Exhaust gas purification catalyst

Patent metadata

Field	Value
Publication number	US-10159935-B2
Application number	US-201515517990-A
Country	US
Kind code	B2
Filing date	Oct 7, 2015
Priority date	Oct 16, 2014
Publication date	Dec 25, 2018
Grant date	Dec 25, 2018

Abstract

An exhaust gas purification catalyst having an excellent exhaust gas purification ability while reducing the increase in pressure loss. Exhaust gas purification catalyst includes entrance cell, exit cell, and a wall-flow substrate having partition wall to separate these cell, a catalytic layer formed from exhaust inlet-side ends in the extending direction in sections of the interior of partition wall facing entrance cell, and a catalytic layer formed on the surface of partition wall facing exit cell from exhaust outlet-side ends in the extending direction of partition wall, having a length shorter than the entire partition wall length.

First claim

The invention claimed is:

1. A wall-flow type exhaust gas purification catalyst placed in an exhaust pipe of an internal combustion system that is configured to purify exhaust gas emitted from the internal combustion system, with the exhaust gas purification catalyst comprising:
a substrate that has a wall-flow structure and comprises an entrance cell whose exhaust inlet side has an open end as well as an exit cell whose exhaust outlet side has an open end wherein the cells are separated with a porous partition wall,
a first catalytic layer formed in the porous partition wall facing the entrance cell, from the exhaust inlet-side end in an extending direction of the porous partition wall, and
a second catalytic layer formed on a surface of the porous partition wall facing the exit cell, from the exhaust outlet-side end in the extending direction of the porous partition wall, having a length shorter than the porous partition wall having an entire length L w ,
wherein in a thickness direction vertical to the extending direction, the partition wall has an overall thickness T w and the first catalytic layer is formed to a thickness T 1 that is 60% or greater of the T w .

2. The exhaust gas purification catalyst according to claim 1 , wherein the second catalytic layer has a length L 2 in the extending direction, equivalent to 10% or greater, but 50% or less of the L w .

3. The exhaust gas purification catalyst according to claim 1 , wherein the first catalytic layer has a length L 1 in the extending direction, equivalent to 60% or greater, but 90% or less of the L w .

4. The exhaust gas purification catalyst according to claim 1 , wherein, in a thickness direction vertical to the extending direction, the porous partition wall has an overall thickness T w and the second catalytic layer is formed to a thickness T 2 , equivalent to 30% or less of the T w on the surface of the porous partition wall facing the exit cell.

5. The exhaust gas purification catalyst according to claim 1 , wherein, in the extending direction, the first and second catalytic layers have lengths L 1 and L 2 that satisfy the next inequality L w <(L 1 +L 2 ) <2L w , with the first and second catalytic layers partially overlapping in the extending direction.

6. The exhaust gas purification catalyst according to claim 5 , wherein the first and second catalytic layers overlap over a length equivalent to 5% or greater, but 20% or less of the L w.

7. The exhaust gas purification catalyst according to claim 1 , wherein, the thickness T 1 is 80% or greater of the T w.

8. The exhaust gas purification catalyst according to claim 1 , wherein, the thickness T 1 is less than 100% of the T w.

9. The exhaust gas purification catalyst according to claim 1 , wherein, the thickness T 1 is 95% or less of the T w.

10. A wall-flow type exhaust gas purification catalyst placed in an exhaust pipe of an internal combustion system that is configured to purify exhaust gas emitted from the internal combustion system, with the exhaust gas purification catalyst comprising:
a substrate that has a wall-flow structure and comprises an entrance cell whose exhaust inlet side has an open end as well as an exit cell whose exhaust outlet side has an open end wherein the cells are separated with a porous partition wall,
a first catalytic layer formed in the porous partition wall facing the entrance cell, from the exhaust inlet-side end in an extending direction of the porous partition wall, and
a second catalytic layer formed on a surface of the porous partition wall facing the exit cell, from the exhaust outlet-side end in the extending direction of the porous partition wall, having a length shorter than the porous partition wall having an entire length L w ,
wherein each of the first catalytic layer and the second catalytic layer contains a purification catalyst for cleaning exhaust gas, and
wherein the purification catalyst in the first catalytic layer consists of a precious metal of the platinum group.

11. The exhaust gas purification catalyst according to claim 10 , wherein a relative catalytic metal-carrying rate is lower in the first catalytic layer than in the second catalytic layer.

12. The exhaust gas purification catalyst according to claim 11 , wherein each of the catalytic metal-carrying rates of the first catalytic layer and the second catalytic layer is in a range of from 0.05% to 1.5% by mass of the respective catalytic layers.

13. The exhaust gas purification catalyst according to claim 11 , wherein each of the catalytic metal-carrying rates of the first catalytic layer and the second catalytic layer is in a range of from 0.2% to 1% by mass of the respective catalytic layers.

Assignees

• Cataler Corp
• Toyota Motor Co Ltd

Inventors

• Onoe Ryota
• Sakagami Shingo
• Ito Tsuyoshi
• Takeuchi Masahiko
• Miyoshi Naoto
• Sato Akemi

Classifications

• B01D2255/407

  Zr-Ce mixed oxides · CPC title

• Y02T10/20

  Cross-Sectional Technologies · mapped topic

• B01J35/04

  Operations & Transport · mapped topic

• B01J37/0244

  Coatings comprising several layers · CPC title

• B01D53/945 Primary

  characterised by a specific catalyst · CPC title