Exhaust gas catalyst and method of manufacturing same

Abstract

The present invention involves an exhaust gas catalyst and method of manufacturing same. The invention provides for a cost-effective material which lowers the cold-start emissions from the exhaust of vehicles. The invention is a passive system which accelerates the light-off temperature of catalyst in a cost-effective fashion. The invention includes a method of manufacturing an exhaust gas catalyst capable of lowering cold-start emissions including the steps of providing an oxide mixture having praseodymium and cerium, doping about 0-10% weight zirconium and about 0-10% weight yttrium to the oxide mixture, adding about 0-2% weight metal including palladium, platinum, or rhodium to the oxide mixture, mixing gamma aluminum to the oxide mixture for washcoating and washcoating the oxide mixture onto a monolithic substrate.

Description

[0001] This invention relates to an exhaust gas catalyst capable of lowering cold-start emissions and a method of manufacturing the exhaust gas catalyst.[0002] The need to lower vehicle exhaust emissions continues to create challenges, especially in the wake of stringent environmental regulations. The need to lower cold-start emissions is at the heart of most emissions reduction strategy, since cold-start emissions account for a significant portion of exhaust emissions from any given vehicle. During startup, hydrocarbons can be passed through the exhaust system before the catalyst can heat up and convert the hydrocarbons to more desirable gases. Although a large portion of hydrocarbons are reduced, an amount of hydrocarbons and other undesirable gases may be allowed to pass through the exhaust system without reduction thereof.[0003] One solution to the cold-start emission problem is providing a material that is able to give off oxygen to the catalyst during startup conditions such t...

AI Technical Summary

Benefits of technology

[0008] Accordingly it is an object of the present invention to provide a cost effective material which lowers the cold-start emissions from the exhaust of vehicles.

[0009] It is another object of the present invention to provide a passive system which accelerates the light-off temperature of catalysts in a cost-effective fashion.

[0010] Yet another object of this invention is to provide a method of manufacturing an exhaust gas catalyst capable of lowering cold-start emissions through a three-way catalyst including mixed metal oxides.

Problems solved by technology

The need to lower vehicle exhaust emissions continues to create challenges, especially in the wake of stringent environmental regulations.

However, palladium is an extremely expensive material which typically contributes to approximately 95% of the total cost of the catalyst.

Generally, systems that incorporate additional hardware, such as the examples mentioned above, result in high costs for implementation.

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