Exhaust gas purifying catalyst and method for producing the same

Patent metadata

Field	Value
Publication number	US-10189011-B2
Application number	US-201715701723-A
Country	US
Kind code	B2
Filing date	Sep 12, 2017
Priority date	Sep 15, 2016
Publication date	Jan 29, 2019
Grant date	Jan 29, 2019

Abstract

An exhaust gas purifying catalyst with an excellent effect of suppressing deterioration due to aggregation of a noble metal catalyst during endurance at high temperature, and a production method therefor. The method for producing the exhaust gas purifying catalyst that has a porous carrier and a noble metal catalyst supported thereon includes: preparing the porous carrier that contains alumina-ceria-zirconia composite oxide particles and has physical property values, after subjected to baking at 900° C. for 5 hours, of a pore diameter of the particles in the range of 2 to 20 nm, a specific surface area of the particles in the range of 75 to 115 m 2 /g, a crystallite size of a ceria-zirconia composite oxide contained in the particles in the range of 4 to 6 nm, and a bulk density of the particles in the range of 0.5 to 0.9 cm 3 /g, and bringing a noble metal chemical solution having an aggregate of platinum or the like with a grain size adjusted to less than or equal to 1 nm with the use of a platinum nitric acid solution or the like, into contact with the porous carrier, so that the noble metal catalyst is supported on the porous carrier.

First claim

What is claimed is:

1. A method for producing an exhaust gas purifying catalyst including a porous carrier and a noble metal catalyst supported on the porous carrier, the porous carrier containing particles of an alumina-ceria-zirconia composite oxide including ceria-zirconica composite oxide, the method comprising:
preparing the porous carrier having physical property values, after subjected to baking at 900° C. for 5 hours, of a pore diameter of the particles in a range of 2 to 20 nm, a specific surface area of the particles in a range of 75 to 115 m 2 /g, a crystallite size of the ceria-zirconia composite oxide that is contained in the particles in a range of 4 to 6 nm, and a bulk density of the particles in a range of 0.5 to 0.9 cm 3 /g; and
bringing a noble metal chemical solution into contact with the porous carrier, the noble metal chemical solution having an aggregate of one of platinum, palladium, or rhodium with a grain size adjusted to less than or equal to 1 nm with use of one of a platinum nitric acid solution, palladium nitric acid solution, or rhodium nitric acid solution, so that the noble metal catalyst is supported on the porous carrier.

2. The method according to claim 1 , further comprising dissolving a cerium compound and a zirconium compound in distilled water to blend a mixture, and adding aluminum isopropoxide to the mixture to obtain the porous carrier.

3. An exhaust gas purifying catalyst comprising:
a porous carrier; and
a noble metal catalyst supported on the porous carrier,
wherein:
the porous carrier contains particles of an alumina-ceria-zirconia composite oxide including ceria-zirconia composite oxide,
the porous carrier has physical property values, after subjected to baking at 900° C. for 5hours, of a pore diameter of the particles in a range of 2 to 20 nm, a specific surface area of the particles in a range of 75 to 115 m 2 /g, a crystallite size of a-the ceria-zirconia composite oxide that is contained in the particles in a range of 4 to 6 nm, and a bulk density of the particles in a range of 0.5 to 0.9 cm 3 /g, and
in each of 256 ×256 regions obtained through division of a field of view of 87.04 ×87.04μm of an electron microscope with a magnification of 1000—, a correlation coefficient of concentrations between the noble metal catalyst and Al of the porous carrier is greater than or equal to 0.2.

Assignees

• Kanazawa Takaaki
• Haga Shunsuke
• Naito Isao
• Chiba Akiya
• Abe Motoya
• Toyota Motor Co Ltd

Inventors

• Kanazawa Takaaki
• Haga Shunsuke
• Naito Isao
• Chiba Akiya
• Abe Motoya

Classifications

• B01D2255/2092

  Aluminium · CPC title

• B01J35/1061

  Operations & Transport · mapped topic

• B01D2255/9207

  Specific surface · CPC title

• B01J37/0215

  Coating · CPC title

• B01D2255/1023

  Palladium · CPC title