Exhaust cleaning catalyst

Patent metadata

Field	Value
Publication number	US-9694348-B2
Application number	US-201414914299-A
Country	US
Kind code	B2
Filing date	Dec 9, 2014
Priority date	Dec 13, 2013
Publication date	Jul 4, 2017
Grant date	Jul 4, 2017

Abstract

Provided is an exhaust catalyst that exhibits higher NO X -reducing activities at the time of engine restart while maintaining its catalytic activities during normal traveling. This invention provides an exhaust cleaning catalyst comprising a substrate and a catalyst coating layer that includes CeO 2 . Catalyst coating layer is constituted in its thickness direction with multiple coating layers. In a top coating layer located at the outermost surface, the CeO 2 content in a top coating layer's upstream portion is less than the CeO 2 content in a top coating layer's downstream portion; and the CeO 2 content in the top coating layer's upstream portion is less than the CeO 2 content in a lower coating layer. The CeO 2 content per liter of catalyst volume in the entire coating layer is 10 g/L to 30 g/L.

First claim

The invention claimed is:

1. An exhaust cleaning catalyst placed in an exhaust path from an internal combustion engine to clean exhaust expelled from the internal combustion engine,
the catalyst comprising a porous substrate and a catalyst coating layer formed on the porous substrate,
the catalyst coating layer having a carrier and a precious metal catalyst carried by the carrier,
the carrier comprising an OSC material that includes at least CeO 2 ,
the catalyst coating layer being constituted in its thickness direction with multiple coating layers that includes at least two layers having different compositions, wherein
in its top coating layer forming the uppermost layer that is located at the outermost surface among the multiple coating layers;
the CeO 2 content in a top coating layer's upstream portion that includes at least 20% of the full length of the top coating layer from the exhaust entrance-side end along the exhaust flow direction is less than the CeO 2 content in a top coating layer's downstream portion that includes at least 20% of the full length of the top coating layer from the exhaust exit-side end along the exhaust flow direction; and
the CeO 2 content in the top coating layer's upstream portion is less than the CeO 2 content in a lower coating layer that is closer to the porous substrate than the top coating layer is among the multiple coating layers; and

the CeO 2 content per liter of catalyst volume in the entire catalyst coating layer is 10 g/L to 30 g/L.

2. The exhaust cleaning catalyst according to claim 1 , wherein the CeO 2 content in the top coating layer's upstream portion is 1/100 to 1/2 times the CeO 2 content in the top coating layer's downstream portion.

3. The exhaust cleaning catalyst according to claim 1 , wherein the CeO 2 content per liter of catalyst volume in the top coating layer's upstream portion is 0.1 g/L to 2 g/L.

4. The exhaust cleaning catalyst according to claim 1 , wherein with the full length of the top coating layer in the exhaust flow direction being 100, the (upstream/downstream) ratio of length of top coating layer's upstream portion along the exhaust flow direction to length of top coating layer's downstream portion along the exhaust flow direction is 20/80 to 75/25.

5. The exhaust cleaning catalyst according to claim 1 , wherein the precious metal catalyst is at least one species among Pt, Pd and Rh.

6. The exhaust cleaning catalyst according to claim 5 , wherein the top coating layer comprises Pd and Rh as the precious metal catalyst.

Assignees

• Cataler Corp

Inventors

• Hoshino Sho
• Hirai Akimasa
• Taki Kenichi
• Matsueda Satoshi

Classifications

• B01J35/45

  Nanoparticles · CPC title

• B01D2258/014

  Stoichiometric gasoline engines · CPC title

• B01J35/006

  Operations & Transport · mapped topic

• F01N3/101

  Three-way catalysts · CPC title

• B01J2523/00

  Constitutive chemical elements of heterogeneous catalysts · CPC title