Ford Global Technolgoies, LLC

Rachael Jean Harrington

Jeffrey Scott Hepburn

Giovanni Cavataio

Hungwen Jen

Eva Thanasiu

Jason Aaron Lupescu

Lifeng Xu

Paul Matthew Laing

Carolyn Parks Hubbard

Gang Guo

Mark John Jagner

Michael Daniel Shane

Methods are provided for emissions control of a vehicle. In one example, a catalyst may include a cerium-based support material and a transition metal catalyst loaded on the support material, the transition metal catalyst including nickel and copper, wherein nickel in the transition metal catalyst is included in a monatomic layer loaded on the support material. In some examples, limiting nickel to the monatomic layer may mitigate extensive transition metal catalyst degradation ascribed to sintering of thicker nickel washcoat layers. Further, by utilizing the cerium-based support material, side reactions involving nickel in the transition metal catalyst with other support materials may be prevented.

Exhaust treatment system including nickel-containing catalyst

Methods and systems are provided for emissions control of a vehicle. In one example, a catalyst may include a cerium-based support material and a transition metal catalyst loaded on the support material, the transition metal catalyst including nickel and copper, wherein nickel in the transition metal catalyst is included in a monatomic layer loaded on the support material. In some examples, limiting nickel to the monatomic layer may mitigate extensive transition metal catalyst degradation ascribed to sintering of thicker nickel washcoat layers. Further, by utilizing the cerium-based support material, side reactions involving nickel in the transition metal catalyst with other support materials may be prevented.

A hydrocarbon trap catalyst and method of forming the same are disclosed. The method may include introducing copper into a zeolite at 10% to 75% of an ion-exchange level of the zeolite, introducing at least one of nickel and manganese into a zeolite at 50% to 100% total of an ion-exchange level of the zeolite, and applying a three-way catalyst layer. The copper and nickel and/or manganese may be introduced into a single zeolite or the copper may be introduced into a first zeolite layer and the nickel and/or manganese may be introduced into a second zeolite layer. If copper and another metal are introduced into the same zeolite, copper may be introduced first. The disclosed trap catalyst may increase the release temperature of hydrocarbons such as ethanol, propylene and toluene, and thus reduce vehicle cold start tailpipe emissions.

Use of transition metals to reduce cold start emissions

Phosphorus tolerant or resistant three-way catalysts (TWC) are disclosed. The TWC may include a substrate defining a plurality of channels. It may include front and rear washcoat portions overlying the substrate and having respective first and second washcoat loadings, the first washcoat loading being at most 2.0 g/inand less than the second washcoat loading. The front washcoat portion may include a catalyst material supported on a support material comprising a cerium oxide, such as ceria or CZO, or a pre-phosphated material, such as AlPO, or CePO. In one embodiment, the support material may comprise at least 85 wt. % of a cerium oxide or at least 85 wt. % of a phosphate-containing material. The front portion and the underlying substrate may comprise from 3 to 25 vol. % of the three-way catalyst or the front portion may overly up to an initial 15% of an axial length of the substrate.

Phosphorus tolerant catalyst washcoat structure

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South Lyon, MI, United States of America

Rachael Jean Harrington