Exhaust gas purification device

Patent metadata

Field	Value
Publication number	US-11679379-B2
Application number	US-202217734702-A
Country	US
Kind code	B2
Filing date	May 2, 2022
Priority date	May 20, 2021
Publication date	Jun 20, 2023
Grant date	Jun 20, 2023

Abstract

The exhaust gas purification device includes a substrate, a first catalyst layer, and a second catalyst layer. The substrate includes an upstream end, a downstream end, and a porous partition wall defining a plurality of cells extending between the upstream end and the downstream end. The plurality of cells include an inlet cell opening at the upstream end and sealed at the downstream end, and an outlet cell adjacent to the inlet cell sealed at the upstream end and opening at the downstream end. The first catalyst layer is disposed on a surface of the partition wall in an upstream region. In a downstream region, the second catalyst layer is disposed inside the partition wall, and a second catalyst-containing wall including the partition wall and the second catalyst layer has a porosity of 35% or more.

First claim

What is claimed is:

1. An exhaust gas purification device comprising:
a substrate including:
an upstream end through which an exhaust gas is introduced into the device;
a downstream end through which the exhaust gas is discharged from the device; and
a porous partition wall defining a plurality of cells extending between the upstream end and the downstream end;

a first catalyst layer; and
a second catalyst layer,
wherein the plurality of cells include:
an inlet cell opening at the upstream end and sealed at the downstream end; and
an outlet cell adjacent to the inlet cell with the partition wall interposed between the inlet cell and the outlet cell, the outlet cell being sealed at the upstream end and opening at the downstream end,

wherein the first catalyst layer is disposed on a surface of the partition wall in an upstream region including the upstream end of the substrate,
wherein, in a downstream region including the downstream end of the substrate, the second catalyst layer is disposed inside the partition wall, and a second catalyst-containing wall including the partition wall and the second catalyst layer has a porosity of 35% or more.

2. The exhaust gas purification device according to claim 1 ,
wherein the upstream region overlaps with the downstream region.

3. The exhaust gas purification device according to claim 1 ,
wherein the length of the first catalyst layer Dx is from 10% to 90% of the distance D in an extending direction from the upstream end I to the downstream end J.

4. The exhaust gas purification device according to claim 3 ,
wherein the length of the first catalyst layer Dx is from 10% to 50% of the distance D.

5. The exhaust gas purification device according to claim 1 ,
wherein the length of the second catalyst layer Dy is from 30% to 100% of the distance D in an extending direction from the upstream end I to the downstream end J.

6. The exhaust gas purification device according to claim 1 ,
wherein the upstream region and the downstream region overlap in an extending direction.

7. The exhaust gas purification device according to claim 1 ,
wherein the components constituting the second catalyst layer are present inside the partition wall in a total weight amount of 80% or more.

8. The exhaust gas purification device according to claim 7 ,
wherein the total weight amount is 85% or more.

9. The exhaust gas purification device according to claim 7 ,
wherein the total weight amount is 90% or more.

10. The exhaust gas purification device according to claim 7 ,
wherein the total weight amount is 99% or more.

11. The exhaust gas purification device according to claim 7 ,
wherein the total weight amount is substantially 100%.

12. The exhaust gas purification device according to claim 1 ,
wherein, in the upstream region, a first catalyst-coated wall including the partition wall and the first catalyst layer is impermeable to gas.

Assignees

• Sugiura Koji
• Hirabayashi Takeshi
• Satou Akemi
• Murawaki Keisuke
• Ota Takaya
• Ikebe Masatoshi
• Takasaki Kohei
• Morishima Takeshi
• Toyota Motor Co Ltd
• Cataler Corp

Inventors

• Sugiura Koji
• Hirabayashi Takeshi
• Satou Akemi
• Murawaki Keisuke
• Ota Takaya
• Ikebe Masatoshi
• Takasaki Kohei
• Morishima Takeshi

Classifications

• F01N2370/02

  used in catalytic reactors · CPC title

• F01N2330/06

  Ceramic, e.g. monoliths · CPC title

• B01D2255/407

  Zr-Ce mixed oxides · CPC title

• F01N2330/48

  characterised by the number of flow passages, e.g. cell density · CPC title

• B01D53/94

  by catalytic processes · CPC title