US4374103A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of using a low cost catalyst system
Assignee: Ford Motor Co
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Filing: 1981-07-20
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Granted: 1983-02-15
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Expires: 2001-07-20
Abstract
Abstract There is disclosed a method of using an exhaust gas catalyst for treatment of exhaust gases developed by burning a hydrocarbon based fuel in an internal combustion engine. These exhaust gases contain varying amounts of unburned hydrocarbons, carbon monoxide and oxides of nitrogen depending upon the operating conditions of the internal combustion engine. This specification teaches the use of an improved catalyst composition in which a support medium is provided for supporting the catalyst system, the support medium having an upstream support portion and a downstream support portion over which the exhaust gases pass in succession. The upstream support portion of the support medium has deposited thereon palladium and the downstream support portion of the support medium has deposited thereon palladium and tungsten. Tungsten is present on the downstream support portion of the support medium in a quantity such that tungsten is available to substantially all of the palladium on that portion of the support medium. The catalyst system has particular utility as a three-way catalyst operating at approximately stoichiometric conditions or as a catalyst for use in conjunction with the so-called "fast burn/low friction" engines or as an oxidation catalyst.
Inventors
- 👤 Haren S. Gandhi
- 👤 Karen M. Adams
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 08:43
CPC Classifications
B; B01; B01D; B01D53/00; B01D53/34; B01D53/92; B01D53/94; B01D53/9445; B01D53/945; B01J; B01J23/00; B01J23/38; B01J23/54; B01J23/56; B01J23/64; B01J23/652; B01J23/6527; Y; Y02; Y02T; Y02T10/00; Y02T10/10; Y02T10/12
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
203 words
In a process for treatment of exhaust gases from an internal combustion engine, the steps of: burning a hydrocarbon fuel or a fuel containing hydrocarbons and alcohol blends in the internal combustion engine thereby to generate exhaust gases from the internal combustion engine containing various amounts of unburned hydrocarbons, carbon monoxide and oxides of nitrogen depending upon operating conditions of the internal combustion engine; and passing said generated exhaust gases over an improved catalyst comprising: a support medium for supporting a catalyst system, said support medium having both an upstream support portion over which exhaust gases initially flow and a downstream support portion over which exhaust gases flow after passing over said upstream support portion thereof; palladium on said upstream support portion; palladium on said downstream support portion; and finely divided tungsten on said downstream support portion, said tungsten being present on said downstream support portion in quantities that tungsten is available to substantially of said palladium on said downstream support portion so that said palladium/tungsten combination is effective in the catalytic oxidation of unburned hydrocarbons and carbon monoxide and the catalytic reduction of oxides of nitrogen without significant production of ammonia when the internal combustion engine is operating under fuel rich conditions.
Claim 2
Dependent Claim
203 words
In a process for treatment of exhaust gases from an internal combustion engine, the steps of: burning a hydrocarbon fuel or a fuel containing hydrocarbons and alcohol blends in the internal combustion engine thereby to generate exhaust gases from the internal combustion engine containing various amounts of unburned hydrocarbons, carbon monoxide and oxides of nitrogen depending upon operating conditions of the internal combustion engine; and passing said generated exhaust gases over an improved catalyst comprising: a support medium for supporting a catalyst system, said support medium having both an upstream support portion over which exhaust gases initially flow and a downstream support portion over which exhaust gases flow after passing over said upstream support portion thereof; palladium on said upstream support portion; palladium on said downstream support portion; and finely divided tungsten on said downstream support portion, said tungsten being present on said downstream support portion in quantities that tungsten is available to substantially of said palladium on said downstream support portion so that said palladium/tungsten combination is effective in the catalytic oxidation of unburned hydrocarbons and carbon monoxide and the catalytic reduction of oxides of nitrogen without significant production of ammonia when the internal combustion engine is operating under fuel rich conditions.
Claim 3
Dependent Claim
207 words
In a process for treatment of exhaust gases from an internal combustion engine, the steps of: burning a hydrocarbon fuel or a fuel containing hydrocarbons and alcohol blends in the internal combustion engine thereby to generate exhaust gases from the internal combustion engine containing various amounts of unburned hydrocarbons, carbon monoxide and oxides of nitrogen depending upon operating conditions of the internal combustion engine; and passing said generated exhaust gases over an improved catalyst comprising: a support medium for supporting a catalyst system, said support medium having both an upstream support portion over which exhaust gases initially flow and a downstream support portion over which exhaust gases flow after passing over said upstream support portion thereof; finely divided palladium on said upstream support portion; finely divided palladium on said downstream support portion; and finely divided tungsten on said downstream support portion, said tungsten being present on said downstream support portion in quantities that tungsten is available to substantially of said palladium on said downstream support portion so that said palladium/tungsten combination is effective in the catalytic oxidation of unburned hydrocarbons and carbon monoxide and the catalytic reduction of oxides of nitrogen without significant prodction of ammonia when the internal combustion engine is operating under fuel rich conditions.
Claim 4
Dependent Claim
207 words
In a process for treatment of exhaust gases from an internal combustion engine, the steps of: burning a hydrocarbon fuel or a fuel containing hydrocarbons and alcohol blends in the internal combustion engine thereby to generate exhaust gases from the internal combustion engine containing various amounts of unburned hydrocarbons, carbon monoxide and oxides of nitrogen depending upon operating conditions of the internal combustion engine; and passing said generated exhaust gases over an improved catalyst comprising: a support medium for supporting a catalyst system, said support medium having both an upstream support portion over which exhaust gases initially flow and a downstream support portion over which exhaust gases flow after passing over said upstream support portion thereof; finely divided palladium on said upstream support portion; finely divided palladium on said downstream support portion; and finely divided tungsten on said downstream support portion, said tungsten being present on said downstream support portion in quantities that tungsten is available to substantially of said palladium on said downstream support portion so that said palladium/tungsten combination is effective in the catalytic oxidation of unburned hydrocarbons and carbon monoxide and the catalytic reduction of oxides of nitrogen without significant prodction of ammonia when the internal combustion engine is operating under fuel rich conditions.
Claim 5
Dependent Claim
19 words
The process of claim 1 or 2, in which the support media is a gamma alumina coated monolithic substrate.
Claim 6
Dependent Claim
16 words
The process of claim 1 or 2, in which the support media is gamma alumina pellets.
Claim 7
Dependent Claim
17 words
The process of claim 1 or 2, in which the support media is a washcoated metallic substrate.
Claim 8
Dependent Claim
18 words
The process of claim 1 or claim 2, in which said upstream support portion also has molybdenum thereon.
Claim 9
Dependent Claim
116 words
In a process for treatment of exhaust gases from an internal combustion engine, the steps of: burning a hydrocarbon fuel or a fuel containing hydrocarbons and alcohol blends in the internal combustion engine thereby to generate exhaust gases from the internal combustion engine containing various amounts of unburned hydrocarbons, carbon monoxide and oxides of nitrogen depending upon operating conditions of the internal combustion engine; and passing said generated exhaust gases over an improved catalyst comprising: a support medium for supporting a catalyst system, said support medium having both an upstream support portion over which exhaust gases initially flow and a downstream support portion over which exhaust gases flow after passing over said upstream support portion thereof;
Claim 10
Dependent Claim
116 words
In a process for treatment of exhaust gases from an internal combustion engine, the steps of: burning a hydrocarbon fuel or a fuel containing hydrocarbons and alcohol blends in the internal combustion engine thereby to generate exhaust gases from the internal combustion engine containing various amounts of unburned hydrocarbons, carbon monoxide and oxides of nitrogen depending upon operating conditions of the internal combustion engine; and passing said generated exhaust gases over an improved catalyst comprising: a support medium for supporting a catalyst system, said support medium having both an upstream support portion over which exhaust gases initially flow and a downstream support portion over which exhaust gases flow after passing over said upstream support portion thereof;
Claim 11
Dependent Claim
133 words
02 to 1.0% by weight of the substrate of finely divided palladium on both said upstream portion and said downstream portion of said suport medium; and on said downstream support portion of said substrate from 2 to 50 times the weight of palladium present on said downstream support portion of said substrate of finely divided tungsten, said tungsten being present on the said downstream portion of said catalyst support medium in a quantity such that tungsten is available to substantially all of said finely divided palladium on the catalyst support medium so that said palladium/tungsten combination is particularly effective in the catalytic oxidation of unburned hydrocarbons and carbon monoxide and the catalytic reduction of oxides of nitrogen without significant production of ammonia when the internal combustion engine is operating under fuel rich conditions.
Claim 12
Dependent Claim
133 words
02 to 1.0% by weight of the substrate of finely divided palladium on both said upstream portion and said downstream portion of said suport medium; and on said downstream support portion of said substrate from 2 to 50 times the weight of palladium present on said downstream support portion of said substrate of finely divided tungsten, said tungsten being present on the said downstream portion of said catalyst support medium in a quantity such that tungsten is available to substantially all of said finely divided palladium on the catalyst support medium so that said palladium/tungsten combination is particularly effective in the catalytic oxidation of unburned hydrocarbons and carbon monoxide and the catalytic reduction of oxides of nitrogen without significant production of ammonia when the internal combustion engine is operating under fuel rich conditions.
Claim 13
Dependent Claim
17 words
The process of claim 7, in which the support media is a gamma alumina coated monolithic substrate.
Claim 14
Dependent Claim
14 words
The process of claim 7, in which the support media is gamma alumina pellets.
Claim 15
Dependent Claim
15 words
The process of claim 7, in which the support media is a washcoated metallic substrate.
Claim 16
Dependent Claim
23 words
The process of claim 7, in which said finely divided tungsten is present from 5 to 20 times the weight of palladium present.
Claim 17
Dependent Claim
16 words
The process of claim 7, in which said upstream support portion also has has molybdenum thereon.
Claim 18
Dependent Claim
177 words
In a process for treatment of exhaust gases from an internal combustion engine, the steps of: burning a hydrocarbon fuel or a fuel containing hydrocarbons and alcohol blends in the internal combustion engine thereby to generate exhaust gases from the internal combustion engine containing various amounts of unburned hydrocarbons, carbon monoxide and oxides of nitrogen depending upon operating conditions of the internal combustion engine; and passing said generated exhaust gases over an improved catalyst comprising: a support medium for supporting a catalyst system, said support medium having both an upstream support portion over which exhaust gases initially flow and a downstream support portion over which exhaust gases flow after passing over said upstream support portion thereof; palladium on said upstream support portion; on said downstream support portion a presynthesized PdWO x (x goes from 1 to 3), said presynthesized palladium/tungsten compound being effective in the catalytic oxidation of unburned hydrocarbons and carbon monoxide and the catalytic reduction of oxides of nitrogen without significant production of ammonia when the internal combustion engine is operating under fuel rich conditions.
Claim 19
Dependent Claim
177 words
In a process for treatment of exhaust gases from an internal combustion engine, the steps of: burning a hydrocarbon fuel or a fuel containing hydrocarbons and alcohol blends in the internal combustion engine thereby to generate exhaust gases from the internal combustion engine containing various amounts of unburned hydrocarbons, carbon monoxide and oxides of nitrogen depending upon operating conditions of the internal combustion engine; and passing said generated exhaust gases over an improved catalyst comprising: a support medium for supporting a catalyst system, said support medium having both an upstream support portion over which exhaust gases initially flow and a downstream support portion over which exhaust gases flow after passing over said upstream support portion thereof; palladium on said upstream support portion; on said downstream support portion a presynthesized PdWO x (x goes from 1 to 3), said presynthesized palladium/tungsten compound being effective in the catalytic oxidation of unburned hydrocarbons and carbon monoxide and the catalytic reduction of oxides of nitrogen without significant production of ammonia when the internal combustion engine is operating under fuel rich conditions.
Claim 20
Dependent Claim
17 words
The process of claim 13, in which the support media is a gamma alunina coated monolithic substrate.
Claim 21
Dependent Claim
14 words
The process of claim 13, in which the support media is gamma alumina pellets.
Claim 22
Dependent Claim
15 words
The process of claim 13, in which the support media is a washcoated metallic substrate.
Claim 23
Dependent Claim
14 words
The process of claim 13, in which said upstream portion also has molybdenum thereon.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1986-02-14 | 1986-08-16 | 1987-02-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-02-14 | 1990-08-16 | 1991-02-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-02-14 | 1994-08-16 | 1995-02-15 | $7700.00 | Window Closed / Lapsed |