Exhaust gas purification catalyst

Patent metadata

Field	Value
Publication number	US-10076725-B2
Application number	US-201615550078-A
Country	US
Kind code	B2
Filing date	Feb 16, 2016
Priority date	Feb 17, 2015
Publication date	Sep 18, 2018
Grant date	Sep 18, 2018

Abstract

A wall-flow-type exhaust gas purification catalyst with an oxygen storage material that has an increased OSC and exhibits its OSC without a compromise provides an exhaust gas purification catalyst having a wall-flow-type substrate, a first catalytic layer and a second catalytic layer. The first catalytic layer is provided to an internal portion of a partition wall in contact with an entrance cell. The second catalytic layer is provided to an internal portion of a partition wall in contact with an exit cell. Each of the first and second catalytic layers has an oxygen storage material. The ratio (D 1 /D 2 ) of the coating density D 1 of the first catalytic layer to the coating density D 2 of the second catalytic layer is 1.1 to 1.8.

First claim

The invention claimed is:

1. A wall-flow-type exhaust gas purification catalyst to be placed in an exhaust pipe of an internal combustion system to purify exhaust gas emitted from the internal combustion system, the exhaust gas purification catalyst comprising:
a substrate having a wall-flow structure with an exhaust inlet-side end and an exhaust outlet-side end, the substrate having an entrance cell that is open on the exhaust inlet-side end and an exit cell that is open on the exhaust outlet-side end, separated with a porous partition wall,
a first catalytic layer provided to an internal portion of the partition wall in contact with the entrance cell, having a length L 1 from the exhaust inlet-side end in the running direction of the partition wall with L 1 being less than the total length L w of the partition wall in the running direction,
a second catalytic layer provided to an internal portion of the partition wall in contact with the exit cell, having a length L 2 from the exhaust outlet-side end in the running direction of the partition wall with L 2 being less than the total length L w of the partition wall in the running direction; wherein
in the internal portion of the partition wall in contact with the entrance cell, near the exhaust outlet-side end, the exhaust gas purification catalyst has a substrate-exposing segment free of the first and second catalytic layers,
each of the first and second catalytic layers comprises an oxygen storage material, and
the first catalytic layer has a coating density D 1 and the second catalytic layer has a coating density D 2 with a D 1 /D 2 ratio value of 1.1 or higher, but 1.8 or lower.

2. The exhaust gas purification catalyst according to claim 1 wherein D 1 /D 2 is 4 or higher, but 1.7 or lower.

3. The exhaust gas purification catalyst according to claim 1 having an overall average catalyst coating density D A of 40 g/L or greater, but 150g/L or less.

4. The exhaust gas purification catalyst according to claim 1 wherein the first catalytic layer has an oxygen storage material content O 1 per L of the substrate and the second catalytic layer has an oxygen storage material content O 2 per L of the substrate, satisfying O 1 >O 2 .

5. The exhaust gas purification catalyst according to claim 4 having an O 1 to O 2 ratio (O 1 /O 2 ) of 1.4 or higher, but 1.7 or lower.

6. The exhaust gas purification catalyst according to claim 4 wherein the oxygen storage material content O 1 is 30 g/L or greater, but 50 g/L or less; and the oxygen storage material content O 2 is 20 g/L or greater, but 35 g/L or less.

7. The exhaust gas purification catalyst according to claim 1 wherein each of the first catalytic layer and the second catalytic layer comprises the oxygen storage material as a promoter carrying no catalytic metal.

8. The exhaust gas purification catalyst according to claim 1 wherein the first catalytic layer comprises rhodium.

9. The exhaust gas purification catalyst according to claim 1 wherein the second catalytic layer comprises palladium.

10. The exhaust gas purification catalyst according to claim 1 wherein the first and second catalytic layers are formed to partially overlap each other in the running direction, with L w , L 1 and L 2 satisfying the next inequality:
L w <( L 1 +L 2 )<2 L w .

11. The exhaust gas purification catalyst according to claim 1 wherein
the partition wall has a total thickness T W in a direction perpendicular to the running direction of the partition wall,
the first catalytic layer has a thickness T 1 ,
the second catalytic layer has a thickness T 2 , and
the first and second catalytic layers are formed to partially overlap each other in the thickness direction, with T W , T 1 and T 2 satisfying the next inequality:
T W <( T 1 +T 2 )<2 T w .

12. The exhaust gas purification catalyst according to claim 1 , wherein the first catalytic layer and the second catalytic layer are unevenly distributed in the internal portion of the partition wall.

13. The exhaust gas purification catalyst according to claim 1 , wherein
when a partition wall cross section of the first catalytic layer is analyzed under an electron microscope, with the overall coating density over a length 0.1L w from the exhaust inlet-side end in the running direction being 100%, the density distribution of the first catalytic layer present in the inside of the partition wall is 80% or higher, and
when a partition wall cross section of the second catalytic layer is analyzed under an electron microscope, with the overall coating density over a length 0.1L w from the exhaust outlet-side end in the running direction being 100%, the density distribution of the second catalytic layer present in the inside of the partition wall is 80% or higher.

Assignees

• Cataler Corp
• Toyota Motor Co Ltd

Inventors

• Onoe Ryota
• Sakagami Shingo
• Nomura Yasutaka
• Morishita Yuta
• Kuriyama Junji
• Sekine Hiroshi
• Ochiai Daisuke
• Miyoshi Naoto
• Takeuchi Masahiko
• Sato Akemi

Classifications

• B01J23/63

  with rare earths or actinides · CPC title

• B01D2255/908

  O2-storage component incorporated in the catalyst · CPC title

• F01N3/281

  Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates · CPC title

• B01J35/04

  Operations & Transport · mapped topic

• B01D2255/1025

  Rhodium · CPC title