JP2013513482A - 自動車用途のための先進的な触媒 - Google Patents
自動車用途のための先進的な触媒 Download PDFInfo
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- 239000003054 catalyst Substances 0.000 title claims abstract description 73
- 239000000463 material Substances 0.000 claims abstract description 116
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims abstract description 96
- 239000002105 nanoparticle Substances 0.000 claims abstract description 75
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 73
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims abstract description 50
- 229910052697 platinum Inorganic materials 0.000 claims abstract description 42
- 229910052763 palladium Inorganic materials 0.000 claims abstract description 26
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- 229910052703 rhodium Inorganic materials 0.000 claims abstract description 26
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims abstract description 24
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- XQQWBPOEMYKKBY-UHFFFAOYSA-H trimagnesium;dicarbonate;dihydroxide Chemical compound [OH-].[OH-].[Mg+2].[Mg+2].[Mg+2].[O-]C([O-])=O.[O-]C([O-])=O XQQWBPOEMYKKBY-UHFFFAOYSA-H 0.000 claims 4
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- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 15
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- -1 platinum ions Chemical class 0.000 description 12
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- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 1
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- VUZPPFZMUPKLLV-UHFFFAOYSA-N methane;hydrate Chemical compound C.O VUZPPFZMUPKLLV-UHFFFAOYSA-N 0.000 description 1
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Abstract
Description
本願は、2009年12月15日に出願され、表題が「MATERIALS PROCESSING」である米国仮特許出願第61/284,329号に対する優先権を主張し、この米国仮特許出願は、本明細書内に述べられているがごとく、その全体が本明細書により参考として本明細書に援用される。
車用触媒コンバータは、例えば、自動車排気における3つの有害な化合物を有害の少ない化合物に変えるために触媒を用いる。3つの有害な化合物は、未燃ガソリンの形態での炭化水素と、ガソリンの燃焼によって形成される一酸化炭素と、エンジンの熱が空気中の窒素を酸素と化合させるときに作られる窒素酸化物とを含む。触媒コンバータに用いられる2つの主要な構造がある−ハニカムおよびセラミックビーズである。今日のほとんどの自動車は、ハニカム構造を用いる。ハニカム構造は、排気管の前に付けられるマフラ様パッケージに収容される。触媒は、一酸化炭素を二酸化炭素に、炭化水素を二酸化炭素と水とに変えることを助け、窒素酸化物を窒素と酸素とに戻すように変えることを助ける。
一局面において、触媒コンバータは、ハニカム構造を含み、ハニカム構造は、ハニカム構造上に少なくとも1つのナノ粒子を有する。いくつかの実施形態において、少なくとも1つのナノ粒子は、ナノ活性材料と、ナノ支持部とを含む。ナノ活性材料は、典型的には、ナノ支持部上にある。ナノ活性材料は、白金、パラジウム、ロジウム、または合金である。合金は、白金、パラジウム、ロジウムの性質を持つ。ナノ支持部は、アルミナである。他の実施形態において、ナノ支持部は、部分的に還元されたアルミナ表面を含み、部分的に還元されたアルミナ表面は、ナノ支持部の表面上のナノ活性材料の動きを制限する。
添付の図面に例示されるように、ここで本発明の実装に参照が詳細になされる。図面は、同一縮尺ではない場合がある。同じ参照指標が、同一または類似の要素を参照するために図面および以下の詳細な説明の全体を通して用いられる。明快さの利益において、本明細書において説明される実装のありふれた特徴の必ずしもすべてが示され説明されるとは限らない。任意のそのような実際の実装の開発において、用途、安全規則および事業関連制約への準拠など開発者の特有の目標を達成するために多くの実装特有の決定がなされなければならないこと、ならびにこれらの特有の目標が実装および開発者によりさまざまに変化することは、もちろん理解される。さらに、そのような開発努力が本開示の利益を有する当業者にとって工学の日常の仕事であることは理解される。
ディーゼルエンジンは、ディーゼル酸化触媒(DOC)と、分離NOx還元技術と、ディーゼル微粒子フィルタ(DPF)とを含む。DOCは、二元触媒コンバータであり、二元触媒コンバータは、(1)COおよびO2をCO2に変え、(2)HaCbおよびO2をCO2およびH2Oに変える。DOCは、酸化剤として白金を用いる。DOCを生成する従来の方法は、ミクロンサイズの白金イオンを用いる。本発明の実施形態は、代わりにナノサイズの白金粒子を用いる。図4〜図5は、本発明にしたがって先進的なDOC触媒を生成する2つの発明プロセスを例示する。分離NOx還元技術は、還元剤として尿素を用いることによってNOx排出を還元する。DPFは、ディーゼルエンジンの排気ガスから副粒子(例えば、非気体炭化水素)を捕獲する。
ガスエンジンは、酸素豊富から酸素欠乏に(例えば、酸化状態から還元状態に)循環する。そのようなものとして、ガスエンジン用の従来の触媒コンバータは、酸化触媒と、還元触媒とを含む。還元触媒は、従来の触媒コンバータにおいて第1の段階である。還元触媒は、NOx排出を還元することを助けるために白金およびロジウムを用いる。例えば、ロジウムは、COおよびNO2をN2およびCO2に触媒する。酸化触媒は、従来の触媒コンバータにおいて第2の段階である。酸化触媒は、白金およびパラジウムを用いて未燃の炭化水素および一酸化炭素を酸化することによって、未燃の炭化水素および一酸化炭素を還元する。例えば、白金は、COおよびO2をCO2に触媒し、HaCbおよびO2をCO2およびH2Oに触媒する。パラジウムは、H2およびO2をC2Oに触媒する。酸化触媒は、一酸化炭素および炭化水素の、排気管内の残りの酸素との反応を助ける。従って、ガスエンジンは、3つの有害な化合物を還元するために三元触媒コンバータを用いる。
Claims (75)
- ハニカム構造を含む触媒コンバータであって、該ハニカム構造は、該ハニカム構造上に少なくとも1つのナノ粒子を有する、触媒コンバータ。
- 前記少なくとも1つのナノ粒子は、ナノ活性材料と、ナノ支持部とを含む、請求項1に記載の触媒コンバータ。
- 前記ナノ活性材料は、白金である、請求項2に記載の触媒コンバータ。
- 前記ナノ活性材料は、パラジウムである、請求項2に記載の触媒コンバータ。
- 前記ナノ活性材料は、ロジウムである、請求項2に記載の触媒コンバータ。
- 前記ナノ活性材料は、合金である、請求項2に記載の触媒コンバータ。
- 前記ナノ支持部は、アルミナである、請求項2に記載の触媒コンバータ。
- 前記ナノ支持部は、部分的に還元されたアルミナ表面を含み、該部分的に還元されたアルミナ表面は、該ナノ支持部の表面上の前記ナノ活性材料の動きを制限するように構成される、請求項2に記載の触媒コンバータ。
- 触媒コンバータにおけるキンセイ石基板であって、
a.第1の型のナノ粒子と、
b.第2の型のナノ粒子と、
c.第3の型のナノ粒子と
を含む、キンセイ石基板。 - 前記第1の型のナノ粒子は、ナノ活性材料と、ナノ支持部とを含む、請求項9に記載のキンセイ石基板。
- 前記ナノ活性材料は、白金である、請求項10に記載のキンセイ石基板。
- 前記ナノ支持部は、アルミナである、請求項10に記載のキンセイ石基板。
- 前記ナノ支持部は、部分的に還元されたアルミナ表面を含み、該部分的に還元されたアルミナ表面は、該ナノ支持部の表面上の前記ナノ活性材料の動きを制限するように構成される、請求項10に記載のキンセイ石基板。
- 前記第2の型のナノ粒子は、ナノ活性材料と、ナノ支持部とを含む、請求項9に記載のキンセイ石基板。
- 前記ナノ活性材料は、パラジウムである、請求項14に記載のキンセイ石基板。
- 前記ナノ支持部は、アルミナである、請求項14に記載のキンセイ石基板。
- 前記ナノ支持部は、部分的に還元されたアルミナ表面を含み、該部分的に還元されたアルミナ表面は、該ナノ支持部の表面上の前記ナノ活性材料の動きを制限するように構成される、請求項14に記載のキンセイ石基板。
- 前記第3の型のナノ粒子は、ナノ活性材料と、ナノ支持部とを含む、請求項9に記載のキンセイ石基板。
- 前記ナノ活性材料は、ロジウムである、請求項18に記載のキンセイ石基板。
- 前記ナノ支持部は、アルミナである、請求項18に記載のキンセイ石基板。
- 前記ナノ支持部は、部分的に還元されたアルミナ表面を含み、該部分的に還元されたアルミナ表面は、該ナノ支持部の表面上の前記ナノ活性材料の動きを制限するように構成される、請求項18に記載のキンセイ石基板。
- 触媒コンバータを作製する方法であって、
a.少なくとも1つのナノ粒子を用いて分散を生成することと、
b.薄め塗膜を得ることと
を包含する、方法。 - 前記少なくとも1つのナノ粒子は、ナノ活性材料と、ナノ支持部とを含む、請求項22に記載の方法。
- 前記ナノ活性材料は、白金である、請求項23に記載の方法。
- 前記ナノ活性材料は、パラジウムである、請求項23に記載の方法。
- 前記ナノ活性材料は、ロジウムである、請求項23に記載の方法。
- 前記ナノ活性材料は、合金である、請求項23に記載の方法。
- 前記ナノ支持部は、アルミナである、請求項23に記載の方法。
- 前記ナノ支持部は、部分的に還元されたアルミナ表面を含み、該部分的に還元されたアルミナ表面は、該ナノ支持部の表面上の前記ナノ活性材料の動きを制限するように構成される、請求項23に記載の方法。
- 前記生成することは、
a.高温凝縮技術でキャリア材料と、異なる触媒材料とを混合し、それによって、前記少なくとも1つのナノ粒子を生成することと、
b.液体と化合することと
を包含する、請求項22に記載の方法。 - 前記キャリア材料は、アルミナである、請求項30に記載の方法。
- 前記異なる触媒材料は、白金と、パラジウムと、ロジウムとを含む、請求項30に記載の方法。
- 前記高温凝縮技術は、プラズマである、請求項30に記載の方法。
- 前記生成することは、
a.高温凝縮技術でキャリア材料と第1の触媒材料とを混合し、それによって、第1の型のナノ粒子を生成することと、
b.該高温凝縮技術で該キャリア材料と第2の触媒材料とを混合し、それによって、第2の型のナノ粒子を生成することと、
c.該高温凝縮技術で該キャリア材料と第3の触媒材料とを混合し、それによって、第3の型のナノ粒子を生成することと、
d.該第1の型のナノ粒子と、該第2の型のナノ粒子と、該第3の型のナノ粒子とを一緒にして集めることと、
e.液体と化合することと
を包含する、請求項22に記載の方法。 - 前記キャリア材料は、アルミナである、請求項34に記載の方法。
- 前記第1の触媒材料は、白金である、請求項34に記載の方法。
- 前記第2の触媒材料は、パラジウムである、請求項34に記載の方法。
- 前記第3の触媒材料は、ロジウムである、請求項34に記載の方法。
- 前記高温凝縮技術は、プラズマである、請求項34に記載の方法。
- a.前記分散と前記薄め塗膜とを混合することと、
b.該混合をモノリスに適用することと、
c.該モノリスを乾燥させることと、
d.該モノリスをか焼することと
をさらに包含する、請求項22に記載の方法。 - a.前記薄め塗膜をモノリスに適用することと、
b.該モノリスを乾燥させることと、
c.該モノリスをか焼することと、
d.前記分散を該モノリスに与えることと、
e.該モノリスを乾燥させることと、
f.該モノリスをか焼することと
をさらに包含する、請求項22に記載の方法。 - 三元触媒コンバータを作製する方法であって、
a.異なる型のナノ粒子を用いることによって分散を生成することと、
b.薄め塗膜を得ることと、
c.該分散と該薄め塗膜とを混合することと、
d.該混合をモノリスに適用することと、
e.該モノリスを乾燥させることと、
f.該モノリスをか焼することと
を包含する、方法。 - 前記生成することは、高温凝縮技術を用いることを包含する、請求項42に記載の方法。
- 前記高温凝縮技術は、プラズマである、請求項42に記載の方法。
- 前記異なる型のナノ粒子の各々は、ナノ活性材料と、ナノ支持部とを含む、請求項42に記載の方法。
- 前記ナノ活性材料は、白金である、請求項45に記載の方法。
- 前記ナノ活性材料は、パラジウムである、請求項45に記載の方法。
- 前記ナノ活性材料は、ロジウムである、請求項45に記載の方法。
- 前記ナノ活性材料は、合金である、請求項45に記載の方法。
- 前記ナノ支持部は、アルミナである、請求項45に記載の方法。
- 前記ナノ支持部は、部分的に還元されたアルミナ表面を含み、該部分的に還元されたアルミナ表面は、該ナノ支持部の表面上の前記ナノ活性材料の動きを制限するように構成される、請求項45に記載の方法。
- 三元触媒コンバータを作製する方法であって、
a.異なる型のナノ粒子を用いて分散を生成することと、
b.薄め塗膜を得ることと、
c.該薄め塗膜をモノリスに適用することと、
d.該モノリスを乾燥させることと、
e.該モノリスをか焼することと、
f.該分散を該モノリスに与えることと、
g.該モノリスを乾燥させることと、
h.該モノリスをか焼することと
を包含する、方法。 - 前記生成することは、高温凝縮技術を用いることを包含する、請求項52に記載の方法。
- 前記高温凝縮技術は、プラズマである、請求項53に記載の方法。
- 前記異なる型のナノ粒子の各々は、ナノ活性材料と、ナノ支持部とを含む、請求項52に記載の方法。
- 前記ナノ活性材料は、白金である、請求項55に記載の方法。
- 前記ナノ活性材料は、パラジウムである、請求項54に記載の方法。
- 前記ナノ活性材料は、ロジウムである、請求項55に記載の方法。
- 前記ナノ活性材料は、合金である、請求項55に記載の方法。
- 前記ナノ支持部は、アルミナである、請求項55に記載の方法。
- 前記ナノ支持部は、部分的に還元されたアルミナ表面を含み、該部分的に還元されたアルミナ表面は、該ナノ支持部の表面上の前記ナノ活性材料の動きを制限するように構成される、請求項55に記載の方法。
- 二元触媒コンバータを作製する方法であって、
a.同じ型のナノ粒子を用いることによって分散を生成することと、
b.薄め塗膜を得ることと、
c.該分散と該薄め塗膜とを混合することと、
d.該混合をモノリスに適用することと、
e.該モノリスを乾燥させることと、
f.該モノリスをか焼することと
を包含する、方法。 - 前記生成することは、高温凝縮技術を用いることを包含する、請求項62に記載の方法。
- 前記高温凝縮技術は、プラズマである、請求項63に記載の方法。
- 前記同じ型のナノ粒子の各々は、ナノ活性材料と、ナノ支持部とを含む、請求項62に記載の方法。
- 前記ナノ活性材料は、白金である、請求項65に記載の方法。
- 前記ナノ支持部は、アルミナである、請求項65に記載の方法。
- 前記ナノ支持部は、部分的に還元されたアルミナ表面を含み、該部分的に還元されたアルミナ表面は、該ナノ支持部の表面上の前記ナノ活性材料の動きを制限するように構成される、請求項65に記載の方法。
- 二元触媒コンバータを作製する方法であって、
a.同じ型のナノ粒子を用いて分散を生成することと、
b.薄め塗膜を得ることと、
c.該薄め塗膜をモノリスに適用することと、
d.該モノリスを乾燥させることと、
e.該モノリスをか焼することと、
f.該分散を該モノリスに与えることと、
g.該モノリスを乾燥させることと、
h.該モノリスをか焼することと
を包含する、方法。 - 前記生成することは、高温凝縮技術を用いることを包含する、請求項69に記載の方法。
- 前記高温凝縮技術は、プラズマである、請求項70に記載の方法。
- 前記同じ型のナノ粒子の各々は、ナノ活性材料と、ナノ支持部とを含む、請求項69に記載の方法。
- 前記ナノ活性材料は、白金である、請求項72に記載の方法。
- 前記ナノ支持部は、アルミナである、請求項71に記載の方法。
- 前記ナノ支持部は、部分的に還元されたアルミナ表面を含み、該部分的に還元されたアルミナ表面は、該ナノ支持部の表面上の前記ナノ活性材料の動きを制限するように構成される、請求項72に記載の方法。
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Also Published As
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US9533289B2 (en) | 2017-01-03 |
WO2011075399A1 (en) | 2011-06-23 |
JP2015211974A (ja) | 2015-11-26 |
RU2012129989A (ru) | 2014-01-27 |
AU2010332088B2 (en) | 2015-01-15 |
US9308524B2 (en) | 2016-04-12 |
BR112012014723A2 (pt) | 2016-04-05 |
CN102844113B (zh) | 2016-03-02 |
US9126191B2 (en) | 2015-09-08 |
IL220388A (en) | 2016-08-31 |
US20110143933A1 (en) | 2011-06-16 |
EP2512664A1 (en) | 2012-10-24 |
CN105879861A (zh) | 2016-08-24 |
AU2010332088A1 (en) | 2012-07-26 |
CN102844113A (zh) | 2012-12-26 |
US20160067679A1 (en) | 2016-03-10 |
US20150141236A1 (en) | 2015-05-21 |
EP2512664A4 (en) | 2014-05-28 |
CA2784507A1 (en) | 2011-06-23 |
RU2583054C2 (ru) | 2016-05-10 |
MX2012006991A (es) | 2012-11-23 |
BR112012014723A8 (pt) | 2016-10-04 |
MX343783B (es) | 2016-11-23 |
KR20120112564A (ko) | 2012-10-11 |
JP6127097B2 (ja) | 2017-05-10 |
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