公开(公告)号：US20210094027A1

公开(公告)日：2021-04-01

申请号：US16970667

申请日：2019-01-25

Applicant: CATALER CORPORATION ,  TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Shunsuke OISHI ,  Takaya OTA ,  Isao CHINZEI ,  Hiromasa SUZUKI ,  Yoshinori SAITO ,  Seiji NAKAHIGASHI

IPC: B01J37/02 ,  B01J23/46 ,  B01J23/10 ,  B01J35/00 ,  F01N3/08

Abstract: The exhaust gas purification catalyst device includes an upper layer which includes first carrier particles and rhodium, and a lower layer which includes second carrier particles, and the upper layer includes a rhodium enriched area in the range a, from the upstream end in the exhaust gas flow to 50% of the upper layer length, and a range b from the upper layer top surface to 18 μm in the depth direction. The rhodium enriched area contains at least 50% and less than 100% of all the rhodium in the upper layer.

公开(公告)号：US20190105637A1

公开(公告)日：2019-04-11

申请号：US16151847

申请日：2018-10-04

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  CATALER CORPORATION

Inventor： Hiromasa SUZUKI ,  Yoshinori SAITO ,  Tatsuya OHASHI ,  Shunsuke OHISHI ,  Takaya OTA

IPC: B01J23/46 ,  B01J23/44 ,  B01J35/00 ,  B01D53/94 ,  F01N3/28

CPC classification number: B01J23/464 ,  B01D53/945 ,  B01D53/9468 ,  B01D2255/1023 ,  B01D2255/1025 ,  B01D2255/2042 ,  B01D2255/407 ,  B01D2255/9022 ,  B01D2255/9025 ,  B01D2255/9032 ,  B01D2255/908 ,  B01J23/44 ,  B01J35/0006 ,  B01J35/0066 ,  F01N3/28 ,  F01N2370/02 ,  F01N2510/06 ,  F01N2510/0682 ,  F01N2510/0684

Abstract: The exemplary embodiments relate to an exhaust gas purification catalyst that is excellent in terms of HC purification capacity and warm-up performance. Such exhaust gas purification catalyst comprises a substrate and a catalyst coating layer formed on the surface of the substrate, wherein the catalyst coating layer comprises an upper and lower layer comprising a lower layer being closer to the surface of the substrate and an upper layer being relatively remote from the surface of the substrate, the upper layer of the catalyst coating layer comprises Rh, Pd, and a carrier, the upper layer of the catalyst coating layer comprises an uppermost surface Pd layer having a Pd concentration relatively higher than that in any other portion in the upper layer within an area extending over a length of 20 mm or more from one end on the upstream side in the downstream direction on the surface of the upper layer, the lower layer of the catalyst coating layer comprises at least one noble metal selected from Pd and Pt and a carrier, and 60% or more of Pd by mass in the uppermost surface Pd layer exists in a layer up to 50% of the upper layer in a thickness direction from the surface of the uppermost surface Pd layer being relatively remote from the surface of the substrate.

公开(公告)号：US20180243728A1

公开(公告)日：2018-08-30

申请号：US15553020

申请日：2016-02-17

Applicant: KABUSHIKI KAISHA TOYOTA CHUO KENKYUSHO ,  TOYOTA JIDOSHA KABUSHIKI KAISHA ,  CATALER CORPORATION

Inventor： Satoru KATOH ,  Toshitaka TANABE ,  Masahide MIURA ,  Hiromasa SUZUKI ,  Hiroaki NAITO ,  Hirotaka ORI ,  Keiichi NARITA ,  Michihiko TAKEUCHI ,  Tatsuya OHASHI

IPC: B01J23/63 ,  B01D53/94 ,  B01J35/02 ,  B01J35/10 ,  B01J37/02 ,  B01J37/08 ,  B01J35/04 ,  F01N3/28

CPC classification number: B01J23/63 ,  B01D53/94 ,  B01D2255/1021 ,  B01D2255/407 ,  B01D2255/9202 ,  B01J35/023 ,  B01J35/026 ,  B01J35/04 ,  B01J35/10 ,  B01J35/1076 ,  B01J35/108 ,  B01J37/0018 ,  B01J37/0036 ,  B01J37/0219 ,  B01J37/0234 ,  B01J37/08 ,  F01N3/28 ,  F01N2330/02 ,  F01N2330/06 ,  F01N2510/068

Abstract: A catalyst for purification of exhaust gas, wherein a substrate and a catalyst coat layer which is formed on a surface of the substrate and which comprises catalyst particles, wherein the catalyst coat layer has an average thickness in a range of 25 to 160 μm, and a void fraction in a range of 50 to 80% by volume as measured by a weight-in-water method, 0.5 to 50% by volume of all voids in the catalyst coat layer consist of high-aspect ratio pores which have equivalent circle diameters in a range of 2 to 50 μm in a cross-sectional image of a cross-section of the catalyst coat layer which the cross-section is perpendicular to a flow direction of exhaust gas in the substrate, and which have aspect ratios of 5 or higher, and the high-aspect ratio pores have an average aspect ratio in a range of 10 to 50.

公开(公告)号：US20220250037A1

公开(公告)日：2022-08-11

申请号：US17610789

申请日：2020-05-11

Applicant: CATALER CORPORATION ,  TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Kana IWATA ,  Minoru ITOU ,  Shunsuke OHISHI ,  Takeru YOSHIDA ,  Hiromasa SUZUKI ,  Masaru KAKINOHANA ,  Satoshi KAMITANI

IPC: B01J23/44 ,  B01J23/10 ,  B01J35/04 ,  F01N3/28 ,  B01D53/94 ,  F01N3/10

Abstract: An exhaust gas purification catalyst device having a substrate and one or more catalytic noble metals supported on the substrate. The substrate has a plurality of cells partitioned by a porous wall 1 and includes ceria-zirconia compound oxide particles. A specific noble metal that is one of the one or more catalytic noble metals satisfies both the following requirements (1) and (2): (1) the noble metal 50% support depth for the specific noble metal is 30% or less of the distance from the surface of the porous wall 1 to the center of the interior of the porous wall 1, and (2) the noble metal 90% support depth for the specific noble metal is 35% or more of the distance from the surface of the porous wall 1 to the center of the interior of the porous wall 1.

公开(公告)号：US20160288096A1

公开(公告)日：2016-10-06

申请号：US15035413

申请日：2014-11-10

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  CATALER CORPORATION

Inventor： Takahiko FUJIWARA ,  Yuki AOKI ,  Hiromasa SUZUKI ,  Isao CHINZEI ,  Yuji YABUZAKI

IPC: B01J23/44 ,  B01J35/00 ,  B01D53/94 ,  B01J23/10

CPC classification number: B01J23/44 ,  B01D53/945 ,  B01D2255/1021 ,  B01D2255/1023 ,  B01D2255/40 ,  B01D2255/407 ,  B01D2255/9022 ,  B01D2255/9032 ,  B01D2255/908 ,  B01J23/002 ,  B01J23/10 ,  B01J23/63 ,  B01J35/0006 ,  B01J35/002 ,  B01J37/0244 ,  B01J37/0248 ,  Y02T10/22

Abstract: Provided is an exhaust gas control catalyst in which a catalyst layer containing at least one of Pd and Pt is formed on a substrate (1), the exhaust gas control catalyst including a first OSC material having a pyrochlore structure and an OSC material whose oxygen storage rate is faster than that of the first OSC material having a pyrochlore structure in a catalyst layer front stage (21) which is in a range from an exhaust gas upstream end of the catalyst layer to a length position which is 50% or lower of a total length of the catalyst layer.

Abstract translation: 本发明提供一种废气控制催化剂，其中在基板（1）上形成有包含Pd和Pt中的至少一种的催化剂层，所述排气控制催化剂包括具有烧绿石结构的第一OSC材料和其储氧 速率比在催化剂层前段（21）中具有烧绿石结构的第一OSC材料的速率快，其范围从催化剂层的废气上游端到50％以下的长度位置 催化剂层的总长度。

公开(公告)号：US20220412244A1

公开(公告)日：2022-12-29

申请号：US17620806

申请日：2020-06-17

Applicant: CATALER CORPORATION ,  TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Kana IWATA ,  Minoru ITOU ,  Takeru YOSHIDA ,  Masaru KAKINOHANA ,  Hiromasa SUZUKI ,  Atsushi TANAKA

IPC: F01N3/28 ,  B01J35/04 ,  B01J23/63 ,  B01J21/04

Abstract: An exhaust gas purification catalyst apparatus has a honeycomb base material and a catalyst noble metal supported by the honeycomb base material, wherein: the honeycomb base material contains ceria-zirconia composite oxide particles as one of the constituent materials, is of a wall flow type, and includes inlet-side cells and outlet-side cells demarcated by porous partition walls; the catalyst noble metal is supported in inlet-side support regions and outlet-side support regions; each of the inlet-side support regions is formed with a specific length from the exhaust gas flow upstream end; the catalyst noble metal 70% support depth is not greater than 50% of the thickness of the porous partition walls; each of the outlet-side support regions is formed with a specific length from the exhaust gas flow downstream end; and the catalyst noble metal 70% support depth is greater than 50% of the thickness of the porous partition walls.

公开(公告)号：US20220339606A1

公开(公告)日：2022-10-27

申请号：US17861320

申请日：2022-07-11

Applicant: CATALER CORPORATION ,  TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Shunsuke OISHI ,  Takaya OTA ,  Yoshinori SAITO ,  Seiji NAKAHIGASHI ,  Isao CHINZEI ,  Hiromasa SUZUKI

IPC: B01J23/63 ,  B01D53/94 ,  B01J35/00 ,  B01J37/02 ,  F01N3/28

Abstract: Methods for exhaust gas purification, including the steps of: attaching an exhaust gas purification catalyst to an exhaust system of an internal combustion engine, and supplying an exhaust gas to the exhaust gas purification catalyst, where the exhaust gas purification catalyst includes an upper layer containing first carrier particles which are particles of an inorganic oxide and rhodium, and a lower layer containing second carrier particles which are particles of an inorganic oxide, the upper layer includes a rhodium-rich portion near the surface of the upper layer on the upstream side of the exhaust gas flow, and the existence range of the rhodium-rich portion is in a range of greater than 50% to 80% of the length of the upper layer from a downstream side end of an exhaust gas flow and of less than 20 μm in the depth direction from an outermost surface of the upper layer.

公开(公告)号：US20180264409A1

公开(公告)日：2018-09-20

申请号：US15534805

申请日：2015-12-11

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  CATALER CORPORATION

Inventor： Hiromasa SUZUKI ,  Takeru YOSHIDA ,  Masahide MIURA ,  Isao CHINZEI ,  Mitsuyoshi OKADA ,  Toshitaka TANABE ,  Akihiko SUDA ,  Hirotaka ORI ,  Akiya CHIBA ,  Kosuke IIZUKA ,  Akira MORIKAWA

IPC: B01D53/94 ,  B01J37/02 ,  B01J37/03 ,  C04B35/488

CPC classification number: B01D53/945 ,  B01D2255/1021 ,  B01D2255/1025 ,  B01D2255/2061 ,  B01D2255/2063 ,  B01D2255/2066 ,  B01D2255/40 ,  B01D2255/407 ,  B01D2255/9032 ,  B01D2255/908 ,  B01D2255/9207 ,  B01D2258/012 ,  B01J23/002 ,  B01J23/63 ,  B01J35/0006 ,  B01J35/002 ,  B01J35/023 ,  B01J37/0201 ,  B01J37/0244 ,  B01J37/0248 ,  B01J37/03 ,  B01J37/038 ,  C01F17/0043 ,  C01G25/02 ,  C01P2002/50 ,  C01P2002/54 ,  C04B35/488 ,  C04B35/6261 ,  C04B2235/3224 ,  C04B2235/3229 ,  C04B2235/3244 ,  C04B2235/443 ,  C04B2235/5436 ,  C04B2235/604 ,  C04B2235/664 ,  C04B2235/76 ,  Y02T10/22

Abstract: The object of the present invention is to provide a high-performance exhaust gas purifying catalyst that can achieve oxygen absorption/release capacity and NOx purification performance. The object is solved by an exhaust gas purifying catalyst, which comprises a ceria-zirconia composite oxide having a pyrochlore-type ordered array structure in the upstream part of the catalyst coating layer, in which the ceria-zirconia composite oxide contains at least one additional element selected from the group consisting of praseodymium, lanthanum, and yttrium at 0.5 to 5.0 mol % of the total cation amount, and has a molar ratio of (cerium+the additional element):(zirconium) of 43:57 to 48:52.

公开(公告)号：US20220212171A1

公开(公告)日：2022-07-07

申请号：US17611390

申请日：2020-05-11

Applicant: CATALER CORPORATION ,  TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Kana IWATA ,  Minoru ITOU ,  Shunsuke OHISHI ,  Takeru YOSHIDA ,  Masaru KAKINOHANA ,  Satoshi KAMITANI ,  Hiromasa SUZUKI

IPC: B01J23/46 ,  F01N3/10 ,  B01J23/42 ,  B01J23/44 ,  B01J35/04 ,  B01J35/00 ,  B01J23/10 ,  B01J37/02 ,  B01J37/08

Abstract: An exhaust gas purification catalytic device includes: a substrate; at least one type of noble-metal catalyst that is supported on the substrate; and a coating layer on the surface of the substrate. The substrate includes a plurality of cells which are demarcated by porous walls. The substrate and the coating layer each include ceria-zirconia composite oxide particles.

公开(公告)号：US20220016601A1

公开(公告)日：2022-01-20

申请号：US17295683

申请日：2019-11-14

Applicant: CATALER CORPORATION ,  TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Shunsuke OHISHI ,  Takaya OTA ,  Ryosuke TAKASU ,  Mitsuyoshi OKADA ,  Minoru ITOU ,  Kana IWATA ,  Takumi TOJO ,  Takeru YOSHIDA ,  Masaru KAKINOHANA ,  Hiromasa SUZUKI

IPC: B01J23/46 ,  B01D53/94 ,  B01J23/10 ,  B01J35/04 ,  B01J37/02 ,  B01J37/04 ,  B01J37/08

Abstract: An exhaust-gas purification apparatus includes: a honeycomb base material including a plurality of exhaust-gas flow paths partitioned by a porous wall; and one or more catalyst noble metals carried by the honeycomb base material. The catalyst noble metals are selected from the group consisting of platinum, palladium, and rhodium. The honeycomb base material has a noble metal concentrated surface section in which a 50%-by-mass noble metal carry depth for a specific noble metal that is one type among one or two catalyst noble metals is less than 50% of the distance from the surface to the center of the inside of the porous wall. The 50%-by-mass noble metal carry depth is the depth at which, when the amount of the specific noble metal carried between the surface and the center of the inside of porous wall is used as a reference, 50% by mass of specific noble metal is carried.