Abstract: The present invention relates to a zoned catalytic article, particularly useful for TWC, which comprises: a) a catalyst composition coat comprising a first zone of the catalyst composition coat, comprising a platinum group metal component consisting of a platinum component supported on a support; and a second zone of the catalyst composition coat, comprising a rhodium component and at least one of a platinum component and a palladium component supported individually or together on a support, and b) a substrate; wherein the first zone and the second zone of the catalyst composition coat are carried on a single piece of substrate or carried on respective pieces of substrate useful for treatment of exhaust gases and an exhaust treatment system comprising the zoned catalytic article. The present invention also relates to an exhaust treatment system comprising the zoned catalytic article.

Abstract: Aspects of the invention pertain to catalytic articles and methods of making catalytic articles comprising a first catalytic coating comprising a platinum group metal, wherein the first catalytic coating is substantially free of Cu, Ni, Fe, Mn, V, Co, Ga, Mo, Mg, Cr and Zn; a second catalytic coating comprising a non-PGM metal, wherein the second catalytic coating is substantially free of any platinum group metal; and one or more substrates, wherein the first catalytic coating is separated from the second catalytic coating, optionally with a barrier layer.

Abstract: Aspects of the invention pertain to catalytic articles and methods of making catalytic articles comprising a first catalytic coating comprising a platinum group metal, wherein the first catalytic coating is substantially free of Cu, Ni, Fe, Mn, V, Co, Ga, Mo, Mg, Cr and Zn; a second catalytic coating comprising a non-PGM metal, wherein the second catalytic coating is substantially free of any platinum group metal; and one or more substrates, wherein the first catalytic coating is separated from the second catalytic coating, optionally with a barrier layer.

Abstract: Exhaust gas treatment substrates, and systems and methods including the same are provided. Catalyst substrates having flow properties where in configuring an outer, peripheral zone, more exhaust gas flows through a central zone as compared to the outer, peripheral zone. The outer, peripheral zone can have a trapping or adsorbing material on surfaces of its passages, or it can have a longer axial length as compared to the inner zone, or its passages can have smaller openings as compared to the inner zone. In one embodiment, an overcoat containing a trapping material such as a hydrocarbon trap is applied to an inlet end. In another embodiment, catalyst having an oxygen storage component is applied to an outlet end.

Abstract: A catalyst material including a catalyst carrier including a porous alumina support and a hindrance layer on the alumina support, the hindrance layer comprising one or more barium sulfate, strontium sulfate, zirconium sulfate, and calcium sulfate is described. The catalyst carrier further includes a rare earth oxide. The catalyst material can further comprise a platinum group metal oxide. The hindrance layer may prevent the rare earth oxide from forming a complex with the support. The catalyst material is useful for methods and systems of abating pollutants from automotive exhaust gas.

Abstract: A catalyst material including a catalyst carrier including a porous alumina support and a hindrance layer on the alumina support, the hindrance layer comprising one or more barium sulfate, strontium sulfate, zirconium sulfate, and calcium sulfate is described. The catalyst carrier further includes a rare earth oxide. The catalyst material can further comprise a platinum group metal oxide. The hindrance layer may prevent the rare earth oxide from forming a complex with the support. The catalyst material is useful for methods and systems of abating pollutants from automotive exhaust gas.

Abstract: A catalyst material including a catalyst carrier including a porous alumina support and a hindrance layer on the alumina support, the hindrance layer comprising one or more of a sulfate, carbonate, hydroxide, or oxide of barium, strontium, or calcium is described. The catalyst carrier further includes a rare earth oxide. The catalyst material can further comprise a platinum group metal. The catalyst material is useful for methods and systems of abating pollutants from automotive exhaust gas.

Abstract: A pliable refractory metal carrier (46) may have coated thereon an anchor layer (47) to improve adherence to the carrier (46) of a catalytic coating (48). The conformable catalyst member (26, 82, 82?, 126, 226, 326) may be bent to conform to a curved or bent exhaust pipe (20, 220, 320) within which it is mounted. The pliable metal carrier may be in the form of a tube such as carrier (46) having perforations (54) formed therein, or it may be a metal strip (76) which is folded into accordion pleats (80) and has perforations (78) formed therein. The perforations (54, 78) serve to permit the passage of exhaust gas therethrough. A series of interior closures (58) and annular baffles (60) may be provided to import a serpentine flow path to gases flowed through an exhaust pipe (22) containing a conformable catalyst member (226) therein. A mounting member (68) may be supplied to fasten one end of the conformable catalyst member (226) to the discharge end of an exhaust pipe (220).

Abstract: Exhaust gas treatment substrates, and systems and methods including the same are provided. Catalyst substrates having flow properties where in configuring an outer, peripheral zone, more exhaust gas flows through a central zone as compared to the outer, peripheral zone. The outer, peripheral zone can have a trapping or adsorbing material on surfaces of its passages, or it can have a longer axial length as compared to the inner zone, or its passages can have smaller openings as compared to the inner zone. In one embodiment, an overcoat containing a trapping material such as a hydrocarbon trap is applied to an inlet end. In another embodiment, catalyst having an oxygen storage component is applied to an outlet end.

Abstract: Provided are methods for manufacturing a base metal undercoat containing catalyst and an exhaust article containing the catalyst. The catalyst contains a base metal undercoat with an oxygen storage component, substantially free of platinum group metal components, and at least one catalytic layer.

Abstract: A layered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. In one or more embodiments, the catalyst comprises three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising palladium deposited on a refractory metal oxide and an oxygen storage component; a second layer deposited on the first layer and comprising rhodium deposited on a refractory metal oxide and an oxygen storage component; and a third layer deposited on the second layer and comprising palladium deposited on a refractory metal oxide.

Abstract: A multilayered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. Provided is a catalytic material of at least four layers in conjunction with a carrier, where each of the layers includes a support, at least three layers comprise a precious metal component, and at least one layer comprises an oxygen storage component (OSC). The catalytic material can further comprise a fifth layer, where at least four layers comprise a precious metal component, at least one layer comprises an oxygen storage component, and at least one layer is substantially free of an oxygen storage component.

Abstract: An emissions treatment catalyst formed using pH-compatible ingredients is disclosed. Engine exhaust treatment systems including such catalysts are also provided. Methods of making and using these catalysts are also provided. Methods include creating precious metal-support composites where the precious metal precursor has a solution pH that is compatible an aqueous slurry pH of the support. In one example, a basic precious metal solution having a pH of 7 or greater is mixed with a promoted refractory metal oxide support having an aqueous slurry pH of 7 or greater. On the other hand, an acidic precious metal solution having a pH of less than 7 is mixed with a promoted refractory metal oxide support having an aqueous slurry pH of less than 7. The mixture of the salt and the promoted refractory metal oxide support can be thermally treated at a temperature of at least 180° C. to thermally fix the well-dispersed precious metal on the support.

Abstract: A layered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. In one or more embodiments, the catalyst comprises three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising palladium deposited on a refractory metal oxide and an oxygen storage component; a second layer deposited on the first layer and comprising rhodium deposited on a refractory metal oxide and an oxygen storage component; and a third layer deposited on the second layer and comprising palladium deposited on a refractory metal oxide.

Abstract: A layered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. Engine exhaust treatment systems including such catalysts are also provided. The catalyst generally comprises three layers in conjunction with a carrier. The three layers comprise two rhodium-containing layers and one palladium-containing layer. The two rhodium layers can be adjacent to each other, or they can be separated by another precious metal-containing layer. At least one of the two layers comprising the rhodium component comprises an oxygen storage component. Methods of making and using these catalysts are also provided.

Abstract: A layered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. In one or more embodiments, the catalyst comprises three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising palladium deposited on a refractory metal oxide and an oxygen storage component; a second layer deposited on the first layer and comprising rhodium deposited on a refractory metal oxide and an oxygen storage component; and a third layer deposited on the second layer and comprising palladium deposited on a refractory metal oxide.

Abstract: A layered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. In one or more embodiments, the catalyst comprises three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising palladium deposited on a refractory metal oxide and an oxygen storage component; a second layer deposited on the first layer and comprising rhodium deposited on a refractory metal oxide and an oxygen storage component; and a third layer deposited on the second layer and comprising palladium deposited on a refractory metal oxide.

Abstract: Provided are methods for manufacturing a base metal undercoat containing catalyst and an exhaust article containing the catalyst. The catalyst contains a base metal undercoat with an oxygen storage component, substantially free of platinum group metal components, and at least one catalytic layer.

Abstract: A multilayered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. Provided is a catalytic material of at least four layers in conjunction with a carrier, where each of the layers includes a support, at least three layers comprise a precious metal component, and at least one layer comprises an oxygen storage component (OSC). The catalytic material can further comprise a fifth layer, where at least four layers comprise a precious metal component, at least one layer comprises an oxygen storage component, and at least one layer is substantially free of an oxygen storage component.

Abstract: A layered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. In one or more embodiments, the catalyst comprises three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising palladium deposited on a refractory metal oxide and an oxygen storage component; a second layer deposited on the first layer and comprising rhodium deposited on a refractory metal oxide and an oxygen storage component; and a third layer deposited on the second layer and comprising palladium deposited on a refractory metal oxide.