Exhaust gas purifying catalyst

Patent metadata

Field	Value
Publication number	US-11364489-B2
Application number	US-201816649453-A
Country	US
Kind code	B2
Filing date	Oct 12, 2018
Priority date	Oct 19, 2017
Publication date	Jun 21, 2022
Grant date	Jun 21, 2022

Abstract

An exhaust gas purifying catalyst includes: a wall-flow structure substrate including an inlet cell, an outlet cell, and a porous partition; a first catalyst layer formed inside the partition such that a thickness of the first catalyst layer is between 40% and 60%, inclusive, of an overall thickness Tw of the partition; and a second catalyst layer formed inside the partition such that the second catalyst layer extends across an entire region of the partition in a thickness direction thereof.

First claim

The invention claimed is:

1. An exhaust gas purifying catalyst to purify exhaust gas emitted from an internal combustion engine, the exhaust gas purifying catalyst being disposed in an exhaust passage for the internal combustion engine, the exhaust gas purifying catalyst comprising:
a wall-flow structure substrate including
an inlet cell open only at an exhaust gas inflow end,
an outlet cell open only at an exhaust gas outflow end, and
a porous partition that partitions the inlet cell and the outlet cell;

a first catalyst layer formed in a region inside the partition and in contact with at least the inlet cell such that the first catalyst layer extends in a direction of extension of the partition from the exhaust gas inflow end; and
a second catalyst layer formed in a region inside the partition and in contact with at least the outlet cell such that the second catalyst layer extends in the direction of extension of the partition from the exhaust gas outflow end, wherein
assuming that the partition has an overall thickness T w in a thickness direction perpendicular to the direction of extension, the first catalyst layer is formed inside the partition such that a thickness T 1 of the first catalyst layer is between 40% and 60%, inclusive, of the thickness T w , and the second catalyst layer is formed inside the partition such that the second catalyst layer extends across an entire region of the partition in the thickness direction; and
assuming that the first catalyst layer has a length L 1 , the second catalyst layer has a length L 2 , and the porous partition has a total length L w in the direction of extension, the lengths L w , L 1 and L 2 satisfy the following expression: L w <(L 1 +L 2 )<2 L w , and the first catalyst layer and the second catalyst layer partially overlap with each other in the direction of extension.

2. The exhaust gas purifying catalyst according to claim 1 , wherein,
a length L 1 of the first catalyst layer is between 50% and 90%, inclusive, of a total length L w of the partition in the direction of extension.

3. The exhaust gas purifying catalyst according to claim 1 , wherein
a length L 2 of the second catalyst layer is between 20% and 80%, inclusive, of a total length L w of the partition in the direction of extension.

4. The exhaust gas purifying catalyst according to claim 1 , wherein
the first catalyst layer contains a precious metal that is rhodium (Rh), and
the second catalyst layer contains a precious metal that is palladium (Pd).

5. The exhaust gas purifying catalyst according to claim 4 , wherein
a ratio of a content of Rh in the first catalyst layer to a content of Pd in the second catalyst layer is between 0.1 and 2 inclusive, the ratio being represented as Rh/Pd.

6. The exhaust gas purifying catalyst according to claim 1 , wherein
the internal combustion engine is a gasoline engine.

Assignees

• Cataler Corp
• Toyota Motor Co Ltd

Inventors

• Makino Haruka
• Nomura Yasutaka
• Inoda Satoru
• Nakajima Kenji
• Miyoshi Naoto
• Yoshida Takeru
• Sato Akemi

Classifications

• B01D53/9413 Primary

  Processes characterised by a specific catalyst · CPC title

• B01J2235/00

  Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties · CPC title

• B01J35/45

  Nanoparticles · CPC title

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J35/56

  Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths · CPC title