), the filter walls of the substrate being coated on a length of 60% of the filter length in the outlet channels. The loading of the outlet channel was 83.33 g / l, the noble metal loading 1.06 g / l with a ratio of palladium to rhodium of 5: 1. The coated filter thus obtained was dried and then calcined. The total loading of this filter was thus 100 g / l, the total noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as GPF4.

Example 6

Coating of the input channels

a) Alumina stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide. The weight ratio of alumina and oxygen storage component was 56/44. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate. Since the coating suspension was coated on the filter walls of the substrate in the input channels over a length of 80% Filter length. The loading of the inlet channel was 62.5 g / l, the noble metal loading 0.79 g / l with a ratio of palladium to rhodium of 5:

1. The coated filter thus obtained was dried and then calcined.

Coating of the exit channels

b) Aluminum oxide stabilized with lanthanum oxide was combined with a first oxygen storage component, which comprised 40% by weight of ceria, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of ceria, zirconium oxide, lanthanum oxide and yttrium oxide, suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of aluminum oxide and oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly for coating the wall-flow filter substrate obtained under a), the filter walls of the substrate being coated over a length of 80% of the filter length in the outlet channels. The loading of the outlet channel was 62.5 g / l, the noble metal loading 0.79 g / l with a ratio of palladium to rhodium of 5: 1. The coated filter obtained in this way was dried and then calcined. The total loading of this filter was thus 100 g / l, the total noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as GPF5.

Catalytic characterization

The particulate filters VGPF4, GPF4, GPF5 and GPF6 were compared on a cold blow test bench with regard to the exhaust back pressure.

The following table 5 contains pressure loss data which were determined at an air temperature of 21 ° C and a volume flow of 600 m3 / h. The values have been standardized to VGPF4 for a better overview.

Table 5

The filters GPF4, GPF5 and GPF6 according to the invention all surprisingly have a lower pressure loss than the comparative example VGPF4, although they cover a larger surface area of the filter walls. This is quite surprising, since one could actually assume that longer coatings cause a higher exhaust gas back pressure, since here more exhaust gas has to flow through the catalytic coatings, since as a result less exhaust gas can flow through the uncoated filter wall.

Furthermore, it was systematically investigated what the main effects are that are responsible for the lowest possible exhaust back pressure. Various filters with different zone lengths (factor A) and washcoat layer thicknesses (factor B) were prepared and compared with one another. All filters had the same total washcoat loading and the same precious metal content.

Table 6 The statistical evaluation shows that it is particularly advantageous to distribute the washcoat over the largest possible surface on the filter walls with an associated low layer thickness, instead of only covering a small surface with a high layer thickness, since a high layer thickness is to be regarded as the main cause of high exhaust gas back pressure (Figure 2). In addition, the particulate filters were aged together in an engine test bench aging facility. This consists of one Overrun fuel cut-off with an exhaust gas temperature of 950 ° C in front of the catalyst inlet (maximum bed temperature 1030 ° C). The aging time was 19 hours (see Motortechni cal magazine, 1994, 55, 214-218).

The aged catalytically active particulate filters were then tested on an engine test bench in what is known as the “Lambda Sweeptest”. Surprisingly, the statistical evaluation of the test results also shows a significant advantage in the lambda sweep test when the catalytic coating is applied with a small layer thickness on the largest possible surface (FIG. 3). In addition, it was investigated to what extent an embodiment consisting of a short and a long zone differs from an embodiment consisting of two long zones. For this purpose, a filter according to the invention with zone lengths of 60% of the filter length was compared with a comparison filter with zone lengths of 90% in the inlet channel and 30% in the outlet channel. In the light-off test, in which the light-off behavior is determined with a stoichiometric exhaust gas composition with a constant mean air ratio l (l = 0.999 with ± 3.4% amplitude), it is shown that the filter according to the invention with zone lengths of 60% each can convert the corresponding exhaust gas components at lower temperatures than the filter not in accordance with the invention with zone lengths of 90% and 30%. The following table 7 contains the temperatures T o _5, in each of which 50% of the subject components are reacted.

Table 7

Claims

A particulate filter comprising a wall flow filter of length L and two coatings Y and Z, the wall flow filter comprising channels E and A which extend in parallel between first and second ends of the wall flow filter and which are separated by porous walls, the surfaces Form O _E or OA and wherein the channels E are closed at the second end and the channels A are closed at the first end, and the coatings Y and Z include the same oxygen storage components and the same carrier materials for precious metals,

characterized in that

Coating Y is located in the channels E on the surfaces O _E and extends over 55 to 90% of the length L starting from the first end of the wall flow filter, coating Z is located in the channels A on the surfaces OA and starting from the second The end of the wall flow filter extends over 55 to 90% of the length L,

and the coatings Y and Z aluminum oxide in an amount of 20 to 70 wt .-%, based on the total weight of the coating Y or Z, rhodium, palladium or palladium and rhodium and one or more oxygen storage components in an amount of 30 to 80 Wt .-%, based on the total weight of the coating Y or Z contains.

2. Particle filter according to claim 1, characterized in that the Beschich device Y extends from the first end of the wall flow filter to 57 to 80% of the length L of the wall flow filter.

3. Particle filter according to claim 1 and / or 2, characterized in that the coating Z extends from the second end of the wall flow filter to 57 to 80% of the length L of the wall flow filter.

4. Particle filter according to one or more of claims 1 to 3, characterized in that the coatings Y and Z each contain one or more precious metals which are fixed on one or more carrier materials, and one or more oxygen storage components.

5. Particle filter according to claim 4, characterized in that the carrier materials for the noble metals are selected from the series consisting of aluminum oxide, doped aluminum oxide, silicon oxide, titanium dioxide and mixed oxides of one or more thereof.

6. Particle filter according to claim 4 or 5, characterized in that the carrier materials for the noble metals are metal oxides with a BET surface area of 30 to 250 m ² / g (determined in accordance with DIN 66132).

7. Particle filter according to one or more of claims 4 to 6, characterized in that the coatings Y and Z contain a cerium / zirconium / rare earth metal mixed oxide as an oxygen storage component.

8. Particle filter according to claim 7, characterized in that the cerium / zirconium / rare earth metal mixed oxides as rare earth metal oxide lanthanum oxide, yttrium oxide,

Contain praseodymium oxide, neodymium oxide and / or samarium oxide

9. Particle filter according to claim 7 and / or 8, characterized in that the cerium / zirconium / rare earth metal mixed oxides contain lanthanum oxide and yttrium oxide, yttrium oxide and praseodymium oxide or lanthanum oxide and praseodymium oxide as the rare earth metal oxide.

10. Particle filter according to one or more of claims 1 to 9, characterized in that the coatings Y and Z both lanthanum-stabilized aluminum oxide, rhodium, palladium or palladium and rhodium and a zirconium oxide,

Oxygen storage component comprising cerium oxide, yttrium oxide and lanthanum oxide.

11 particle filter according to one or more of claims 1 to 10, characterized in that the coatings Y and Z are both lanthanum-stabilized aluminum oxide, rhodium, palladium or palladium and rhodium and an oxygen storage component comprising zirconium oxide, cerium oxide, praseodymium oxide and lanthanum oxide include.

12. A method for removing particles, carbon monoxide, hydrocarbons and nitrogen oxides from the exhaust gas of internal combustion engines operated with a stoichiometric air / fuel mixture, characterized in that the exhaust gas is passed through a particle filter according to one or more of claims 1 to 11.