Composite Oxide Catalyst for Low-Temperature PM Combustion

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Solution Overview

Problem

Existing particulate matter combustion catalysts for exhaust gases require expensive platinum group elements and suffer from high production costs and decreased combustion efficiency at high temperatures.

Innovation Solution

A composite oxide catalyst comprising cerium, lanthanum, and a third metal, such as manganese or praseodymium, with specific mole percentages, which lowers the oxidation starting temperature of particulate matter without using expensive materials, and is integrated into a porous composite structure for efficient exhaust gas filtration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If platinum group elements are used in particulate matter combustion catalysts, then combustion efficiency is improved, but production cost increases

Engineering Contradiction:

Improvecombustion efficiencyVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive platinum group elements with cheaper alternative materials (metal oxides and organic compounds) that can achieve comparable combustion efficiency. This substitution directly addresses the contradiction by using cost-effective materials while maintaining the required catalytic performance for particulate matter combustion.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the chemical composition parameters of the catalyst by using specific ratios of metal oxides (such as CeO2, La2O3, MnO2) and organic compounds. By optimizing these compositional parameters, the catalyst achieves high combustion efficiency without relying on expensive platinum group elements, thus resolving the cost-efficiency contradiction.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If high temperature durability testing is performed, then catalyst stability is improved, but PM combustion rate decreases

Engineering Contradiction:

Improvecatalyst stabilityVSAvoidPM combustion rate

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent employs composite materials consisting of multiple metal oxides (CeO2, La2O3, MnO2, etc.) combined with organic compounds. This composite structure provides both thermal stability for high-temperature durability and maintained combustion rate by leveraging the synergistic effects of different materials that preserve catalytic activity even after high-temperature exposure.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent optimizes the compositional parameters and physical structure of the catalyst to achieve a balance between stability and activity. By controlling the ratios of metal oxides and organic compounds, and optimizing particle size and surface area, the catalyst maintains high PM combustion rates while achieving sufficient thermal stability.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If oxidation starting temperature is lowered, then particulate matter combustion efficiency is improved, but catalyst material requirements become more stringent

Engineering Contradiction:

Improvecombustion efficiencyVSAvoidcatalyst material requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent achieves low oxidation starting temperature by carefully controlling the compositional parameters of the catalyst. The specific ratios of metal oxides (such as 40-80 wt% CeO2, 10-30 wt% La2O3, 5-20 wt% MnO2) and organic compounds are optimized to maximize catalytic activity at low temperatures, thereby improving combustion efficiency without excessive material complexity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses readily available and inexpensive metal oxides and organic compounds instead of rare or expensive materials. This approach lowers the oxidation starting temperature through clever material selection and composition optimization rather than using complex or expensive catalyst formulations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composite oxide catalyst effectively reduces the oxidation starting temperature of particulate matter, lowers production costs, and enhances the filtration efficiency of particulate matter in exhaust gases, making it suitable for use in gasoline and diesel engines.

Implementation Method 1

a composite oxide catalyst which includes cerium that is a first metal, lanthanum that is a second metal, and a third metal as contained metals

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

a porous composite including the composite oxide catalyst

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS11904298B2Composite oxide catalyst, porous composite, and method of producing composite oxide catalyst

Publication Date: 2024.02.20 NGK INSULATORS LTD

AI summary

A composite oxide catalyst includes Ce that is a first metal, La that is a second metal, and a third metal as contained metals. The third metal is a transition metal, or a rare-earth metal other than Ce and La. A Ce content in the contained metals is higher than or equal to 5 mol % and lower than or equal to 95 mol %. An La content in the contained metals is higher than or equal to 2 mol % and lower than or equal to 93 mol %. A content of the third metal in the contained metals is higher than or equal to 2 mol % and lower than or equal to 93 mol %.