Exhaust gas purification device

Patent metadata

Field	Value
Publication number	US-10357744-B2
Application number	US-201515515830-A
Country	US
Kind code	B2
Filing date	Oct 6, 2015
Priority date	Oct 9, 2014
Publication date	Jul 23, 2019
Grant date	Jul 23, 2019

Abstract

An exhaust gas purification device of the present invention is provided with: a substrate of wall flow structure having an inlet cell, an outlet cell and a porous partition wall; an upstream catalyst layer, provided inside the partition wall and disposed in an upstream portion of the substrate including an exhaust gas inflow end section; and a downstream catalyst layer, provided inside the partition wall and disposed in a downstream portion of the substrate including an exhaust gas outflow end section. The upstream catalyst layer and the downstream catalyst layer each contain a carrier and at least one noble metal from among Pt, Pd and Rh, supported on the carrier. The noble metal in the upstream catalyst layer and the noble metal in the downstream catalyst layer are different from each other.

First claim

The invention claimed is:

1. An exhaust gas purification device, the device comprising:
a substrate of wall flow structure having an inlet cell in which only an exhaust gas inflow end section is open, an outlet cell adjacent to the inlet cell and in which only an exhaust gas outflow end section is open, and a porous partition wall that partitions said inlet cell and said outlet cell from each other;
an upstream catalyst layer provided inside said partition wall and disposed in an upstream portion of said substrate, in a direction of exhaust gas flow, including the exhaust gas inflow end section; and
a downstream catalyst layer provided inside said partition wall and disposed in a downstream portion of said substrate, in a direction of exhaust gas flow, including the exhaust gas outflow end section; wherein
said upstream catalyst layer is formed in a portion corresponding to 20% to 80% of a length of said substrate, from the exhaust gas inflow end section of said substrate towards a downstream side, and
said downstream catalyst layer is formed in a portion corresponding to 20% to 80% of a length of said substrate, from an exhaust gas outflow end section of said substrate towards an upstream side,
with 100% as a total coating amount of said upstream catalyst layer and said downstream catalyst layer, a proportion of the coating amount present inside said partition wall is 85% or higher;

said upstream catalyst layer and said downstream catalyst layer each contain a carrier and at least one noble metal from among Pt, Pd and Rh, supported on the carrier; and
the noble metal comprised in said upstream catalyst layer and the noble metal comprised in said downstream catalyst layer are different from each other.

2. The exhaust gas purification device of claim 1 ,
wherein the coating amount of said upstream catalyst layer per L of volume of said substrate is smaller than the coating amount of said downstream catalyst layer per L of volume of said substrate.

3. The exhaust gas purification device of claim 1 ,
wherein the coating amount of said upstream catalyst layer per L of volume of said substrate is an amount in the range of from 60 g/L to 100 g/L.

4. The exhaust gas purification device of claim 1 ,
wherein said upstream catalyst layer comprises Rh as said noble metal, and
said downstream catalyst layer comprises Pt and/or Pd as said noble metal.

5. The exhaust gas purification device of claim 1 ,
wherein in the thickness direction of said partition wall,
said upstream catalyst layer is unevenly distributed within said partition wall, so as to be in contact with said inlet cell and not in contact with said outlet cell, and
said downstream catalyst layer is unevenly distributed within said partition wall, so as to be in contact with said outlet cell and not in contact with said inlet cell.

6. The exhaust gas purification device of claim 5 ,
wherein said upstream catalyst layer is formed in a portion corresponding to 30% to 70% of the thickness of said partition wall, from a surface of said partition wall in contact with said inlet cell towards the outlet cell, and
said downstream catalyst layer is formed in a portion corresponding to 30% to 70% of the thickness of said partition wall, from a surface of said partition wall in contact with said outlet cell towards the inlet cell.

7. An internal combustion engine comprising the exhaust gas purification device of claim 1 disposed in an exhaust passage of said internal combustion engine, wherein said internal combustion engine is a gasoline engine.

Assignees

• Cataler Corp

Inventors

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

Classifications

• B01J23/63

  with rare earths or actinides · CPC title

• F01N2370/02

  used in catalytic reactors · CPC title

• B01D2255/1021

  Platinum · CPC title

• B01J37/0244

  Coatings comprising several layers · CPC title

• B01D53/9472 Primary

  in different zones · CPC title