Particulate filter provided with catalyst and method for manufacturing said filter

Patent metadata

Field	Value
Publication number	US-10105627-B2
Application number	US-201515305423-A
Country	US
Kind code	B2
Filing date	May 14, 2015
Priority date	Aug 25, 2014
Publication date	Oct 23, 2018
Grant date	Oct 23, 2018

Abstract

A catalyst 20 provided for a filter body for combusting PM contains activated aluminas 21 and 22 , active-oxygen-release materials 23 and 24 , catalytic metal 25 , and alkali earth metal 26 . The alkali earth metal 26 is loaded on each of the activated aluminas 21 and 22 , and the active-oxygen-release materials 23 and 24 . A percentage by mass of the alkali earth metal 26 , loaded on the active-oxygen-release materials 23 and 24 , to the active-oxygen-release material is smaller than a percentage by mass of the alkali earth metal 26 , loaded on the activated aluminas 21 and 22 , to the activated alumina.

First claim

The invention claimed is:

1. A particulate filter comprising:
a filter body configured to collect particulates included in exhaust gas;
an exhaust gas pathway wall included in the filter body; and
a catalyst provided for the exhaust gas pathway, and configured to combust the particulates, wherein
the catalyst contains activated alumina, an active-oxygen-release material, catalytic metal, and alkali earth metal, the active-oxygen-release material including at least one oxide taking in oxygen included in the exhaust gas and releasing the oxygen taken in as active oxygen,
the alkali earth metal is loaded on each of the activated alumina and the active-oxygen-release material,
a percentage by mass of the alkali earth metal, loaded on the active-oxygen-release material, to the active-oxygen-release material is 1% by mass or smaller, and smaller than a percentage by mass of the alkali earth metal, loaded on the activated alumina, to the activated alumina,
the active-oxygen-release material includes a Ce-containing composite oxide and a Ce-free Zr-based composite oxide,
an amount of the alkali earth metal loaded on the activated alumina is greater than a total amount of the alkali earth metal loaded on the Ce-containing composite oxide and the Ce-free Zr-based composite oxide.

2. The particulate filter of claim 1 wherein
a percentage by mass of the alkali earth metal, loaded on the activated alumina, to the activated alumina ranges from 3% by mass to 14% by mass.

3. The particulate filter of claim 1 , wherein
the alkali earth metal includes at least Sr.

4. The particulate filter of claim 1 , wherein
the catalytic metal includes at least one of Pt or Pd.

5. The particulate filter of claim 1 , wherein
the catalyst further includes a binder finer than particles of the activated alumina, and the alkali earth metal is loaded on each of the activated alumina, the active-oxygen-release material, and the binder, and
a total amount of the alkali earth metal, loaded on each of the activated alumina and the binder, is 90% by mass or greater of a full amount of the alkali earth metal included in the catalyst.

6. The particulate filter of claim 5 , wherein
a percentage of the loaded alkali earth metal to the activated alumina ranges from 2% by mass to 7.8% by mass, and
a percentage of the loaded alkali earth metal to the binder ranges from 1.1% by mass to 17.1% by mass.

7. The particulate filter of claim 5 , wherein
a percentage of an amount of the alkali earth metal, loaded on the activated alumina, in the total amount of the alkali earth metal loaded on each of the activated alumina and the binder ranges from 24% by mass to 95% by mass.

8. The particulate filter of claim 1 , wherein
a percentage of an amount of the alkali earth metal, loaded on the activated alumina, in the total amount of the alkali earth metal loaded on each of the activated alumina and the binder ranges from 24% by mass to 95% by mass.

9. A method for manufacturing the particulate filter of claim 1 , comprising:
loading the alkali earth metal on the activated alumina;
forming slurry which is a mixture of the activated alumina loaded with the alkali earth metal and the active-oxygen-release material, such that a portion of the alkali earth metal, dissolving from the activated alumina in the slurry, is loaded on the active-oxygen-release material;
coating the filter body with the slurry; and
loading the catalytic metal either on the activated alumina and the active-oxygen-release material before the forming of the slurry, or on a coating layer formed when the filter body is coated with the slurry.

10. The method for manufacturing the particulate filter of claim 9 , wherein
the preparing further includes preparing a binder finer than particles of the activated alumina,
the alkali earth metal is loaded on each of the activated alumina and the binder, and
in the forming, the slurry is a mixture of the activated alumina loaded with the alkali earth metal, the binder loaded with the alkali earth metal, and the active-oxygen-release material.

Assignees

• Mazda Motor

Inventors

• Takizawa Tomoya
• Harada Koichiro
• Baba Takashi

Classifications

• B01J37/0215

  Coating · CPC title

• B01D2255/9155

  Wall flow filters · CPC title

• B01D2255/204

  Alkaline earth metals · CPC title

• B01D46/0027

  with additional separating or treating functions · CPC title

• F01N3/035

  with catalytic reactors · CPC title