Exhaust gas purification catalyst

Patent metadata

Field	Value
Publication number	US-10668459-B2
Application number	US-201515515828-A
Country	US
Kind code	B2
Filing date	Oct 2, 2015
Priority date	Oct 2, 2014
Publication date	Jun 2, 2020
Grant date	Jun 2, 2020

Abstract

An exhaust gas purification catalyst is provided for which a purification performance is excellent and particle growth of a catalyst metal is suppressed. The exhaust gas purification catalyst is provided with a substrate and a catalyst layer formed on the substrate. The catalyst layer contains a catalyst metal that functions as an oxidation and/or reduction catalyst and contains a support that supports the catalyst metal. The support is constituted of a porous ceramic that, in its volumetric pore diameter distribution measured based on a nitrogen gas adsorption method, has a pore diameter P 10 corresponding to a cumulative 10% from a small pore side and a pore diameter P 90 corresponding to a cumulative 90% from the small pore side that are both in a range from 5 to 50 nm.

First claim

The invention claimed is:

1. An exhaust gas purification catalyst that is disposed in an exhaust pipe of an internal combustion engine and that performs purification of an exhaust gas discharged from the internal combustion engine, the exhaust gas purification catalyst comprising a substrate and a catalyst layer formed on the substrate, wherein
the catalyst layer comprises a catalyst metal that functions as an oxidation and/or reduction catalyst and a support that supports the catalyst metal, wherein
a number-based average particle diameter that is based on electron microscopic observation of said catalyst metal is between 1 nanometer and 5 nanometers, wherein
the support is constituted of a porous ceramic for which, in volumetric pore diameter distribution thereof measured based on a nitrogen gas adsorption method, there exists a first pore diameter and a second pore diameter, wherein
ten percent of all pores have a diameter that is smaller than said first pore diameter, wherein ninety percent of all pores have a diameter that is smaller than said second pore diameter, wherein the first pore diameter is between five and fifty nanometers, and wherein the second pore diameter is between twenty and fifty nanometers, wherein
there exists an average pore diameter, wherein half of all pores have a diameter that is smaller than said average pore diameter, wherein there exists a ratio formed by dividing said average pore diameter by the number-based average particle diameter, and wherein said ratio is between five and thirty inclusive.

2. The exhaust gas purification catalyst according to claim 1 , wherein there exists a ratio between the first pore diameter and the second pore diameter, and wherein said ratio is between 0.35 and 0.6 inclusive.

3. The exhaust gas purification catalyst according to claim 1 , wherein the porous ceramic has a total pore volume, and wherein no more than five percent of said total pore volume is within pores that have a diameter that is greater than one-hundred nanometers.

4. The exhaust gas purification catalyst according to claim 1 , wherein the first pore diameter is between five nanometers and twenty nanometers.

5. The exhaust gas purification catalyst according to claim 1 , wherein the total pore volume of the porous ceramic is at least 0.2 mL/g.

6. The exhaust gas purification catalyst according to claim 1 , wherein a proportion of the catalyst metal is 0.3 to 1 mass % with reference to a total mass of the catalyst layer.

7. The exhaust gas purification catalyst according to claim 1 , wherein said average pore diameter is at least twenty nanometers.

Assignees

• Cataler Corp

Inventors

• Hirano Shusuke
• Tsuji Makoto
• Yamashita Yoshinori

Classifications

• B01J23/44

  Palladium · CPC title

• F01N3/0222

  the structure being monolithic, e.g. honeycombs · CPC title

• F01N2330/06

  Ceramic, e.g. monoliths · CPC title

• B01J35/1052 Primary

  Operations & Transport · mapped topic

• B01J23/63

  with rare earths or actinides · CPC title