Exhaust gas cleaning catalytic device

Patent metadata

Field	Value
Publication number	US-11850573-B2
Application number	US-202017435840-A
Country	US
Kind code	B2
Filing date	Mar 23, 2020
Priority date	Mar 29, 2019
Publication date	Dec 26, 2023
Grant date	Dec 26, 2023

Abstract

This exhaust gas cleaning catalytic device includes a base material and a first catalyst coat layer on the base material. The first catalyst coat layer has a pre-stage section on an exhaust gas flow upstream side, and a post-stage section on an exhaust gas flow downstream side. The first catalyst coat layer pre-stage section and post-stage section each contain inorganic oxide particles and rhodium supported by the inorganic oxide particles, while at least some of the inorganic oxide particles contain ceria. The ceria amount per unit length of the first catalyst coat layer post-stage section is larger than the ceria amount per unit length of the first catalyst coat layer pre-stage section. The first catalyst coat layer pre-stage section is disposed in such a manner that the end portion on the exhaust gas flow upstream side thereof is in direct contact with the exhaust gas flow.

First claim

The invention claimed is:

1. An exhaust gas purification catalytic device, comprising
a substrate, a first catalytic coating layer on the substrate, and a second catalytic coating layer on the first catalytic coating layer
wherein the first catalytic coating layer comprises a first catalytic coating layer upstream portion on an exhaust gas flow upstream side and a first catalytic coating layer downstream portion on an exhaust gas flow downstream side,
wherein the first catalytic coating layer upstream portion and the first catalytic coating layer downstream portion each comprise inorganic oxide particles and rhodium supported on the inorganic oxide particles,
wherein at least a part of the inorganic oxide particles contains ceria,
wherein the total mass (g) of ceria contained in the first catalytic coating layer upstream portion to the first catalytic coating layer downstream portion allocated per 1 L of substrate capacity is 5 g/L or more and 20 g/L or less,
wherein the ratio of ceria content per unit length of the first catalytic coating layer downstream portion to ceria content per unit length of the first catalytic coating layer upstream portion is 1.1 or greater and 3.0 or less,
wherein the first catalytic coating layer upstream portion is arranged such that an end portion on the exhaust gas flow upstream side is in direct contact with an exhaust gas flow,
wherein the second catalytic coating layer comprises inorganic oxide particles and rhodium and palladium supported on the inorganic oxide particles,
wherein at least a part of the inorganic oxide particles in the second catalytic coating layer contains ceria,
wherein the total mass (g) of ceria contained in the second catalytic coating layer allocated per 1 L of substrate capacity is 10 g/L or more and 30 g/L or less,
wherein the ratio of ceria content per unit length of the second catalytic coating layer to ceria content per unit length of the first catalytic coating layer downstream portion is 1.1 or greater and 2.0 or less.

2. The exhaust gas purification catalytic device according to claim 1 , wherein the ceria of the first catalytic coating layer is contained in particles of one or more inorganic oxides selected from pure ceria and a composite oxide containing ceria.

3. The exhaust gas purification catalytic device according to claim 2 , wherein the composite oxide containing ceria is a ceria-zirconia composite oxide.

4. The exhaust gas purification catalytic device according to claim 2 , wherein the second catalytic coating layer comprises an alkaline-earth metal compound.

5. The exhaust gas purification catalytic device according to claim 2 , wherein the ratio of mass of an alkaline-earth metal compound to the total mass of the first catalytic coating layer is 5% by mass or less.

6. The exhaust gas purification catalytic device according to claim 2 , wherein the ratio of mass of an alkaline-earth metal compound to the total mass of the first catalytic coating layer is 5% by mass or less.

7. The exhaust gas purification catalytic device according to claim 1 , wherein the ceria of the second catalytic coating layer is contained in particles of one or more inorganic oxides selected from pure ceria and a composite oxide containing ceria.

8. The exhaust gas purification catalytic device according to claim 7 , wherein the composite oxide containing ceria is a ceria-zirconia composite oxide.

9. The exhaust gas purification catalytic device according to claim 7 , wherein the rhodium in the second catalytic coating layer is supported on particles of one or more inorganic oxides selected from pure ceria and the composite oxide containing ceria, and
wherein the palladium of the second catalytic coating layer is supported on particles of an inorganic oxide other than pure ceria and the composite oxide containing ceria.

10. The exhaust gas purification catalytic device according to claim 9 , wherein the second catalytic coating layer comprises an alkaline-earth metal compound.

11. The exhaust gas purification catalytic device according to claim 9 , wherein the ratio of mass of an alkaline-earth metal compound to the total mass of the first catalytic coating layer is 5% by mass or less.

12. The exhaust gas purification catalytic device according to claim 7 , wherein the second catalytic coating layer comprises an alkaline-earth metal compound.

13. The exhaust gas purification catalytic device according to claim 1 , wherein the second catalytic coating layer comprises an alkaline-earth metal compound.

14. The exhaust gas purification catalytic device according to claim 1 , wherein the ratio of mass of an alkaline-earth metal compound of the total mass of the first catalytic coating layer is 5% by mass or less.

15. The exhaust gas purification catalytic device according to claim 1 , wherein the ratio of mass of an alkaline-earth metal compound to the total mass of the first catalytic coating layer is 5% by mass or less.

16. The exhaust gas purification catalytic device according to claim 1 , wherein the molar ratio of rhodium content per unit length of the first catalytic coating layer downstream portion to rhodium content per unit length of the first catalytic coating layer upstream portion is 0.8to 1.2.

17. The exhaust gas purification catalytic device according to claim 1 , wherein the length of the first catalytic coating layer upstream portion is 30% to 70% of the total length of the first catalytic coating layer.

18. An exhaust gas purification method which uses the exhaust gas purification catalyst device according to claim 1 ,
wherein the exhaust gas purification catalyst device is arranged so that the first catalytic coating layer upstream portion faces to an exhaust gas flow upstream side.

Assignees

• Cataler Corp

Inventors

• Chiba Tomohiro
• Murakami Kyosuke
• Taki Kenichi
• Haga Shunsuke

Classifications

• B01J35/50

  characterised by their shape or configuration · CPC title

• B01J23/63 Primary

  with rare earths or actinides · CPC title

• B01J21/066

  Zirconium or hafnium; Oxides or hydroxides thereof · CPC title

• B01J37/0215

  Coating · CPC title

• B01J37/0246

  Coatings comprising a zeolite · CPC title