Exhaust gas purification material

Patent metadata

Field	Value
Publication number	US-10029209-B2
Application number	US-201415037356-A
Country	US
Kind code	B2
Filing date	Dec 5, 2014
Priority date	Dec 11, 2013
Publication date	Jul 24, 2018
Grant date	Jul 24, 2018

Abstract

An exhaust gas purification material according to the present invention is provided with a particulate filter that traps particulate matter in exhaust gas and contains an SCR catalyst for adsorbing ammonia and reducing NOx in the exhaust gas. A maximum allowable adsorption amount of ammonia adsorbable by the filter differs between an upstream portion of the filter including an exhaust gas inlet-side end, and an downstream portion of the filter including an exhaust gas outlet-side end. A maximum allowable adsorption amount of ammonia A in the upstream portion is smaller than a maximum allowable adsorption amount of ammonia B in the downstream portion (A<B).

First claim

The invention claimed is:

1. An exhaust gas purification material that is disposed in an exhaust passage of an internal combustion engine, and purifies exhaust gas emitted by the internal combustion engine, the exhaust gas purification material comprising:
a particulate filter that traps particulate matter in the exhaust gas and contains an SCR catalyst for adsorbing ammonia and reducing NOx in the exhaust gas,
wherein an upstream portion of the filter including an exhaust gas inlet-side end, and a downstream portion of the filter including an exhaust gas outlet-side end, each contain an SCR catalyst,
a maximum allowable adsorption amount of ammonia adsorbable by the filter differs between the upstream portion and the downstream portion,
a maximum allowable adsorption amount of ammonia A in the upstream portion is smaller than a maximum allowable adsorption amount of ammonia B in the downstream portion (A<B),
a composition of the SCR catalyst in the upstream portion is identical to a composition of the SCR catalyst in the downstream portion, and
a content of the SCR catalyst per L of substrate in the upstream portion is smaller than a content of the SCR catalyst per L of substrate in the downstream portion.

2. The exhaust gas purification material according to claim 1 , wherein a value of ratio (B/A) of the maximum allowable adsorption amount of ammonia A in the upstream portion and the maximum allowable adsorption amount of ammonia B in the downstream portion satisfies 1.1≤(B/A).

3. The exhaust gas purification material according to claim 1 , wherein a value of ratio (B/A) of the maximum allowable adsorption amount of ammonia A in the upstream portion and the maximum allowable adsorption amount of ammonia B in the downstream portion satisfies 1.5≤(B/A).

4. The exhaust gas purification material according to claim 1 ,
wherein the upstream portion includes a portion corresponding to at least 20% of the length of the filter from the exhaust gas inlet-side end of the filter towards the exhaust gas outlet, and
the downstream portion includes a portion corresponding to at least 20% of the length of the filter from the exhaust gas outlet-side end of the filter towards the exhaust gas inlet.

5. The exhaust gas purification material according to claim 1 , wherein the filter includes:
a substrate of wall flow structure, having inlet cells in which only an exhaust gas inflow end is open, outlet cells adjacent to the inlet cells and in which only an exhaust gas outflow end is open, and a porous partition wall that separates the inlet cells and the outlet cells;
an upstream catalyst layer provided within the partition wall in the upstream portion and containing an SCR catalyst; and
a downstream catalyst layer provided within the partition wall in the downstream portion and containing an SCR catalyst,
wherein the upstream catalyst layer is formed in such a manner that 80 mass % or more of the total amount of the SCR catalyst is present in a portion corresponding to up to 80% of the thickness of the partition wall, from a surface of the partition wall in contact with the inlet cells towards the outlet cells, and
the downstream catalyst layer is formed in such a manner that 80 mass % or more of the total amount of the SCR catalyst is present in a portion corresponding to up to 80% of the thickness of the partition wall, from the surface of the partition wall in contact the outlet cells towards the inlet cells.

6. An exhaust gas purification device, comprising:
the exhaust gas purification material according to claim 1 ; and
reducing agent solution supply part for supplying a reducing agent solution for generating ammonia, from upstream of the exhaust gas purification material in the exhaust passage.

Assignees

• Cataler Corp

Inventors

• Tsuji Makoto
• Imai Hiroto
• Kobayashi Shintaro

Classifications

• B01J37/0244

  Coatings comprising several layers · CPC title

• B01J37/0246

  Coatings comprising a zeolite · CPC title

• B01J37/0018

  Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat) · CPC title

• F01N2510/0682

  having a discontinuous, uneven or partially overlapping coating of catalytic material, e.g. higher amount of material upstream than downstream or vice versa · CPC title

• B01J2229/186

  not in framework positions · CPC title