Exhaust gas cleaning catalyst

Patent metadata

Field	Value
Publication number	US-11286830-B2
Application number	US-201615547589-A
Country	US
Kind code	B2
Filing date	Jan 25, 2016
Priority date	Feb 4, 2015
Publication date	Mar 29, 2022
Grant date	Mar 29, 2022

Abstract

The exhaust gas cleaning catalyst according is provided with a substrate and a catalyst coat layer formed on a surface of the substrate. The catalyst coat layer is formed as a laminate structure having an upper layer and a lower layer. The upper layer is a Pd-free layer that does not contain Pd, and the lower layer is a Pd-containing layer. In addition, when a region of the lower layer that corresponds to 20% of the length of the exhaust gas cleaning catalyst from the exhaust gas inlet side end towards the exhaust gas outlet side of the exhaust gas cleaning catalyst is divided into four equal regions to be each 5% of the length, the relationship A>B>C is satisfied, where A, B, and C represents the Pd content in the first, second, and third region respectively.

First claim

The invention claimed is:

1. An exhaust gas cleaning catalyst disposed in an exhaust pathway of an internal combustion engine and cleaning exhaust gas emitted by the internal combustion engine, wherein
the exhaust gas cleaning catalyst is provided with a substrate and a catalyst coat layer formed on a surface of the substrate,
the catalyst coat layer is formed as a multilayer structure having an upper layer and a lower layer, with a layer nearer to the surface of the substrate being the lower layer and a layer further from the surface of the substrate being the upper layer,
the upper layer is a Pd-free layer which does not contain Pd,
the lower layer is a Pd-containing layer which contains Pd, and wherein
the lower laver comprises a Pd concentration gradient region and a downstream side region,
the Pd concentration gradient region is a region of the lower layer that corresponds to 20% of the length of the exhaust gas cleaning catalyst from an exhaust gas inlet side end towards an exhaust gas outlet side of the exhaust gas cleaning catalyst, and the Pd concentration gradient region is divided into four equal regions to be each 5% of the length, a relationship A>B>C is satisfied,
where A represents the content of Pd in a first region that is a quarter at the most upstream side, B represents the content of Pd in a second region that is a quarter at the downstream side adjacent to the first region, and C represents the content of Pd in a third region that is a quarter at the downstream side adjacent to the second region, and wherein
the downstream side region is a region of the lower layer that is not the Pd concentration gradient region, and the concentration of Pd in the downstream side region is uniform without concentration gradient.

2. The exhaust gas cleaning catalyst according to claim 1 , wherein
the first region is a region of up to 5 mm in length from the exhaust gas inlet side end towards the exhaust gas outlet side of the exhaust gas cleaning catalyst,
the second region is a region of up to 5 mm at the most at the downstream side adjacent to the first region, and
the third region is a region of up to 5 mm at the most at the downstream side adjacent to the second region.

3. The exhaust gas cleaning catalyst according to claim 1 , wherein when a total mass of Pd contained in the lower layer is 100 parts by mass, the content A of Pd in the first region is greater than the content B of Pd in the second region by 5 parts by mass or more.

4. The exhaust gas cleaning catalyst according to claim 1 , wherein when the total mass of Pd contained in the lower layer is 100 parts by mass, the content B of Pd in the second region is greater than the content C of Pd in the third region by 1 part by mass or more.

5. The exhaust gas cleaning catalyst according to claim 1 , wherein when the total mass of Pd contained in the lower layer is 100 parts by mass, a sum of the content A of Pd in the first region and the content B of Pd in the second region is 20 parts by mass or more.

6. The exhaust gas cleaning catalyst according to claim 1 , wherein the content D of Pd in a fourth region that is a quarter at the downstream side adjacent to the third region satisfies a relationship A>B>C≥D.

7. The exhaust gas cleaning catalyst according to claim 6 , wherein when the total mass of Pd contained in the lower layer is 100 parts by mass, a sum of the content A of Pd in the first region, the content B of Pd in the second region, the content C of Pd in the third region and the content D of Pd in the fourth region is 35 to 99 parts by mass.

8. The exhaust gas cleaning catalyst according to claim 1 , wherein the lower layer has a concentration gradient by which the concentration of Pd continuously decreases from the exhaust gas inlet side end towards the exhaust gas outlet side in a region of the lower layer that corresponds to at least 15% of the length of the exhaust gas cleaning catalyst from the exhaust gas inlet side end towards the exhaust gas outlet side of the exhaust gas cleaning catalyst.

9. The exhaust gas cleaning catalyst according to claim 1 , wherein the upper layer covers the entire lower layer so that the lower layer is not exposed at the surface of the catalyst coat layer.

10. The exhaust gas cleaning catalyst according to claim 1 , wherein
the lower layer includes an OSC material having oxygen storage capacity, and
the Pd is supported on the OSC material.

11. The exhaust gas cleaning catalyst according to claim 1 , wherein the concentration of Pd is uniform in the thickness direction throughout the lower layer.

Assignees

• Cataler Corp
• Toyota Motor Co Ltd

Inventors

• Saito Yoshinori
• Ori Hirotaka
• Sakagami Shingo
• Chinzei Isao
• Yoshida Takeru
• Aoki Yuki

Classifications

• B01D53/86

  Catalytic processes · CPC title

• B01D2255/9032

  Two zones · CPC title

• B01J37/0244

  Coatings comprising several layers · CPC title

• F01N3/2803 Primary

  characterised by structure, by material or by manufacturing of catalyst support · CPC title

• B01D2255/9022

  Two layers · CPC title