Exhaust gas purification catalyst

Patent metadata

Field	Value
Publication number	US-10159934-B2
Application number	US-201615550070-A
Country	US
Kind code	B2
Filing date	Feb 16, 2016
Priority date	Feb 17, 2015
Publication date	Dec 25, 2018
Grant date	Dec 25, 2018

Abstract

Provided is an exhaust gas purification catalyst that combines reduction of pressure loss and enhancement of purification performance. This invention provides an exhaust gas purification catalyst comprising a wall-flow-type substrate and first and second catalytic layers. The first catalytic layer is provided to the interior of a partition wall, in contact with an entrance cell, from an exhaust inlet-side end in the running direction, having a length L 1 less than Lw. The second catalytic layer is provided to the interior of a partition wall, in contact with an exit cell, from an exhaust outlet-side end in the running direction, having a length L 2 less than Lw. An internal portion of partition wall in contact with entrance cell has a substrate-exposing segment near the exhaust outlet-side end.

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 Lw 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 Lw 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.

2. The exhaust gas purification catalyst according to claim 1 wherein the substrate-exposing segment is provided to an internal portion of the partition wall in contact with the entrance cell, having a length L 3 from the exhaust outlet-side end in the running direction of the partition wall, with Lw and L 3 satisfying 0.2Lw≤L 3 ≤0.4Lw.

3. The exhaust gas purification catalyst according to claim 1 wherein the partition wall has a total thickness Tw in the thickness direction perpendicular to the running direction, and the substrate-exposing segment has a thickness T 3 , satisfying 0.4Tw≤T 3 .

4. The exhaust gas purification catalyst according to claim 1 wherein 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 1.3 or higher, but 1.6 or lower.

5. The exhaust gas purification catalyst according to claim 1 wherein the first catalytic layer and the second catalytic layer are formed, partially overlapping in the running direction, so that Lw, L 1 and L 2 satisfy 1.005Lw≤(L 1 +L 2 )≤1.3Lw.

6. The exhaust gas purification catalyst according to claim 1 wherein Lw and L 2 satisfy 0.4Lw≤L 2 ≤0.8Lw.

7. The exhaust gas purification catalyst according to claim 1 wherein
the partition wall has a total thickness Tw in the thickness direction perpendicular to the running direction,
the first catalytic layer has a thickness T 1 satisfying 0.4Lw≤T 1 ≤0.6Tw, and
the second catalytic layer has a thickness T 2 , satisfying 0.4Tw≤T 2 ≤0.6Tw.

8. The exhaust gas purification catalyst according to claim 1 wherein
the first catalytic layer comprises alumina, and
with the total non-volatile content of the first catalytic layer being 100% by mass, the alumina accounts for 15% to 50% by mass.

9. The exhaust gas purification catalyst according to claim 1 wherein
the first catalytic layer comprises cerium, and
with the total non-volatile content of the first catalytic layer being 100% by mass, the cerium accounts for 5% to 35% by mass.

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

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

12. The exhaust gas purification catalyst according to claim 1 wherein
the second catalytic layer comprises alumina, and
with the total non-volatile content of the second catalytic layer being 100% by mass, the alumina accounts for 20% to 65% by mass.

13. The exhaust gas purification catalyst according to claim 1 wherein
the second catalytic layer comprises cerium, and
with the total non-volatile content of the second catalytic layer being 100% by mass, the cerium accounts for 2% to 30% by mass.

14. The exhaust gas purification catalyst according to claim 1 wherein
the second catalytic layer comprises barium, and
with the total non-volatile content of the second catalytic layer being 100% by mass, the barium accounts for 12% by mass or less.

Assignees

• Cataler Corp
• Toyota Motor Co Ltd

Inventors

• Kitamura Ichiro
• Narita Keiichi
• Nomura Yasutaka
• Onoe Ryota
• Morishita Yuta
• Kuriyama Junji
• Sekine Hiroshi
• Inoue Akihito
• Ochiai Daisuke
• Sawada Jun
• Miyoshi Naoto
• Takeuchi Masahiko
• Sato Akemi
• Tanaka Atsushi

Classifications

• B01J23/63

  with rare earths or actinides · CPC title

• B01J35/04

  Operations & Transport · mapped topic

• B01D53/94 Primary

  by catalytic processes · CPC title

• B01J37/02

  Impregnation, coating or precipitation ({B01J37/0009 and B01J37/0018 take precedence } ; protection by coating B01J33/00) · CPC title

• B01J35/57

  Honeycombs · CPC title