• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    the present invention provides a particulate filter for use in a gasoline engine emission treatment system, the filter having an inlet side and an outlet side, where at least the inlet side is loaded with synthetic ash.
    公开号:BR112019012916A2
    申请号:R112019012916
    申请日:2017-12-22
    公开日:2019-12-31
    发明作者:Clowes Lucy；Anthony Howard Michael
    申请人:Johnson Matthey Plc；
    IPC主号:
    专利说明:

    PARTICULATED FILTER, EMISSION TREATMENT SYSTEM UNDERSTANDING THE PARTICULATED FILTER, METHOD TO PRODUCE A PARTICULATED FILTER, AND USE OF A SYNTHETIC GRAY LOADING
    Field of the Invention [001] The present invention relates to a particulate filter, in particular a particulate filter for use in a gasoline engine emission treatment system. The particulate filter provides an advantageous combination of low back pressure and high fresh filtration efficiency.
    Basics of the Invention [002] Gasoline engines produce combustion exhaust streams containing hydrocarbons, carbon monoxide and nitrogen oxides in combination with particulates. It is known to treat the gases with a three-way conversion catalyst composition, and it is known to recover the particulates in particulate collectors such as soot filters.
    [003] Unlike particulates generated by low-burn diesel engines, particulates generated by gasoline engines tend to be finer and lower levels. This is attributed to the different combustion conditions of a diesel engine compared to a gasoline engine. For example, gasoline engines run at a higher temperature than diesel engines. Also, the resulting hydrocarbon components are different in emissions from gasoline engines compared to diesel engines.
    [004] Original equipment manufacturers (OEMs), that is, the vehicle manufacturer, require that particulate gasoline filters (GPFs) have high efficiency of fresh filtration and low back pressure. However, as there is little particulate mass outside the engine from a gasoline engine, no soot cake is generated during the pre-conditioning of the post-treatment system prior to testing. This soot pie is responsible
    Petition 870190071237, of 7/25/2019, p. 7/36
    2/19 at least in part due to the high filtration efficiency of the diesel particulate filter, and with a diesel engine an effective soot cake can be formed in 10-20 km of direction. Since this effect is generally not achievable with a gasoline engine, the targeted fresh filtration efficiency is satisfied using a higher reactive coating load and this increases the pressure drop across the part.
    [005] This consideration applies only to fresh parts in order to satisfy a requirement for an end of line test at the OEM. As the vehicle accumulates mileage, the GPF increases its filtration efficiency because of the accumulation of ash, a by-product of combustion.
    [006] Therefore, for most of a GPF's life, it is over-designed for filtration efficiency and the GPF has a greater pressure drop than it needs for most of its life, reducing the potential performance characteristics of the engine.
    [007] WO 2014162140 (Al) refers to a catalyzed filter to filter particulate matter from exhaust gas comprising one or more catalyst poisons and emitted by a positive ignition internal combustion engine, the filter comprising a porous substrate having a length of total substrate and having inlet and outlet surfaces, where the inlet surfaces are separated from the outlet surfaces by a porous structure containing pores of a first medium pore size, in which the porous substrate is coated with a reactive coating comprising a plurality of solid particles, wherein the porous structure of the porous substrate coated with a reactive coating contains pores of a second medium pore size, where the second medium pore size is smaller than the first medium pore size, whose reactive coating is axially arranged in the porous substrate as a first zone comprising the entry surfaces of a first substrate length less than the total substrate length and a second zone
    Petition 870190071237, of 7/25/2019, p. 8/36
    3/19 comprising the output surfaces of a second substrate length less than the total substrate length, where the sum of the substrate length in the first zone and the substrate length in the second zone> 100%, where the reactive coating of at least the second zone is a three-way catalytic reactive coating comprising one or more precious metals supported on a high surface area oxide, and an oxygen storage component and in which: (i) a specific reactive coating surface area in the first zone> second zone; or (ii) both a reactive coating load and a specific reactive coating surface area in the first zone> second zone.
    [008] It is desirable to provide an improved particulate filter and / or to deal with at least some of the problems associated with the prior art or, at least, to provide a commercially useful alternative to it.
    Summary of the Invention [009] According to a first aspect, a particulate filter is provided for use in a gasoline engine emission treatment system, the filter having an inlet and an outlet side, at least the entry side is loaded with synthetic ash.
    [0010] The present invention will now be described further. In the following passages, different aspects of the invention are defined in more detail. Each aspect thus defined can be combined with any other aspect or aspects, unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous can be combined with any other feature or features indicated as being preferred or advantageous.
    [0011] The particulate filter is typically formed from a porous substrate. The porous substrate may comprise a ceramic material such as, for example, cordierite, silicon carbide, silicon nitride, zirconia,
    Petition 870190071237, of 7/25/2019, p. 9/36
    4/19 mullite, spodumene, alumina-silica-magnesia, zirconium silicate and / or aluminum titanate, typically cordierite or silicon carbide. The porous substrate can be a porous substrate of the type typically used in gasoline engine emission treatment systems.
    [0012] The porous substrate may exhibit a conventional honeycomb structure. The filter can take the form of a conventional “bypass flow filter”. Alternatively, the filter can take the form of a conventional “wall flow filter” (WFF). Such filters are known in the art.
    [0013] The particulate filter is preferably a wall flow filter. Wall flow filters work by forcing a flow of exhaust gases (including particulate matter) to pass through walls formed of a porous material.
    [0014] A wall flow filter typically has a first face and a second face defining a longitudinal direction between them. In use, one of the first and second faces will be the inlet side for exhaust gases and the other will be the outlet side for treated exhaust gases. A conventional wall flow filter has first and second pluralities of channels that extend in the longitudinal direction. The first plurality of channels is opened on the first face and closed on the second face. The second plurality of channels is opened on the second face and closed on the first face. The channels are preferably parallel to each other to provide a constant wall thickness between the channels. As a result, gases entering one of the plurality of channels cannot leave the monolith without diffusion through the channel walls to the other plurality of channels. The channels are closed with the introduction of a sealing material at the open end of a channel. Preferably, the number of channels in the first plurality is equal to the number of channels in the second plurality, and each plurality is uniformly distributed throughout the monolith.
    Petition 870190071237, of 7/25/2019, p. 10/36
    5/19
    Preferably, in a plane orthogonal to the longitudinal direction, the wall flow filter has 15.5 to 77.5 channels per square centimeter (100 to 500 channels per square inch), preferably 31 to 62 (200 to 400). For example, on the first face, the density of first open channels and second closed channels is 31 to 62 channels per square centimeter (200 to 400 channels per square inch). Channels can have cross sections that are rectangular, square, circular, oval, triangular, hexagonal, or other polygonal shapes.
    [0015] The materials that make up synthetic ash are typically not inherently catalytic at the point of loading. Specifically, in the absence of other catalytic species, the material typically has no catalytic effect. In other words, it typically does not catalyze reactions with species contained in the emission to be treated such as, for example, unburned hydrocarbons, carbon monoxide, carbon dioxide, nitrogen-containing species, soot, metals, etc. Certainly, synthetic ash can provide at least a partial catalytic effect when combined with other species loaded on the filter, for example, a catalytic reactive coating. However, synthetic ash is typically not able to provide a catalytic effect on its own under typical filter operating conditions.
    [0016] However, certain preferred synthetic ash components, for example ceria or mixed ceria-zirconia oxides, have at least catalytic activity for combustion of soot from surface to surface contact. However, the definitions in the previous paragraph aim inter alia to distinguish synthetic ash from those generated by the use of fuel-charged catalyst formulations (FBC), in which certain metallorganic compounds contain metallic naphthenates, etc. or colloidal dispersions of very fine metal oxide particles of one or more, for example, Cu, Fe, Pt or Ce in the engine fuel. During the combustion process, the
    Petition 870190071237, of 7/25/2019, p. 11/36
    6/19 catalysts are incorporated into the soot matrix and then collected on the filter. This approach can improve solid-soot catalyst contact with ο O2 and can reduce the temperature for combustion of dry soot (see RM Heck et al, Catalytic Air Pollution Control - Commercial Technology, 3rd Edition (2009), pp. 259-260 and 273; and “Filtres Using Fuel Borne Catalyts”, Paul Richards, Revision 2014.12, DieselNet Technology Guide (available to subscribers at https://www.dieselnet.com/tech/dpf_fbc.php).
    [0017] Filters containing FBC-derived catalyst can also be distinguished in that the filter of the present invention in its fresh state, i.e., as manufactured, for example, non-canned, does not contain FBC-derived catalyst components. They can also be distinguished in that the FBC is present within the structure of the soot particles, that is, in close combination with it, while the synthetic ash of the present invention makes contact with soot only by the surface-to-surface contact between the particles of soot and synthetic ash.
    [0018] The synthetic ash is preferably devoid of catalytic material containing metal of the platinum group. This can reduce the cost of the particulate filter raw materials. The metals in the platinum group include: platinum, palladium, ruthenium, rhodium, osmium and iridium.
    [0019] Synthetic ash typically does not react with the filter material (for example, cordierite, silicon carbide, etc.) at typical filter operating temperatures, for example, up to 300 ° C, or up to 500 ° C, or even 700 ° C, or even up to 800 ° C. Synthetic ash also typically does not react to such temperatures with other species that may be contained in the filter, for example, a catalytic reactive coating (for example, reactive catalytic coatings comprising "conventional TWC catalysts").
    [0020] Synthetic ash is not directly formed by a combustion process. For example, synthetic ash is not a component of a
    Petition 870190071237, of 7/25/2019, p. 12/36 / 19 emission to be treated by the emission treatment system, for example, a product of combustion of a fuel such as gasoline.
    [0021] Synthetic ash can contain one or more species that are present in non-synthetic ash. Synthetic ash is typically substantially free of carbonaceous species, for example, soot.
    [0022] At least the inlet side of the particulate filter is loaded with synthetic ash. The synthetic ash can also be loaded on the outlet side of the filter and / or inside the filter. Loading can be characterized as “on the wall” or “in-wall” loading. The first is characterized by the formation of a synthetic ash on a filter surface. The latter is characterized by the infiltration of synthetic ash into the pores in the porous material. Typically, substantially all of the synthetic ash is carried "on the wall". In contrast, when a catalyst, such as a three-way catalyst (TWC), is also present, typically substantially the entire catalyst is loaded "embedded in the wall". The loading of a synthetic ash "on the wall" can be achieved, for example, by modifying the rheological characteristics of a reactive coating slurry in which the synthetic ash is applied.
    [0023] The synthetic ash can be loaded in the form of a packaged bed, for example, when the synthetic ash is loaded by being "blown" into the particulate filter. Such a packaged bed is typically porous and typically gas permeable. Alternatively, the synthetic ash may be in the form of a porous coating, for example, a coating applied as (i.e., derived from) a reactive coating slurry.
    [0024] It was surprisingly observed that, when incorporated into an emission treatment system for a gasoline engine, the particulate filter exhibits a combination of high efficiency of fresh filtration and a reduced increase in back pressure over time. Without being connected by
    Petition 870190071237, of 7/25/2019, p. 13/36
    8/19 theory, synthetic ash is considered to work in a similar way to a soot cake formed after a long driving distance, for example, after 5,000 km, or after 10,000 km, or 20,000 km (the soot cake) formed after a certain driving distance will certainly depend, inter alia, on the fuel used, the gasoline engine, and the driving conditions). In other words, synthetic ash serves to trap particulate matter contained in the emission, thereby providing high filtration efficiency. Advantageously, this high filtration efficiency is exhibited by the fresh particulate filter from the production line, meaning that the particulate filter is better able to pass an end-of-line performance test at an OEM.
    [0025] As discussed here, in conventional particulate gasoline filters, a high efficiency of fresh filtration is typically provided by the use of high levels of reactive coating loading. Since the particulate filter of the present invention can provide a high efficiency of fresh filtration without the need to use a high level of reactive coating loading, the increase in filter back pressure over time can be reduced. In addition, since less reactive coating is required, the raw material costs of the particulate filter can be reduced. [0026] Since the ash is "synthetic", its composition can be controlled so that it is substantially devoid of species capable of reacting with the particulate filter material or with a catalyst composition loaded in the filter. This is unlike conventional accumulated ash, for example, engine lubricating oils or fuel-loaded additives - as also discussed earlier - and / or soot cake, which typically contain species capable of poisoning conventional catalysts used in fuel emission systems. gasoline. Thus, when the particulate filter is loaded with a catalyst, the particulate filter can provide the combination of high filtration efficiency and
    Petition 870190071237, of 7/25/2019, p. 14/36
    9/19 reduced increase in back pressure over time along with high catalytic performance. Since the ash is “synthetic”, it is possible to control its position in the filter, loading level and particle size to fine-tune the fresh filtration and back pressure characteristics of the filter.
    [0027] The synthetic ash preferably comprises one or more of: aluminum oxide, zinc oxide, zinc carbonate, calcium oxide, calcium carbonate, zirconium and cerium oxide (mixed), zirconium oxide, cerium oxide and hydrated alumina, more preferably one or more of: zinc oxide, zinc carbonate, calcium oxide, calcium carbonate and zirconium oxide. Conventional operating temperatures, such species typically do not react with the materials from which conventional particulate gasoline filters are made. Conventional operating temperatures, such species typically do not react with catalysts typically loaded on particulate gasoline filters, for example, a TWC. In addition, unlike a soot cake, synthetic ash does not "burn" during normal operation. Thus, the filtration efficiency of the particulate filter is typically substantially constant throughout the life of the particulate filter. In the case of a synthetic ash comprising hydrated alumina, the hydrated alumina typically transforms to alumina in situ, that is, in the operating conditions of the particulate filter. In order to provide a particulate filter in which the synthetic ash comprises hydrated alumina, any calcination step would need to be carried out before loading the hydrated alumina. In a preferred embodiment, synthetic ash is free from aluminum oxide and / or cerium and zirconium oxide and / or cerium oxide.
    [0028] The synthetic ash is preferably devoid of catalyst poisoning materials. When the particulate filter is loaded with a catalyst composition such as, for example, a TWC composition, this can serve to avoid any significant decrease in
    Petition 870190071237, of 7/25/2019, p. 15/36
    10/19 catalytic performance of the particulate filter.
    [0029] In this regard, synthetic ash is preferably substantially free of sulfur, phosphorus, magnesium, manganese and lead oxides. Such species are known to poison catalysts typically used in particulate gasoline filters.
    [0030] The filter preferably comprises from 1 to 50 g / L of the synthetic ash, more preferably from 5 to 40 g / L, even more preferably from 10 to 35 g / L, even more preferably from 15 to 35 g / L , also even more preferably from 20 to 30 g / L. Lower levels of synthetic ash may not provide adequate fresh filtration efficiency. Higher levels can increase production costs, and can also increase the back pressure of the filter in use.
    [0031] The filter preferably comprises a porous body comprising a plurality of pores, and further comprises one or more reactive catalytic coatings in at least a portion of the plurality of pores. The use of one or more reactive catalytic coatings can be used to treat components of a gasoline exhaust gas such as, for example, unburned hydrocarbons, carbon monoxide and / or nitrogen oxide. In comparison with conventional particulate gasoline filters, the particulate filter of the present invention may contain lower levels of reactive coating (for example, a TWC reactive coating), for example, less than 61.01 g / dm 3 (1 g / in 3 ), or less than 42.70 g / dm 3 (0.7 g / in 3 ), or less than 30.50 g / dm 3 (0.5 g / in 3 ), or less than 18.30 g / in 3 dm 3 (0.3 g / in 3 ), or from 3.05 to 54.91 g / dm 3 (0.05 to 0.9 g / in 3 ), or from 6.10 to 36.61 g / dm 3 (0.1 to 0.6 g / in 3 ). This is because there is no need to rely on high reactive coating loads in order to achieve high fresh filtration efficiency. In order to provide sufficient catalytic activity to oxidize carbon monoxide and hydrocarbons, as well as to reduce nitrogen oxides (NO X ), the reactive coating (eg
    Petition 870190071237, of 7/25/2019, p. 16/36
    11/19 TWC reactive coating) is preferably present in an amount of 3.03 g / dm 3 (0.05 g / in 3 ) or more, or 6.10 g / dm 3 (0.1 g / in 3 ) or more. The reactive catalytic coating is typically distributed substantially throughout the plurality of pores.
    [0032] One or more reactive coatings preferably includes a TWC reactive coating. Such reactive coatings are known in the art and are particularly effective in gasoline engine emission treatment systems.
    [0033] In one embodiment, the particulate filter is canned. In an alternative embodiment, the filter is not canned. Being "canned" means that the particulate filter has been incorporated into a housing for incorporation into an emission treatment system. Being "non-canned" means that the particulate filter has not yet been incorporated into a housing for incorporation into an emission treatment system, but is still loaded with synthetic ash. In a typical canning process, the particulate filter is jacketed in a support blanket, typically formed of ceramic fibers or alumina fibers, before being incorporated into a metallic housing. Methods of incorporating the particulate filter into a metal housing include, for example, “shell-like packaging”, “filling” and “tourniquet” techniques. Such techniques are known in the art.
    [0034] In an additional aspect, an emission treatment system is provided comprising the particulate filter described here, in which the inlet side of the particulate filter is arranged to be upstream of the outlet side. The inlet side being arranged to be upstream of the outlet side means that emissions from the gasoline engine enter the particulate filter through the inlet side before leaving the filter through the outlet side. The particulate filter is typically canned before being incorporated into the emission treatment system.
    [0035] In an additional aspect, a method for production is provided
    Petition 870190071237, of 7/25/2019, p. 17/36
    12/19 of a particulate filter for use in a gasoline engine emission treatment system, the method comprising:
    providing a filter having an inlet and an outlet side; and load at least the inlet side with synthetic ash.
    [0036] The particulate filter produced according to the method can be the particulate filter as described here. That is, all the features of the first aspect can be freely combined with the additional aspects described here.
    [0037] Synthetic ash can come in contact with the inlet side in the form of a gas suspension. Alternatively, synthetic ash can come in contact with the inlet side in the form of a liquid suspension, for example, a reactive coating.
    [0038] Preferably, the synthetic ash is "dry loaded", that is, loaded without the use of a liquid carrier. Such dry loading can result in the distribution of synthetic ash in the filter in a more similar way imitating the distribution of non-synthetic ash that is charged in a particulate filter during use. In this way, the fresh filtering efficiency of the filter can more closely mimic the filtering efficiency of the filter that is observed after a long driving distance.
    [0039] Once loaded, synthetic ash can take the form of a packed bed. For example, when the particulate filter is a wall flow filter, the synthetic ash can form a packaged bed against the walls of the plurality of open channels on the inlet side. The packaged bed can be formed in the open channels on the inlet side and against the sealing material that closes the channels, that is, towards the outlet end of the inlet channels. The packaged bed is typically porous and typically permeable to gas, the pores being sized to trap
    Petition 870190071237, of 7/25/2019, p. 18/36
    13/19 particulate matter in a gasoline exhaust, for example, soot. The pores of the packaged bed are typically smaller than the pores of the porous substrate of the particulate filter. Alternatively, or in addition, the packed bed may be more porous than the walls of the porous substrate (i.e., it can provide a high level of filtration by providing a long path length). The packaged bed can extend along the walls of the plurality of open channels on the entrance side. The packaged bed may take the form of a layer or membrane, for example, a continuous layer or membrane. The packaged bed may extend along the entire length of the walls of the plurality of channels, or along only part of the length of the walls. Instead of being a packaged bed, the synthetic ash can be in the form of a porous coating, for example, a coating applied as (i.e., derived from) a reactive coating slurry. The porous coating can be arranged on a wall flow filter in a manner similar to the packaged bed discussed above.
    [0040] The method can additionally comprise canning the filter loaded with synthetic ash. Techniques for canning the filter loaded with synthetic ash are known in the art and examples of such techniques are referred to above.
    [0041] The synthetic ash can be loaded in particulate form. The particulates can have a D90, for example, less than 10 pm, or less than 5 pm, although other particle size distributions may be employed. The synthetic ash is preferably charged in particulate form having a D90 of less than 1 pm. Such particle distributions can help prevent a significant amount of synthetic ash from entering the pores of the porous substrate. For the avoidance of doubt, D90 measurements were obtained by Particle Size Analysis by Laser Diffraction using a Malvern Mastersizer 2000, which is a volume-based technique
    Petition 870190071237, of 7/25/2019, p. 19/36
    14/19 (ie, D90 can also be referred to as DV90 (or D (v, 0.90)) and applies a Mie mathematical theory model to determine a particle size distribution. Synthetic ash samples for measurements of D90 were prepared by sonication in distilled water without surfactant for 30 seconds at 35 watts.
    [0042] In a preferred embodiment, loading at least the inlet side with synthetic ash comprises:
    put the inlet side in contact with the synthetic ash; and providing a gaseous flow from the inlet side to the outlet side and / or a vacuum from the outlet side to compact the synthetic ash against the filter.
    [0043] The inlet side preferably comes into contact with the synthetic ash in the form of both a gas suspension (ie, by blowing the synthetic ash into the inlet side) and a liquid suspension (for example, a reactive coating).
    [0044] The method may additionally comprise calcining the loaded synthetic ash. Calcination can reduce the back pressure of the resulting particulate filter.
    [0045] In a further aspect, the present invention provides for the use of a synthetic ash filler to increase the efficiency of fresh filtration of a filter for use in an emission treatment system for a gasoline engine.
    Brief Description of the Drawings [0046] The invention will now be described in relation to the following non-limiting figures, in which:
    Figure IA is a perspective view showing schematically a particulate filter 1 according to an embodiment of the present invention.
    [0047] Figure 1B is a cross-sectional view on line A-A of the
    Petition 870190071237, of 7/25/2019, p. 20/36
    15/19 particulate filter 1 shown in FIG. 1 A.
    [0048] Figure 2 shows a schematic diagram of an emission treatment system for a gasoline engine.
    [0049] Figure 3 shows X-ray images of particulate filters according to the modalities of the present invention.
    [0050] Figure 4 shows a graph of back pressure characteristics of particulate filters according to the modalities of the present invention and a particulate filter of the prior art.
    [0051] Figure 5 shows a graph of filtration efficiencies of a particulate filter according to an embodiment of the present invention and a particulate filter of the prior art.
    [0052] Figure 6 shows X-ray images of particulate filters: Comparative filter III and Filter IV according to an embodiment of the present invention.
    Detailed Description of the Invention [0053] A particulate filter 1 according to an embodiment of the present invention is shown in FIG. IA and FIG. 1B. In this embodiment, the particulate filter is a wall flow filter. It includes a large number of channels arranged in parallel with each other in the longitudinal direction (shown by a double sided arrow “a” in FIG. IA) of filter 1. The large number of channels includes a first subset of channels 5 and a second subset of channels 10.
    [0054] The channels are represented in such a way that the second subset of channels 10 is closer than the first subset of channels 5. However, the channels may alternatively be substantially the same size.
    [0055] The first subset of channels 5 is opened at an end portion on a first end face 15 of the wall flow monolith 1 and is sealed with a sealing material 20 in a portion of
    Petition 870190071237, of 7/25/2019, p. 21/36
    16/19 end on a second end face 25.
    [0056] On the other hand, the second subset of channels 10 is opened at an end portion on the second end face 25 of the wall flow monolith 1 and is sealed with a sealing material 20 at an end portion on the first face end cap 15.
    [0057] The filter 1 can be provided with a catalytic material in the pores of the walls of the channels 35. The catalyst supported on the wall of the channel 35 of the monolith 1 works as a catalyst to treat the exhaust fumes.
    [0058] Synthetic ash 50 is located in the first subset of channels 5 and is packaged against the sealing material 20 in the end portion on the second face 25. The packaged bed of synthetic ash extends from the sealing material along the channel walls 35.
    [0059] Therefore, when the particulate filter is used in an exhaust system, exhaust gases G (in FIG. IB “G” indicates exhaust gases and the arrow indicates an exhaust flow direction) introduced in the first subset of channels 5 will pass through synthetic ash 50 and the wall of channel 35 disposed between channel 5a and channels 10a and 10b, and then flow out of monolith 1. In this way, particulate matter in the exhaust gases is captured by the synthetic ash 50.
    [0060] In the emission treatment system 100 embodiment shown in FIG. 2, the exhaust gas flow 110 passes through the particulate filter 1. The exhaust gas 110 passes from the gasoline engine 115 through the duct system 120 to the exhaust system 125.
    [0061] It should be noted that the particulate filter is described here as a single component. However, during formation of an emission treatment system, the filter used can be formed by adhering to a plurality of channels or adhering to each other a plurality of smaller filters, as described herein. Such techniques are well known in the art, as well as
    Petition 870190071237, of 7/25/2019, p. 22/36
    17/19 coatings and appropriate emission treatment system configurations.
    [0062] The catalytic wall flow monolith will now be described further in relation to the following non-limiting example.
    Example 1:
    [0063] Filter I: a particulate filter was prepared by loading ZnO powder on the inlet side of a 65% uncoated cordierite wall flow filter with commercial 300/8 porosity. The ZnO powder was placed on a support mesh above the inlet of the filter to be coated and an air stream was directed from the inlet side through the wall flow filter and out of the outlet side, thereby extracting the ZnO powder through the mesh and into the filter, compacting the ZnO powder against the sealing plugs of the inlet channels. Approximately 45 g of ZnO powder was loaded into the filter, providing a loading level of approximately 25 g / L.
    [0064] Filter II: a second particulate filter was prepared in a similar way to Filter I, but with Disperal® powder (a high purity dispersible alumina hydrate) used instead of ZnO.
    [0065] Filter III (Comparative): another particulate filter was prepared by coating a non-coated cordierite wall flow filter of 65% commercial 300/8 porosity with TWC reactive coating (24.41 g / dm 3 ( 0.4 g / in 3 ) reactive coating loading, 84.9 g / m 3 (30 g / ft 3 ) PGM (0: 27: 3, Pt / Pd / Rh)) on the inlet and outlet sides.
    [0066] Filter IV: another particulate filter was prepared first as in Filter III, by coating a non-coated cordierite wall flow filter of 65% commercial 300/8 porosity with TWC reactive coating 24.41 g / dm 3 (0.4 g / in 3 ) reactive coating loading, 1.071 g / m 3 (30 g / ft 3 ) PGM, (0: 27: 3, Pt / Pd / Rh)) on the inlet and outlet sides and calcination at 500 ° C before 45 g of Disperal® powder
    Petition 870190071237, of 7/25/2019, p. 23/36
    18/19 be loaded on the inlet side of the coated filter, prepared in a similar manner to Filters I and II.
    [0067] X-ray images of Filters I and II are shown in Figure 3 [top: Filter II (Disperal®); base: Filter I (ZnO)], with the input sides being at the top of the images. The dark bands indicate the A plugs at the top and bottom of the filters. Additional dark shading at the bottom of the filters corresponds to synthetic ash B compacted against the channel end plugs.
    [0068] Back pressure characteristics of the particulate filters were investigated, both before and after calcination at 500 ° C, and the results are shown in Figure 4 together with the results of a wall flow filter without containing synthetic ash (top curves) for base: Disperal®, non-calcined (Filter II); Disperal®, calcined (Filter IIC); ZnO, non-calcined (Filter I); ZnO calcined (Filter IC); and uncoated (dashed)). It can be seen that filters loaded with synthetic ash, particularly after calcination, showed counterpressure characteristics similar to a filter in which no synthetic ash was loaded.
    [0069] The fresh filtration efficiencies of the filter and an uncoated particulate filter on which no synthetic ash was loaded were measured with TWC in the first position (substrate with 1L volume as CPSI 400/4 and a catalyst coating as 750 g / m 3 (21 g / ft 3 ) (0: 18: 3), Pt / Pd / Rh) (conforming to Euro 5 of 2L gasoline direct injection engine; NEDC test; Engine PN = 1.28 x 10 12 ), and the results are shown in Figure 5. It can be seen that the fresh filtration efficiency of the particulate filter loaded with ZnO (right side) was 91%, whereas the particulate filter without synthetic ash showed an efficiency 73% fresh filtration. The results indicate that the particulate filter of the present invention provides an advantageous combination of high fresh filtration and low back pressure.
    Petition 870190071237, of 7/25/2019, p. 24/36
    19/19 [0070] Similar to Figure 3, X-ray images of Filters III and IV are shown in Figure 6 (top: Comparative Filter III; bottom: Filter IV), with the input sides being at the top of the images.
    [0071] Although preferred embodiments of the invention have been described in detail here, those skilled in the art will understand that variations can be made to them without departing from the scope of the invention or the attached claims.
    [0072] For the avoidance of doubt, the full contents of all documents cited here are incorporated here by reference.
    权利要求:
    Claims (18)
    [1]
    1. Particulate filter for use in a gasoline engine emission treatment system, the filter having an inlet side and an outlet side, characterized by the fact that at least the inlet side is loaded with synthetic ash.
    [2]
    2. Particulate filter according to claim 1, characterized by the fact that the particulate filter is a wall flow filter.
    [3]
    3. Particulate filter according to claim 1 or 2, characterized in that the synthetic ash comprises one or more of: aluminum oxide, zinc oxide, zinc carbonate, calcium oxide, calcium carbonate, cerium oxide and zirconium (mixed), zirconium oxide, cerium oxide and hydrated alumina.
    [4]
    4. Particulate filter according to claim 3, characterized by the fact that the synthetic ash comprises one or more of: zinc oxide, zinc carbonate, calcium oxide, calcium carbonate and zirconium oxide.
    [5]
    5. Particulate filter according to any one of the preceding claims, characterized in that the synthetic ash is devoid of catalytic material containing platinum group metal and / or devoid of catalyst poisoning materials.
    [6]
    6. Particulate filter according to claim 5, characterized by the fact that the catalyst poisoning materials in the synthetic ash are substantially free of sulfur, phosphorus, magnesium, manganese and lead oxides.
    [7]
    Particulate filter according to any one of the preceding claims, characterized in that the filter comprises from 1 to 50 g / E of the synthetic ash, preferably from 5 to 40 g / E, more preferably from 10 to 35 g / E , even more preferably from 15 to 35
    Petition 870190071237, of 7/25/2019, p. 26/36
    2/3 g / L, also more preferably from 20 to 30 g / L.
    [8]
    Particulate filter according to any one of the preceding claims, characterized in that the filter comprises a porous body comprising a plurality of pores, and additionally comprising one or more reactive catalytic coatings in at least a portion of the plurality of pores, in that one or more reactive coatings preferably includes a TWC reactive coating.
    [9]
    9. Particulate filter according to any of the preceding claims, characterized by the fact that the particulate filter is non-canned.
    [10]
    Emission treatment system comprising the particulate filter as defined in any one of claims 1 to 8, characterized in that the inlet side of the particulate filter is arranged to be upstream of the outlet side.
    [11]
    11. Method for producing a particulate filter for use in a gasoline engine emission treatment system, the method characterized by the fact that it comprises:
    providing a filter having an inlet and an outlet side; and load at least the inlet side with synthetic ash.
    [12]
    12. Method according to claim 11, characterized in that the particulate filter is as defined in any one of claims 1 to 9.
    [13]
    Method according to claim 11 or 12, characterized in that the method additionally comprises canning the filter loaded with synthetic ash.
    [14]
    14. Method according to any of the claims
    11 to 13, characterized by the fact that synthetic ash is loaded in the form
    Petition 870190071237, of 7/25/2019, p. 27/36
    3/3 particulate having a D90 less than 1 pm.
    [15]
    Method according to any one of claims 11 to 14, characterized in that loading at least the inlet side with synthetic ash comprises:
    put the inlet side in contact with the synthetic ash; and providing a gaseous flow from the inlet side to the outlet side and / or a vacuum from the outlet side to compact the synthetic ash against the filter.
    [16]
    16. Method according to claim 15, characterized by the fact that the inlet side comes into contact with the synthetic ash in the form of both a gas suspension and a liquid suspension.
    [17]
    Method according to any one of claims 11 to 16, characterized in that it additionally comprises calcining the charged synthetic ash.
    [18]
    18. Use of a synthetic ash filler, characterized by the fact that it is to increase the efficiency of fresh filtration of a filter for use in an emission treatment system for a gasoline engine.
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    同族专利:
    公开号 | 公开日
    US20200191030A1|2020-06-18|
    GB201622179D0|2017-02-08|
    WO2018115900A1|2018-06-28|
    RU2019123064A|2021-01-25|
    GB2585160A|2020-12-30|
    GB2585160B|2021-08-04|
    CN110325718A|2019-10-11|
    CN110325718B|2021-11-19|
    GB2560663B|2020-10-21|
    GB2560663A|2018-09-19|
    US11047276B2|2021-06-29|
    RU2760413C2|2021-11-24|
    GB201808471D0|2018-07-11|
    EP3559420A1|2019-10-30|
    RU2019123064A3|2021-05-20|
    GB202013999D0|2020-10-21|
    JP2020503471A|2020-01-30|
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    法律状态:
    2021-10-13| B350| Update of information on the portal [chapter 15.35 patent gazette]|
    2022-01-25| B06W| Patent application suspended after preliminary examination (for patents with searches from other patent authorities) chapter 6.23 patent gazette]|
    优先权:
    申请号 | 申请日 | 专利标题
    GBGB1622179.8A|GB201622179D0|2016-12-23|2016-12-23|Gasoline particulate filter|
    PCT/GB2017/053878|WO2018115900A1|2016-12-23|2017-12-22|Gasoline particulate filter|
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