Exhaust gas purification catalyst device

Patent metadata

Field	Value
Publication number	US-11524285-B2
Application number	US-201916970667-A
Country	US
Kind code	B2
Filing date	Jan 25, 2019
Priority date	Feb 21, 2018
Publication date	Dec 13, 2022
Grant date	Dec 13, 2022

Abstract

The exhaust gas purification catalyst device includes an upper layer which includes first carrier particles and rhodium, and a lower layer which includes second carrier particles, and the upper layer includes a rhodium enriched area in the range a, from the upstream end in the exhaust gas flow to 50% of the upper layer length, and a range b from the upper layer top surface to 18 μm in the depth direction. The rhodium enriched area contains at least 50% and less than 100% of all the rhodium in the upper layer.

First claim

The invention claimed is:

1. An exhaust gas purification catalyst, comprising:
an upper layer containing first carrier particles and rhodium, and
a lower layer containing second carrier particles,

wherein
the upper layer includes a rhodium-rich portion near the surface of the upper layer on the upstream side of the exhaust gas flow,
the existence range of the rhodium-rich portion is in a range of up to 50% of the length of the upper layer from an upstream side end of an exhaust gas flow and of up to 18 μm in the depth direction from an outermost surface of the upper layer, and
the rhodium-rich portion contains rhodium in an amount of 55% to less than 100% of the total rhodium included in the upper layer.

2. The exhaust gas purification catalyst according to claim 1 , wherein the range of the rhodium-rich portion in an exhaust gas flow direction is up to 30% of the length from the upper layer exhaust stream flow upstream side end.

3. The exhaust gas purification catalyst according to claim 2 , wherein the range of the rhodium-rich portion in the depth direction is up to 15 μm in the depth direction from the outermost surface of the upper layer.

4. The exhaust gas purification catalyst according to claim 1 , wherein a content of ceria in the upper layer is greater than 5% by mass to 25% by mass or less, when the total mass of the first carrier particles in the upper layer is 100% by mass.

5. The exhaust gas purification catalyst according to claim 4 , wherein the content of ceria in the upper layer is 7% by mass to 15% by mass, when the total mass of the first carrier particles in the upper layer is 100% by mass.

6. The exhaust gas purification catalyst according to claim 1 , wherein rhodium equal to 50% or more of the rhodium included in the rhodium-rich portion is in the range of up to 50% of the length of the rhodium-rich portion from the upstream side end of the exhaust gas flow.

7. The exhaust gas purification catalyst according to claim 1 , wherein the lower layer and the upper layer are present on a substrate.

8. The exhaust gas purification catalyst according to claim 1 , wherein the lower layer constitutes a part or the entirety of a substrate, and the upper layer is present on the lower layer.

9. A method for the production of the exhaust gas purification catalyst according to claim 1 , comprising the steps of:
providing a coating liquid including a rhodium precursor to an exhaust gas upstream side end of an exhaust gas purification catalyst precursor comprising an upper layer containing first carrier particles and rhodium and a lower layer containing second carrier particles, and thereafter suctioning from an exhaust gas downstream side end of the exhaust gas purification catalyst precursor.

Assignees

• Cataler Corp
• Toyota Motor Co Ltd

Inventors

• Oishi Shunsuke
• Ota Takaya
• Chinzei Isao
• Suzuki Hiromasa
• Saito Yoshinori
• Nakahigashi Seiji

Classifications

• Y02A50/20

  Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters · CPC title

• F01N3/0842

  Nitrogen oxides · CPC title

• F01N2510/0684

  having more than one coating layer, e.g. multi-layered coatings · CPC title

• B01D2255/9022

  Two layers · CPC title

• B01J37/0228

  in several steps · CPC title