Exhaust gas catalyst

Patent metadata

Field	Value
Publication number	US-9694354-B2
Application number	US-201314423210-A
Country	US
Kind code	B2
Filing date	Sep 25, 2013
Priority date	Nov 20, 2012
Publication date	Jul 4, 2017
Grant date	Jul 4, 2017

Abstract

An object of the present invention is to provide an exhaust gas catalyst that can achieve high purification performance. The exhaust gas catalyst includes: a base material ( 3 ) having a plurality of inner wall surfaces ( 7 ) formed by a plurality of through holes ( 5 ) penetrating therethrough from a first end surface ( 3 a ) to a second end surface ( 3 b ); and a plurality of catalyst layers ( 9 ) formed on the plurality of inner wall surfaces ( 7 ), respectively, wherein: each of the through holes ( 5 ) has a central axis ( 5 X); each of the catalyst layers ( 9 ) is sectioned into a first region ( 9 A) extending from the first end surface ( 3 a ) toward the second end surface ( 3 b ) by a predetermined distance, a second region ( 9 B) extending from the second end surface ( 3 b ) toward the first end surface ( 3 a ) by a predetermined distance, and a third region ( 9 C) placed between the first region ( 9 A) and the second region ( 9 B); and the catalyst layer ( 9 ) is formed such that a distance (h 1 ) from the central axis ( 5 X) of the through hole ( 5 ) to an inner surface ( 9 m ) of the catalyst layer ( 9 ) in the first region ( 9 A) of the catalyst layer ( 9 ) is smaller than a distance (h 3 ) from the central axis ( 5 X) of the through hole ( 5 ) to the inner surface ( 9 m ) of the catalyst layer ( 9 ) in the third region ( 9 C) of the catalyst layer ( 9 ), but is larger than a distance (h 2 ) from the central axis ( 5 X) of the through hole ( 5 ) to the inner surface ( 9 m ) of the catalyst layer ( 9 ) in the second region ( 9 B).

First claim

The invention claimed is:

1. An exhaust gas catalyst comprising:
a base material having a first end surface, a second end surface, and a plurality of inner wall surfaces formed by a plurality of through holes penetrating therethrough from the first end surface to the second end surface; and
a plurality of catalyst layers formed on the plurality of inner wall surfaces, respectively, wherein:
each of the through holes has a central axis;
the first end surface side is an exhaust gas inflow side and the second end surface side is an exhaust gas outflow side;
each catalyst layer is sectioned into a first region extending from the first end surface toward the second end surface by a predetermined distance, a second region extending from the second end surface toward the first end surface by a predetermined distance, and a third region placed between the first region and the second region;
the third region of the catalyst layer is closer to the first end surface side than to the second end surface side;
each catalyst layer is formed such that a distance from the central axis of the through hole to an inner surface of the catalyst layer in the first region of the catalyst layer is smaller than a distance from the central axis of the through hole to the inner surface of the catalyst layer in the third region of the catalyst layer, but larger than a distance from the central axis of the through hole to the inner surface of the catalyst layer in the second region of the catalyst layer;
each catalyst layer has a uniform thickness in an entire region including the first region, the second region and the third region;
in each region, each catalyst layer has a constant height;
the plurality of catalyst layers is made of the same composition in a whole region including the first region, the second region, and the third region,
at least one dummy layer is formed between the inner wall surface and the catalyst layer in the first region, and
at least one dummy layer is formed between the inner wall surface and the catalyst layer in the second region; and
the base material is a monolith honeycomb base material made of a heat-resistant ceramic.

2. The exhaust gas catalyst according to claim 1 , wherein the third region has a length of not less than 10% but not more than 50% of the overall length of the through hole.

Assignees

• Toyota Motor Co Ltd

Inventors

• Aoki Yuki
• Suzuki Hiromasa
• Onoe Ryota

Classifications

• B01D53/9454 Primary

  characterised by a specific device · CPC title

• Y10T428/24273

  including aperture · CPC title

• F01N3/023

  using means for regenerating the filters, e.g. by burning trapped particles · CPC title

• F01N2330/06

  Ceramic, e.g. monoliths · CPC title

• B01D2255/2065

  Cerium · CPC title