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(12) United States Patent (10) Patent No.: US 7,094,730 B2 Labarge Et Al

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(12) United States Patent (10) Patent No.: US 7,094,730 B2 Labarge Et Al US00709473OB2 (12) United States Patent (10) Patent No.: US 7,094,730 B2 LaBarge et al. (45) Date of Patent: Aug. 22, 2006 (54) GAS TREATMENT DEVICE, METHODS FOR 6,605,259 B1 8/2003 Henry MAKING AND USING THE SAME, AND A 6,623,704 B1 9/2003 Roth VEHICLE EXHAUST SYSTEM 6,624,113 B1 9/2003 Labarge et al. 6,643,928 B1 11/2003 Hardesty et al. (75) Inventors: William J. LaBarge, Bay City, MI 6,692,551 B1* 2/2004 Wernholm et al. ............ 95/146 (US); Joachim Kupe, Davisburg, MI 6,774,080 B1* 8/2004 LaBarge et al. ............ 5O2/17O (US); Conrad Anderson, Davison, MI 6,832,473 B1* 12/2004 Kupe et al. ................... 60,286 (US) 2002/0068,679 A1* 6/2002 Yan et al. ..................... 5O2.66 2002/0132727 A1* 9/2002 Labarge et al. ............... 5O2/73 (73) Assignee: Delphi Technologies, Inc., Troy, MI (US) FOREIGN PATENT DOCUMENTS (*) Notice: Subject to any disclaimer, the term of this patent is extended or adjusted under 35 WO WO 96.31434 10, 1996 U.S.C. 154(b) by 475 days. WO WO 98.15500 4f1998 WO WO 98,17389 4f1998 (21) Appl. No.: 10/284,895 WO WO 98.18884 5, 1998 WO WO 98,46353 10, 1998 (22) Filed: Oct. 31, 2002 WO WO 98.48456 10, 1998 WO WO 01/14060 A2 3, 2001 (65) Prior Publication Data US 2004/0O86440 A1 May 6, 2004 OTHER PUBLICATIONS (51) Int. Cl. "Kinetic and Mechanism of Forfmation of Tricalcium Aluminate, BOI. 23/56 (2006.01) Ca3AI2O6, B.M. Mohamed, et al., Article in Press, Oct. 18, 2001, (52) U.S. Cl. ...................................................... SO2/332 10 pages. (58) Field of Classification Search ..................... None Lin-chiuan Yan et al "Synthesis and characterization of aerogel See application file for complete search history. derived cation-substituted barium hexaaluminates' Applied Cataly sis A: General 171 (1998) pp. 219-228. (56) References Cited Sadamori "Application concepts and evaluation of Small-scale U.S. PATENT DOCUMENTS catalytic combustors for natural gas' Catalysis Today 47 (1999) pp. 325-338. 4,962,214. A 10, 1990 Villacorta et al. ... ... 556.33 Johansson et al “Catalytic combustion of gasified biomasses over 5,170,624 A * 12/1992 Cornelison et al. .. ... 60/300 MN-substituted hexaaluminate for gas turbine applications' Cataly 5,179,126 A 1/1993 Wurtman et al. 514,646 sis Today 45 (1998) pp. 159-165. 5,410,876 A * 5/1995 Simko ........ 60,288 Johannson et al “Catalytic combustion of gasified biomass over 5,477,905 A 12/1995 Knapp et al. .. ... 164/61 hexaaluminate catalysts: influence of palladium loading and age 5,512,251 A * 4, 1996 Brunson et al. .. 422,174 ing Applied Catalysis A: General 182 (1999) pp. 199-208. 5,547.467 A 8/1996 Pliquett et al. ... ... 604/20 ArtizZu-Duartetal “Catalytic combustion of methane on substituted 5,565,215 A 10, 1996 Gref et al. ........ ... 424/501 barium hexaaluminates' Catalysis Today 59 (2000) pp. 163-177. 5,567,397 A 10, 1996 Le Gal et al. .... ... 422,192 5,580,533 A 12/1996 Kivioja et al. ........... 423/213.5 ArtizZu-Duart et al "Catalytic combustion of methane over copper 5,633,711 A 5, 1997 Nelson et al. ... 356/318 and manganese-substituted barium hexaaluminates' Catalysis 5,703,001 A 12, 1997 Rizkalla ........... ... 502/.347 Today 54 (1999) pp. 181-190. 5,720,901 A 2/1998 De Jong et al. .. ... 252/.373 Xu et al “Catalytic properties of Ni modified hexaaluminates 5,755,841 A 5/1998 Boucot et al. ............. 48,127.7 LaNiA1, 2010s for CO, reforming of methane to synthesis gas” 5,815,398 A 9/1998 Dighe et al. ........... 364,478.05 Applied Catalysis A: General 198 (2000) pp. 267-273. 5,823,761 A * 10, 1998 Euzen et al. ..................... 43.7 5,830,822 A * 11/1998 Euzen 5O2,355 (Continued) 5,849,659 A * 12/1998 Tanaka et al. .............. 502,324 5,850,734. A * 12/1998 Ketcham ..................... 60,274 Primary Examiner Colleen P. Cooke 5,915,951 A 6/1999 EuZen et al. ................... 431/7 (74) Attorney, Agent, or Firm—Paul L. Marshall 6,159,430 A 12/2000 Foster, et al. 6,242,263 B1* 6/2001 Faber et al. ................ 436/143 (57) ABSTRACT 6,254,842 B1* 7/2001 Hu et al. ................. 423,213.5 6,338,827 B1 1/2002 Nelson 6,354,903 B1 3, 2002 Nelson Gas treatment devices and vehicle exhaust systems are 6,361,821 B1 3/2002 Anderson et al. disclosed herein. In one embodiment, the vehicle exhaust 6,391,822 B1 5, 2002 Dou et al. system, comprises: an engine, a gas treatment device dis 6,438,839 B1 8/2002 Hardesty et al. posed downstream from the engine, the gas treatment device 6,455,463 B1 9/2002 Labarge et al. comprising a housing, a Substrate disposed within the hous 6.464,945 B1 10/2002 Hemingway ing, the Substrate comprising a catalyst and a hexaaluminate 6,464,947 B1 10/2002 Balland comprising a catalyst stabilizer disposed in a hexaaluminate 6,497.847 B1 12/2002 Foster et al. 6,532,659 B1 3/2003 DeSousa et al. crystal structure. 6,544,924 B1 4/2003 Jackson et al. ............. 502,251 6,591497 B1 7/2003 Foster et al. 10 Claims, No Drawings US 7,094.730 B2 Page 2 OTHER PUBLICATIONS -L. Jang etal “Catalytic oxidation of methane over hexaaluminates and hexaaluminate-supported Pd catalysts' Catalysis Today 47 Kikuchi et al "Thick-film coating of hexaaluminate catalyst on (1999) pp. 103-113. ceramic Substrates and its catalytic activity for high-temperature Groppi et al "Preparation, characterization and catalytic activity of methane combustion' Applied Catalysis A: General 218 (2001) pp. pure and Substituted La-Hexaaluminate systems for high tempera 101-111. ture catalytic combustion”. Applied Catalysis B: Enviromental 35 Pocoroba et al "Ageing of palladium, platinum and manganese (2001) pp. 137-148. based combustion catalysts for biogas applications' Catalysis Today Han et al "Synthesis of manganese Substituted hexaaluminate and 59 (2000) pp. 179-189. its fabrication into monolithic honeycombs for catalytic combus Inoue et al "Thick-film coating of hexaaluminate catalyst on tion' Materials Science and Engineering A302 (2001) pp. 286-293. ceramic Substrates for high-temperature combustion' Catalysis Today 47 (1999) pp. 181-190. * cited by examiner US 7,094,730 B2 1. 2 GAS TREATMENT DEVICE, METHODS FOR comprising a crystal stabilizer disposed in a hexaaluminate MAKING AND USING THE SAME, AND A crystalline structure and reducing a concentration of at least VEHICLE EXHAUST SYSTEM one component in the gas. In one embodiment, the method for making a gas treat TECHNICAL FIELD ment device, comprises: disposing a catalyst with a hexaalu minate comprising a crystal stabilizer disposed in a hexaalu The disclosure relates to a gas treatment device, and minate crystalline structure onto a substrate, disposing the especially relates to a gas treatment device comprising a substrate in a housing having an inlet for receiving gas and substrate with a hexaaluminate. an outlet, and disposing a retention material between the 10 housing and the substrate BACKGROUND OF THE INVENTION The above-described and other features will be appreci ated and understood by those skilled in the art from the Gas, e.g., exhaust gas, treatment devices such as catalytic following detailed description, drawings, and appended converters, evaporative emissions devices, hydrocarbon claims. scrubbing devices, diesel particulate traps, non-thermal 15 plasma reactors, and the like, are employed in various DESCRIPTION OF THE PREFERRED applications to physically and/or catalytically treat environ EMBODIMENT mentally unfriendly gas emissions. Such gas treatment devices incorporate a substrate, support, monolith, or brick, Gas treatment devices (otherwise know as exhaust emis which includes a catalyst material coated thereon. A mount sion control devices, such as catalytic converters, nitrogen ing device such as a mat support material comprising an oxide (NOx) adsorbers and converters, sulfur traps, plasma intumescent material, non-intumescent material, or a com reactors (e.g., non-thermal plasma reactors) typically com bination of both, is disposed about the substrate forming a prise a housing disposed around a substrate comprising a mat support material/substrate subassembly. catalyst. Disposed between the housing and the substrate is In order to meet the stringent requirements imposed by 25 a retention material. The device is disposed in an exhaust regulations governing the emission of pollutants, gas treat system of a vehicle, downstream of the engine, in the ment devices are designed such that they can withstand underfloor, close-coupled, or manifold position. In the under higher temperatures over longer periods, e.g., so that they floor position, e.g., downstream from the engine where the can be disposed in a close coupled (e.g., about 12 inches exhaust gas temperatures typically do not exceed about 850° from the manifold) or manifold location where temperatures 30 C. in the device, a catalyst is disposed on ceramic or similar reach and exceed about 1200°C. The catalysts of these gas substrate. In contrast, the close-coupled position (e.g., treatment devices often degrade and their catalytic perfor upstream from the under floor position and near the engine mance is reduced at temperatures greater than 1,000° C. Of manifold where temperatures in the device can reach about the possible causes for this degradation in performance, 900° C.), and the manifold position (e.g., integral with the sintering of the support upon which the catalyst is deposited, 35 engine exhaust manifold where temperatures are typically and sintering of the catalyst’s active phase and/or encapsu about 1,000° C.
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