Gas treatment device, methods for making and using the same, and a vehicle exhaust system
View Patent ↗Gas treatment devices and vehicle exhaust systems are disclosed herein. In one embodiment, the vehicle exhaust system, comprises: an engine, a gas treatment device disposed downstream from the engine, the gas treatment device comprising a housing, a substrate disposed within the housing, the substrate comprising a catalyst and a hexaaluminate comprising a catalyst stabilizer disposed in a hexaaluminate crystal structure.
1. A gas treatment device, comprising:
a housing;
a substrate disposed within the housing, the substrate comprising a coating comprising
a catalyst selected from the group consisting of platinum, palladium, rhodium, ruthenium, iridium, gold, silver, and combinations comprising at least one of these catalysts,
a hexaaluminate comprising a crystal stabilizer disposed in a hexaaluminate crystalline structure, said crystal stabilizer being selected from the group consisting of barium, lanthanum, strontium, ruthenium, and combinations comprising at least one of the foregoing crystal stabilizers; and
a catalyst stabilizer selected from the group consisting of calcium-zirconium oxide, cesium-zirconium oxide, barium-zirconium oxide, and combinations comprising at least one of the foregoing catalyst stabilizers.
2. The gas treatment device of claim 1 , wherein the catalyst comprises platinum.
3. The gas treatment device of claim 1 , wherein the substrate comprises a metal foil.
4. The gas treatment device of claim 1 , wherein the catalyst stabilizer is cesium-zirconium oxide comprising about 10 wt % to about 20 wt % cesium oxide and about 80 wt % to about 90 wt % zirconium oxide, based upon a total weight of the catalyst stabilizer.
5. The gas treatment device of claim 1 , further comprising a retention material disposed between the housing and the substrate.
6. The gas treatment device of claim 1 , wherein the catalyst comprises palladium in an amount of about 25 g/ft 3 to about 40 g/ft 3 , and wherein the crystal stabilizer selected from the group consisting of lanthanum and barium.
7. A gas treatment device, comprising:
a housing;
a metal foil disposed within the housing and comprising a coating, and
a retention material disposed between the housing and the substrate; wherein the coating comprises
a catalyst selected from the group consisting of platinum, palladium, rhodium, ruthenium, iridium, gold, silver, and combinations comprising at least one of these catalysts;
a hexaaluminate comprising a crystal stabilizer disposed in a hexaaluminate crystalline structure, said crystal stabilizer being selected from the group consisting of barium, lanthanum, strontium, ruthenium, and combinations comprising at least one of the foregoing crystal stabilizers; and
a catalyst stabilizer selected from the group consisting of calcium-zirconium oxide, cesium-zirconium oxide, barium-zirconium oxide, and combinations comprising at least one of the foregoing catalyst stabilizers.
8. A vehicle exhaust system, comprising:
an engine;
a gas treatment device disposed downstream from the engine, the gas treatment device comprising a housing, a substrate disposed within the housing, the substrate comprising a coating comprising
a catalyst selected from the group consisting of platinum, palladium, rhodium, ruthenium, iridium, gold, silver, and combinations comprising at least one of these catalysts:
a hexaaluminate comprising a crystal stabilizer disposed in a hexaaluminate crystalline structure, said crystal stabilizer being selected from the group consisting of barium, lanthanum, strontium, ruthenium, and combinations comprising at least one of the foregoing crystal stabilizers; and
a catalyst stabilizer selected from the group consisting of calcium-zirconium oxide, cesium-zirconium oxide, barium-zirconium oxide, and combinations comprising at least one of the foregoing catalyst stabilizers.
9. The vehicle exhaust system of claim 8 , wherein the gas treatment device is located in the manifold position, and the substrate comprises metal foil.
10. The vehicle exhaust system of claim 9 , wherein the gas treatment device is located in the close-coupled position, and the substrate comprises metal foil.