Methods for exhaust gas purification

Patent metadata

Field	Value
Publication number	US-11633724-B2
Application number	US-202217861320-A
Country	US
Kind code	B2
Filing date	Jul 11, 2022
Priority date	Feb 21, 2018
Publication date	Apr 25, 2023
Grant date	Apr 25, 2023

Abstract

Methods for exhaust gas purification, including the steps of: attaching an exhaust gas purification catalyst to an exhaust system of an internal combustion engine, and supplying an exhaust gas to the exhaust gas purification catalyst, where the exhaust gas purification catalyst includes an upper layer containing first carrier particles which are particles of an inorganic oxide and rhodium, and a lower layer containing second carrier particles which are particles of an inorganic oxide, the upper layer includes a rhodium-rich portion near the surface of the upper layer on the upstream side of the exhaust gas flow, and the existence range of the rhodium-rich portion is in a range of greater than 50% to 80% of the length of the upper layer from a downstream side end of an exhaust gas flow and of less than 20 μm in the depth direction from an outermost surface of the upper layer.

First claim

The invention claimed is:

1. A method for exhaust gas purification, comprising the steps of:
attaching an exhaust gas purification catalyst to an exhaust system of an internal combustion engine, and
supplying an exhaust gas to the exhaust gas purification catalyst, wherein
the exhaust gas purification catalyst comprises
an upper layer containing first carrier particles which are particles of an inorganic oxide and rhodium, and
a lower layer containing second carrier particles which are particles of an inorganic oxide,
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 greater than 50% to 80% of the length of the upper layer from a downstream side end of an exhaust gas flow and of less than 20 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, and

the exhaust gas purification catalyst is attached to the exhaust system so that the rhodium-rich portion thereof faces the downstream side of the exhaust gas flow.

2. The method according to claim 1 , wherein the range of the rhodium-rich portion in an exhaust gas flow direction is up to 70% of the length from the upper layer exhaust stream flow downstream side end.

3. The method according to claim 2 , wherein the range of the rhodium-rich portion in the depth direction is a range of up to 18 μm in the depth direction from the outermost surface of the upper layer.

4. The method according to claim 1 , wherein
the upper layer contains ceria, and 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 method 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 method according to claim 1 , wherein a quantity of rhodium included in the range of the rhodium-rich portion up to 50% of the length of the rhodium-rich portion from the downstream side end of the exhaust gas flow is 70% or less of the quantity of rhodium included in the rhodium-rich portion.

7. The method according to claim 1 , wherein the lower layer and the upper layer are present on a substrate.

8. The method 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.

Assignees

• Cataler Corp
• Toyota Motor Co Ltd

Inventors

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

Classifications

• B01D2255/2092

  Aluminium · CPC title

• B01D2255/2068

  Neodymium · CPC title

• B01D53/9413

  Processes characterised by a specific catalyst · CPC title

• B01J23/63 Primary

  with rare earths or actinides · CPC title

• B01D2255/2042

  Barium · CPC title