Patents by Inventor Stephen J. Golden
Stephen J. Golden has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 9555400Abstract: Synergized Platinum Group Metals (SPGM) catalyst system for TWC application is disclosed. Disclosed SPGM catalyst system may include a washcoat that includes stoichiometric Cu—Mn spinel structure, supported on doped ZrO2, and an overcoat that includes PGM, such as platinum (Pt) supported on carrier material oxides, such as alumina. SPGM catalyst system shows significant improvement in nitrogen oxide reduction performance under lean and also rich operating conditions. Additionally, disclosed SPGM catalyst system exhibits enhanced catalytic activity for carbon monoxide conversion. Furthermore, disclosed SPGM catalyst systems are found to have enhanced catalytic activity compared to PGM catalyst system, showing that there is a synergistic effect between PGM catalyst, such as Pt, and Cu—Mn spinel within disclosed SPGM catalyst system, which help in activity and thermal stability of disclosed SPGM catalyst.Type: GrantFiled: February 24, 2014Date of Patent: January 31, 2017Assignee: Clean Diesel Technologies, Inc.Inventors: Zahra Nazarpoor, Stephen J. Golden
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Publication number: 20160361711Abstract: The present disclosure describes zero-platinum group metals (ZPGM) material compositions including binary Cu—Mn spinel oxide powders having stable reduction/oxidation (redox) reversibility useful for TWC and oxygen storage material applications. The behavior of Cu—Mn spinel oxide powder is analyzed under oxidation-reduction environments to determine redox reversibility, catalytic activity, and spinel structure stability. Characterization of spinel powder is performed employing X-ray diffraction analysis, hydrogen temperature-programmed reduction technique, transmission electron microscopy analysis, and X-ray photoelectron spectroscopy analysis. Test results confirm the phase and structural stability of the Cu—Mn spinel oxide during redox reaction, thereby indicating that the Cu—Mn spinel oxide can be employed in a plurality of TWC applications.Type: ApplicationFiled: June 14, 2016Publication date: December 15, 2016Inventors: Zahra Nazarpoor, Stephen J. Golden
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Publication number: 20160361710Abstract: The present disclosure describes zero-platinum group metals (ZPGM) material compositions including binary Cu—Mn spinel oxide powders that possess stable reduction/oxidation (redox) reversibility useful for TWC and oxygen storage material (OSM) applications. The redox behavior of Cu—Mn spinel oxide powders is analyzed under oxidation-reduction environments to determine spinel structure stability. The XRD, TPR and XPS analyses confirm the redox stability and reversibility of the Cu—Mn spinel oxide.Type: ApplicationFiled: June 14, 2016Publication date: December 15, 2016Inventors: Zahra Nazarpoor, Stephen J. Golden
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Publication number: 20160354765Abstract: The present disclosure describes support oxides, including include Niobium Oxide, which are employed in three-way catalytic (TWC) systems. Disclosed herein are TWC sample systems that are configured to include a substrate and one or more of a washcoat layer, an impregnation layer, and/or an overcoat layer. The disclosed one or more of washcoat layer and/or overcoat layer are formed using a slurry that includes an oxide mixture and an Oxygen Storage Material. The disclosed oxide mixtures include niobium oxide (Nb2O5), zirconia, and alumina. Further, other disclosed oxide mixtures additionally include NiO.Type: ApplicationFiled: June 5, 2015Publication date: December 8, 2016Inventors: Randal L. Hatfield, Zahra Nazarpoor, Johnny T. Ngo, Stephen J. Golden
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Patent number: 9511355Abstract: Synergies resulting from combinations of catalyst systems including Copper-Manganese material compositions and PGM catalysts are disclosed. Variations of catalyst system configurations are tested to determine most effective material composition, formulation, and configuration for an optimal synergized PGM (SPGM) catalyst system. The synergistic effect of the selected SPGM catalyst system is determined under steady state and oscillating test conditions, from which the optimal NO/CO cross over R-value indicates enhanced catalytic behavior of the selected SPGM catalyst system as compared with current PGM catalysts for TWC applications. According to principles in the present disclosure, application of Pd on alumina-based support as overcoat and Cu—Mn spinel structure supported on Nb2O5—ZrO2 as washcoat on suitable ceramic substrate, produce higher catalytic activity, efficiency, and better performance in TWC condition, especially under lean condition, than commercial PGM catalysts.Type: GrantFiled: November 26, 2013Date of Patent: December 6, 2016Assignee: Clean Diesel Technologies, Inc. (CDTI)Inventors: Zahra Nazarpoor, Stephen J. Golden
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Patent number: 9511358Abstract: Spinels having a general formula of AB2O4, where A and B are a transition metal but not the same transition metal are disclosed. Spinel and spinel compositions of the application are useful in various applications and methods as further described.Type: GrantFiled: September 30, 2014Date of Patent: December 6, 2016Assignee: Clean Diesel Technologies, Inc.Inventors: Zahra Nazarpoor, Stephen J. Golden
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Patent number: 9511350Abstract: Diesel oxidation ZPGM catalyst systems are disclosed. ZPGM catalyst systems may oxidize toxic gases, such as carbon monoxide, hydrocarbons and nitrogen oxides that may be included in exhaust gases. ZPGM catalyst systems may include: a substrate, a washcoat, and an impregnation layer. The washcoat may include at least one carrier material oxides. The impregnation layer may include at least one ZPGM catalyst, carrier material oxides and OSMs. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems.Type: GrantFiled: May 10, 2013Date of Patent: December 6, 2016Assignee: Clean Diesel Technologies, Inc. (CDTI)Inventors: Zahra Nazarpoor, Stephen J. Golden
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Publication number: 20160346765Abstract: Sulfur-resistant synergized platinum group metals (SPGM) catalysts with significant oxidation capabilities are disclosed. Catalytic layers of SPGM catalyst samples are prepared using conventional synthesis techniques to build a washcoat layer completely or substantially free of PGM material. The SPGM catalyst includes a washcoat layer comprising YMn2O5 (pseudobrookite) and an overcoat layer including a Pt/Pd composition with total PGM loading of at or below 5.0 g/ft3. Resistance to sulfur poisoning and catalytic stability is observed under 5.2 gS/L condition to assess significant improvements in NO oxidation, and HC and CO conversions.Type: ApplicationFiled: June 1, 2015Publication date: December 1, 2016Applicant: CLEAN DIESEL TECHNOLOGIES, INC.Inventors: Zahra Nazarpoor, Stephen J. Golden
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Patent number: 9486783Abstract: A diesel oxidation catalyst (DOC) system for the treatment of exhaust gas emissions, including oxidation of nitrogen oxides (NO), unburned hydrocarbons (HC), and carbon monoxide (CO) is disclosed. Fresh and hydrothermally aged Zero-PGM (ZPGM) DOC samples are prepared and configured with an alumina-based washcoat on ceramic substrate, overcoat including doped Zirconia support oxide, and impregnation layer of Cu—Mn spinel of selected base metal loadings. Testing of fresh and hydrothermally aged ZPGM DOC system samples including Cu—Mn spinel is developed to evaluate the performance of Cu—Mn spinel active phase in oxidation CO, HC, and NO, as well as production of NO2. Key to improvement in light-off performance and NO oxidation is to have a diesel oxidation catalyst that is substantially PGM-free and available for a plurality of applications in lean burn engine operations.Type: GrantFiled: April 11, 2014Date of Patent: November 8, 2016Assignee: Clean Diesel Technologies, Inc. (CDTI)Inventors: Zahra Nazarpoor, Stephen J. Golden
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Patent number: 9486784Abstract: The effect of aging temperature on oxygen storage materials (OSM) substantially free from platinum group (PGM) and rare earth (RE) metals is disclosed. Samples of ZPGM-ZRE metals OSM, hydrothermally aged at a plurality of high temperatures are found to have significantly high oxygen storage capacity (OSC) and phase stability than conventional PGM catalysts with Ce-based OSM. ZPGM-ZRE metals OSM includes a formulation of Cu—Mn stoichiometric spinel structure deposited on Nb—Zr oxide support and may be converted into powder to be used as OSM application or coated onto catalyst substrate. ZPGM-ZRE metals OSM, after aging condition, presents enhanced level of thermal stability and OSC property which shows improved catalytic activity than conventional PGM catalysts including Ce-based OSM. ZPGM-ZRE metals OSM may be suitable for a vast number of applications, and more particularly in underfloor catalyst systems.Type: GrantFiled: July 17, 2014Date of Patent: November 8, 2016Assignee: Clean Diesel Technologies, Inc.Inventors: Zahra Nazarpoor, Stephen J. Golden
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Publication number: 20160312730Abstract: Modified calibration strategies for controlling an internal combustion engine and monitoring catalyst performance are disclosed. The modified calibration strategies are implemented using an engine and test cell/catalyst chamber setup wherein the engine is a Euro V 1.2 L turbo gasoline direct injection engine and test cells/catalyst chamber are implemented as substantially free of platinum group metals (PGM) catalysts, herein referred as ZPGM catalysts, and synergized PGM (SPGM) catalysts including a stoichiometric spinel structure within the catalyst configuration. The utilization of an open ECU enables the modified calibration of the engine out targeted AFR. The conventional ECU AFR control strategies are not modified to have the ECU AFR control strategies to continue running normally and only the final engine out targeted AFR values are modified by applying offset AFR values.Type: ApplicationFiled: April 21, 2015Publication date: October 27, 2016Applicant: CLEAN DIESEL TECHNOLOGIES, INC.Inventors: Maxime Launois, Zahra Nazarpoor, Stephen J. Golden
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Patent number: 9475005Abstract: Three way catalysts (TWCs) for catalyst systems are disclosed. The disclosed TWC systems include Iron (Fe)-activated Rhodium (Rh) and Barium (Ba)-Palladium (Pd) layers capable of interacting with conventional and/or non-conventional catalyst supports and additives. Variations of TWC system samples are produced including Fe-activated Rh layers deposited onto a washcoat (WC) layer having one or more of an oxygen storage material (OSM). Other TWC system samples are produced including an impregnation (IMPG) layer having loading variations of Ba within a Pd, Ce, and Nd applied onto an OSM WC layer, and a further overcoat layer including Fe-activated Rh is applied onto the IMPG layer. The catalytic performance of disclosed TWC catalysts is evaluated by performing a series of light-off tests, wide pulse perturbation tests, and standard isothermal oxygen storage capacity oscillating tests. Disclosed TWC catalysts exhibit high catalytic performance and significant oxygen storage capacity.Type: GrantFiled: June 5, 2015Date of Patent: October 25, 2016Assignee: Clean Diesel Technologies, Inc.Inventors: Randal L. Hatfield, Edward J. Lee, Johnny T. Ngo, Stephen J. Golden
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Patent number: 9475004Abstract: The present disclosure describes rhodium iron catalysts of use in catalyst systems. Disclosed here are TWCs configured to include a substrate and one or more of a washcoat layer, an impregnation layer, and/or an overcoat layer. Disclosed herein are one or more of a washcoat layer and/or an overcoat layer formed using a slurry that includes one or more of an oxygen storage material, a refractory support oxide, iron, and rhodium. Disclosed herein are methods of preparing catalysts wherein a washcoat layer is deposited onto the substrate, one or more impregnation layers may be deposited onto the washcoat layer, one or more overcoat layers may be deposited onto the impregnation washcoat layer, and one or more additional impregnation layers may be deposited onto the one or more washcoat layers.Type: GrantFiled: June 5, 2015Date of Patent: October 25, 2016Assignee: Clean Diesel Technologies, inc.Inventors: Randal L. Hatfield, Stephen J. Golden, Johnny T. Ngo
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Patent number: 9468912Abstract: Variations of ZPGM bulk powder catalyst materials, including Cu—Co—Mn ternary spinel systems for TWC applications are disclosed. Bulk powder catalyst samples are prepared employing a plurality of molar ratio variations, including disclosed Cu—Co—Mn spinel on Praseodymium-Zirconia support oxide made by incipient wetness method, or Cu—Co—Mn spinel on Niobium-Zirconia support oxide, which may be synthesized by co-precipitation method. A plurality of bulk powder catalyst samples may be tested by performing isothermal steady state sweep test, employing a flow reactor at inlet temperature of about 450° C., and testing a gas stream from lean to rich condition and influence on TWC performance measured/analyzed, which may lead into significant improvements in the manufacturing of ZPGM bulk powder catalyst materials for TWC applications.Type: GrantFiled: November 17, 2014Date of Patent: October 18, 2016Assignee: Clean Diesel Technologies, Inc.Inventors: Zahra Nazarpoor, Oguzhan Selim Yaglidere, Stephen J. Golden
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Publication number: 20160279611Abstract: The invention generally relates to three-way catalysts and catalyst formulations capable of simultaneously converting nitrogen oxides, carbon monoxide, and hydrocarbons into less toxic compounds. Such three-way catalyst formulations contain ZrO2-based mixed-metal oxide support oxides doped with an amount of lanthanide. Three-way catalyst formulations with the support oxides of the present invention demonstrate higher catalytic activity, efficiency and longevity than comparable catalysts formulated with traditional support oxides.Type: ApplicationFiled: March 26, 2015Publication date: September 29, 2016Applicant: CLEAN DIESEL TECHNOLOGIES, INC.Inventors: Stephen J. Golden, Randal Hatfield, Jason D. Pless, Johnny T. Ngo
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Publication number: 20160263561Abstract: Variations of ZPGM catalyst material compositions including cerium-cobalt spinel oxide systems for ZPGM DOC applications are disclosed. The disclosed ZPGM catalyst compositions include CexCo3?xO4 spinel and effect of adding copper to Ce-Co as CuxCe1?xCo2O4 spinel systems supported on doped zirconia support oxide, which are produced by the incipient wetness (IW) methodology. ZPGM catalyst compositions are subjected to BET-surface area and XRD analyses to determine the thermal stability and spinel phase formation of supported spinal systems, respectively. DOC performance of ZPGM catalyst compositions is determined under steady state DOC light off test condition to verify/compare oxidation activity of disclosed spinel compositions, desirable and suitable for ZPGM catalyst materials in DOC applications.Type: ApplicationFiled: March 13, 2015Publication date: September 15, 2016Applicant: Clean Diesel Technologies, Inc.Inventors: Zahra Nazarpoor, Stephen J. Golden
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Publication number: 20160263526Abstract: Synergized PGM catalyst converters configured as three-way catalyst (TWC) systems are disclosed. The disclosed SPGM system configurations exhibit high thermal stability, attenuated air to fuel (A/F) perturbations, enhanced TWC activity, and high catalytic conversion efficiency as a result of synergizing a low PGM loading close-coupled catalyst (CCC), with Ce-based oxygen storage, with a front spinel zone of suitable mixed metal oxide compositions acting as pre-catalyst for oxygen storage. The attenuation of A/F perturbations to lower amplitude, before exhaust gas emissions go into the standard PGM CCC, allows the system to work within a range of R values very close to the stoichiometric point for both lean and rich conditions, and high catalytic conversion efficiency in NOX, CO, and HC conversions. The disclosed SPGM system configurations can be utilized in a plurality of TWC applications, such as conventional TWC systems including an optional underfloor catalyst.Type: ApplicationFiled: March 13, 2015Publication date: September 15, 2016Applicant: CLEAN DIESEL TECHNOLOGIES, INC.Inventor: Stephen J. Golden
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Patent number: 9427730Abstract: Bimetallic Synergized Platinum Group Metals (SPGM) catalyst systems for TWC application are disclosed. Disclosed bimetallic SPGM catalyst systems may include a washcoat with a Cu—Mn spinel structure and an overcoat that includes PGMs, such as Pd/Rh or Pt/Rh supported on carrier material oxides, such as alumina. Bimetallic SPGM catalyst systems show significant improvement in nitrogen oxide reduction performance under lean operating conditions, which allows a reduced consumption of fuel. Additionally, disclosed bimetallic SPGM catalyst systems exhibit enhanced catalytic activity for carbon monoxide conversion. Furthermore, bimetallic SPGM catalyst systems are found to have enhanced catalytic activity for fresh, hydrothermally aged and fuel cut aged conditions compared to PGM catalyst system, showing that there is a synergistic effect between PGM catalyst and Cu—Mn spinel within the disclosed SPGM catalyst system which help in performance and thermal stability of disclosed SPGM catalyst systems.Type: GrantFiled: November 17, 2014Date of Patent: August 30, 2016Assignee: Clean Diesel Technologies, Inc.Inventors: Zahra Nazarpoor, Stephen J. Golden
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Publication number: 20160167024Abstract: Synergized Platinum Group Metals (SPGM) catalyst system for TWC application is disclosed. Disclosed SPGM catalyst system may include a washcoat that includes Cu—Mn spinel structure, supported on doped ZrO2, and an overcoat that includes PGM, such as Rhodium (Rh) supported on carrier material oxides, such as alumina. SPGM catalyst system shows significant improvement in nitrogen oxide reduction performance under lean and also rich operating conditions. Furthermore, disclosed SPGM catalyst systems are found to have enhanced fresh and aged catalytic activity compared to PGM catalyst system, showing that there is a synergistic effect between PGM catalyst, such as Rh, and Cu—Mn spinel within disclosed SPGM catalyst system, which help in activity and thermal stability of disclosed SPGM catalyst.Type: ApplicationFiled: December 16, 2014Publication date: June 16, 2016Applicant: CLEAN DIESEL TECHNOLOGIES, INC.Inventors: Zahra Nazarpoor, Stephen J. Golden
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Publication number: 20160167023Abstract: Variations of bulk powder catalyst materials, including a plurality of formulations for stoichiometric and non-stoichiometric Co_Mn—Fe spinel and Cu—Mn—Fe spinel, which may be prepared by incipient wetness method, employing variations of molar ratio and general formulation (CoxFezMn2z)3-?O4, and Co1-xMnxFe2O4 spinel supported on doped ZrO2 support oxide. According to principles in present disclosure, a plurality of formulations for fine grain bulk powder compositions of Cu—Mn—Fe spinel with general formulation of CuxMnyFezO4, may provide solutions for enhanced NOx, CO, and HC conversion performance for TWC applications, employing ZPGM materials for a plurality of TWC applications. Additionally, these types of ternary ZPGM fine grain bulk powder spinel compositions may have a cost effective manufacturing advantage.Type: ApplicationFiled: December 11, 2014Publication date: June 16, 2016Applicant: Clean Diesel Technologies, Inc.Inventors: Zahra Nazarpoor, Oguzhan S. Yaglidere, Stephen J. Golden