Catalytic converter

Patent metadata

Field	Value
Publication number	US-9731275-B2
Application number	US-201314761808-A
Country	US
Kind code	B2
Filing date	Nov 26, 2013
Priority date	Jan 23, 2013
Publication date	Aug 15, 2017
Grant date	Aug 15, 2017

Abstract

Provided is a catalytic converter in which the entire catalyst constituting the catalytic converter can be efficiently utilized to purify exhaust gas, and the emission of hydrogen sulfide can be suppressed.
A catalytic converter 10 includes catalyst layers 2 A, 2 B formed of a noble metal catalyst that are formed on cell wall surfaces of a substrate 1 having a cell structure in a longitudinal direction of the substrate 1 in which gas flows, in which the substrate 1 has a center region 1 A having a relatively high cell density and a peripheral region 1 B having a relatively low cell density, and lengths of the catalyst layers 2 A, 2 B of the center region 1 A and the peripheral region 1 B in the longitudinal direction are the same as each other, or the length of the catalyst layer 2 B in the longitudinal direction is shorter than that of the catalyst layer 2 A.

First claim

The invention claimed is:

1. A catalytic converter comprising:
a substrate that has a cell structure and is configured to allow gas to flow through the substrate; and
a catalyst layer that is formed of a noble metal catalyst and is formed on a cell wall surface of the substrate, the catalyst layer extending in a longitudinal direction of the substrate,
wherein the substrate has a center region and a peripheral region, the center region having a cell density higher than a cell density of the peripheral region,
the cell wall surface includes a center cell wall surface provided in the center region and a peripheral cell wall surface provided in the peripheral region,
the cell density of the center region is two times or lower than the cell density of the peripheral region,
the catalyst layer includes a first catalyst layer provided in the center region and a second catalyst layer provided in the peripheral region,
the first catalyst layer includes a first lower layer and a first upper layer,
the first lower layer is provided on the center cell wall surface,
the first upper layer is provided on the first lower layer and is in direct contact with a flow path for exhaust gas,
the second catalyst layer includes a second lower layer and a second upper layer,
the second lower layer is provided on the peripheral cell wall surface,
the second upper layer is provided on the second lower layer and is in direct contact with a flow path for exhaust gas,
a length of the substrate, a length of the first upper layer, and a length of the second upper layer are equal to each other in the longitudinal direction,
a ratio of a length of the first lower layer to the length of the substrate is 80% in the longitudinal direction, and
a ratio of a length of the second lower layer to the length of the substrate is 50% to 80% in the longitudinal direction.

2. A catalytic converter comprising:
a substrate that has a cell structure and is configured to allow gas to flow through the substrate; and
a catalyst layer that is formed of a noble metal catalyst and is formed on a cell wall surface of the substrate, the catalyst layer extending in a longitudinal direction of the substrate,
wherein the substrate has a center region and a peripheral region, the center region having a cell density higher than a cell density of the peripheral region,
the cell wall surface includes a center cell wall surface provided in the center region and a peripheral cell wall surface provided in the peripheral region,
the cell density of the center region is two times or lower than the cell density of the peripheral region,
the catalyst layer includes a first catalyst layer provided in the center region and a second catalyst layer provided in the peripheral region,
the first catalyst layer includes a first lower layer and a first upper layer,
the first lower layer is provided on the center cell wall surface,
the first upper layer is provided on the first lower layer and is in direct contact with a flow path for exhaust gas,
the second catalyst layer includes a second lower layer and a second upper layer,
the second lower layer is provided on the peripheral cell wall surface,
the second upper layer is provided on the second lower layer and is in direct contact with a flow path for exhaust gas,
a length of the substrate, a length of the first upper layer, are a length of the second upper layer are equal to each other in the longitudinal direction, and
a ratio of a length of the first lower layer to the length of the substrate is 70% to 90% in the longitudinal direction.

Assignees

• Aoki Yuki
• Suzuki Hiromasa
• Matsubara Hiroyuki
• Toyota Motor Co Ltd

Inventors

• Aoki Yuki
• Suzuki Hiromasa
• Matsubara Hiroyuki

Classifications

• B01J37/0244

  Coatings comprising several layers · CPC title

• F01N2330/48

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

• B01D2255/9032

  Two zones · CPC title

• B01J23/464

  Rhodium · CPC title

• B01D53/945

  characterised by a specific catalyst · CPC title