Layered NH3 Adsorption Catalyst for Durable Gasoline Exhaust Purification

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Solution Overview

Problem

Existing catalysts fail to address the challenge of efficiently removing NH3 from gasoline engine exhaust gas in vehicles, which is a challenge in the field of gasoline engines, as they do not meet the stringent NH3 emission regulations due to insufficient NH3 purification performance after endurance.

Innovation Solution

A catalyst body for gasoline engines is designed with a stacked NH3 adsorption layer and a catalyst layer configuration that includes a stacked NH3 adsorption layer and a catalyst layer, with a catalyst layer, which is a catalyst layer, which includes a stacked NH3 adsorption layer and a catalyst layer, with a catalyst layer, which includes a stacked NH3 adsorption layer and a catalyst layer, which includes a stacked NH3 adsorption layer and a catalyst layer, which includes a stacked NH2 adsorption layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If metal-supported zeolite (Cu-CHA) is used as NH3 adsorbent, then NH3 adsorption capacity is improved, but NH3 purification performance after endurance deteriorates

Engineering Contradiction:

ImproveNH3 adsorption capacityVSAvoidNH3 purification performance after endurance

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The NH3 adsorption layer is divided into two distinct regions: a front portion containing metal-supported zeolite (Cu-CHA) for initial NH3 adsorption, and a rear portion containing proton-type zeolite for sustained NH3 purification after endurance. This segmentation allows each region to perform its specialized function optimally.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different zeolite types are placed in different locations within the NH3 adsorption layer. The front portion uses metal-supported zeolite with high initial adsorption capacity, while the rear portion uses proton-type zeolite with superior thermal stability and sustained purification performance, creating local quality variations to address different functional requirements.

Inventive Principle:

Principle #3Local quality

2Device complexity

If single-type zeolite is used in NH3 adsorption layer, then device complexity is reduced, but NH3 purification performance after endurance deteriorates

Engineering Contradiction:

Improvecatalyst layer structureVSAvoidNH3 purification performance after endurance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The NH3 adsorption layer is segmented into front and rear portions with different zeolite compositions. The front portion contains metal-supported zeolite while the rear portion contains proton-type zeolite, allowing the system to achieve high NH3 purification performance after endurance without excessive complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The catalyst body uses a composite structure combining two types of zeolite materials in the NH3 adsorption layer. This composite approach leverages the strengths of both metal-supported zeolite (high initial adsorption) and proton-type zeolite (sustained performance at high temperature) to achieve reliable NH3 purification after endurance.

Inventive Principle:

Principle #40Composite materials

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

This catalyst layer, which is a catalyst for gasoline engines, which is a catalyst for gasoline engines, which includes a catalyst for gasoline engines, which is a catalyst for exhaust gas, which includes a catalyst for exhaust gas, which includes a catalyst for exhaust gas, which absorbs and removes harmful components, which is a catalyst for exhaust gas, which is a catalyst for exhaust gas, which removes harmful components, which is a catalyst for exhaust gas, which is a catalyst for exhaust gas, which removes harmful components.

Implementation Method 1

an NH3 adsorption layer containing zeolite

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

a catalyst layer containing a catalytic noble metal

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentEP4458464B1Gasoline engine exhaust gas purification catalyst and exhaust gas purification system using same

Publication Date: 2026.01.21 CATALER CORP

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AI summary

The present invention provides a catalyst body for purifying an exhaust gas from a gasoline engine which exhibits high NH3 purification performance after endurance. A catalyst body for purifying an exhaust gas from a gasoline engine disclosed here is configured to be disposed in an exhaust path of a gasoline engine. The catalyst body for purifying an exhaust gas includes: a base material; an NH3 adsorption layer containing zeolite; and a catalyst layer containing a catalytic noble metal. The NH3 adsorption layer and the catalyst layer are stacked such that the NH3 adsorption layer is located closer to the base material than the catalyst layer. The NH3 adsorption layer includes a front portion and a rear portion, the front portion being located on an upstream side in an exhaust gas flow direction, a rear portion being located downstream of the front portion in the exhaust gas flow direction, when the catalyst body for purifying an exhaust gas is disposed in the exhaust path. The front portion contains metal-supported zeolite. The rear portion contains proton-type zeolite. The catalyst layer covers the front portion and the rear portion of the NH3 adsorption layer.