Exhaust gas purification catalyst

Patent metadata

Field	Value
Publication number	US-9440223-B2
Application number	US-201214369217-A
Country	US
Kind code	B2
Filing date	Dec 26, 2012
Priority date	Dec 28, 2011
Publication date	Sep 13, 2016
Grant date	Sep 13, 2016

Abstract

An exhaust gas purification catalyst is provided with a substrate and a catalyst coating layer formed on the surface of the substrate. The catalyst coating layer is formed into a layered structure having upper and lower layers, with a lower layer being closer to the surface of the substrate and an upper layer being relatively farther therefrom. The catalyst coating layer is provided with Rh and Pd as precious metal catalysts and is provided with an OSC material having an oxygen storage capacity as a support. The Rh is disposed in the upper layer of the catalyst coating layer, and the Pd is disposed in both the upper layer and the lower layer of the catalyst coating layer. At least a portion of the Pd in the upper layer and in the lower layer is supported on the OSC material. The mass ratio of the Pd disposed in the upper layer to the Pd disposed in the lower layer is not more than 0.4.

First claim

The invention claimed is:

1. An exhaust gas purification catalyst comprising a substrate and a catalyst coating layer on a surface of the substrate, wherein
the catalyst coating layer comprises a layered structure having upper and lower layers with the lower layer being closer to the surface of the substrate and the upper layer being relatively farther therefrom,
the catalyst coating layer is provided with Rh and Pd as precious metal catalysts,
the catalyst coating layer is provided with an OSC material having an oxygen storage capacity as a support,
the Rh is disposed in the upper layer of the catalyst coating layer,
the Pd is disposed in both the upper layer and the lower layer of the catalyst coating layer,
the support that supports the Rh in the upper layer is made of a ZrO 2 complex oxide that contains Y 2 O 3 ,
at least a portion of the Pd in the upper layer and in the lower layer is supported on the OSC material,
a mass ratio of the Pd disposed in the upper layer to the Pd disposed in the lower layer is at least 0.01 and not more than 0.4,
each of the lower layer and the upper layer has an upstream end with respect to an exhaust gas flow-through direction,
the upstream end of the lower layer includes an extension region that extends beyond the upstream end of the upper layer,
a front-stage upper layer is disposed on a portion of the surface of the extension region of the lower layer, the portion corresponding to 10% to 40% of the total length of the substrate from the upstream to the downstream thereof, and
the front-stage upper layer is provided with a support and contains an OSC material, and Pd is supported on the support.

2. The exhaust gas purification catalyst according to claim 1 , wherein the OSC material supporting at least a portion of the Pd in the upper layer and in the lower layer is made of CeO 2 or a CeO 2 —ZrO 2 complex oxide.

3. The exhaust gas purification catalyst according to claim 1 , wherein a mass ratio of the Rh to the Pd disposed in the upper layer is 1.25 to 5.

4. The exhaust gas purification catalyst according to claim 1 , wherein the mass ratio of the Pd disposed in the upper layer to the Pd disposed in the lower layer is 0.06 to 0.32.

5. The exhaust gas purification catalyst according to claim 1 , wherein
the support that supports the Rh contains a ZrO 2 complex oxide that contains Y 2 O 3 and Nd 2 O 3 , and
the OSC material that supports the at least a portion of the Pd contains a CeO 2 —ZrO 2 complex oxide that contains La 2 O 3 and Pr 6 O 11 .

Assignees

• Aoki Yuki
• Toyota Motor Co Ltd

Inventors

• Aoki Yuki

Classifications

• Y02T10/22

  Cross-Sectional Technologies · mapped topic

• B01J23/002

  Mixed oxides other than spinels, e.g. perovskite · CPC title

• B01J2523/3725

  Neodymium · CPC title

• B01D2255/1023

  Palladium · CPC title

• B01D2255/2065

  Cerium · CPC title