Catalytic converter

Patent metadata

Field	Value
Publication number	US-9873085-B2
Application number	US-201715446204-A
Country	US
Kind code	B2
Filing date	Mar 1, 2017
Priority date	Apr 13, 2016
Publication date	Jan 23, 2018
Grant date	Jan 23, 2018

Abstract

A catalytic converter with excellent OSC performance and No x purification performance. The catalytic converter includes a substrate with a cell structure and a catalyst layer formed on a cell wall surface of the substrate. The catalyst layer has a catalyst layer arranged on the upstream side and a catalyst layer arranged on the downstream side in an exhaust gas flow direction on the substrate. The catalyst layer on the upstream side includes a support containing an Al 2 O 3 —CeO 2 —ZrO 2 ternary composite oxide (ACZ material) and an Al 2 O 3 —ZrO 2 binary composite oxide (AZ material), and at least Rh that is a noble metal catalyst carried on the support, and the catalyst layer on the downstream side includes a support and Pd or Pt that is a noble metal catalyst carried on the support. In the support in the catalyst layer on the upstream side, the mass proportion of ACZ material/(ACZ material+AZ material) is in the range of 0.33 to 0.5, and greater than or equal to 75% mass Rh is carried on the Al 2 O 3 —ZrO 2 binary composite oxide of the support.

First claim

What is claimed is:

1. A catalytic converter comprising:
a substrate with a cell structure through which exhaust gas flows; and
a catalyst layer formed on a cell wall surface of the substrate,
wherein:
the catalyst layer has a catalyst layer on an upstream side arranged on the upstream side in an exhaust gas flow direction on the substrate, and a catalyst layer on a downstream side arranged on the downstream side in the exhaust gas flow direction on the substrate,
the catalyst layer on the upstream side includes a support containing an Al 2 O 3 —CeO 2 —ZrO 2 ternary composite oxide and an Al 2 O 3 —ZrO 2 binary composite oxide, and at least Rh that is a noble metal catalyst carried on the support,
the catalyst layer on the downstream side includes a support, and Pd or Pt that is a noble metal catalyst carried on the support,
in the support in the catalyst layer on the upstream side, a mass proportion of the Al 2 O 3 —CeO 2 —ZrO 2 ternary composite oxide/(the Al 2 O 3 —CeO 2 —ZrO 2 ternary composite oxide+the Al 2 O 3 —ZrO 2 binary composite oxide) is in a range of 0.33 to 0.5, and
in the catalyst layer on the upstream side, greater than or equal to 75 mass % Rh is carried on the Al 2 O 3 —ZrO 2 binary composite oxide of the support.

2. The catalytic converter according to claim 1 , wherein:
the catalyst layer on the upstream side and the catalyst layer on the downstream side partially overlap with each other, and
in a portion where the catalyst layer on the upstream side and the catalyst layer on the downstream side partially overlap with each other, the catalyst layer on the downstream side is arranged on a surface of the substrate, and the catalyst layer on the upstream side is arranged on a surface of the catalyst layer on the downstream side.

3. A catalytic converter comprising:
a substrate with a cell structure through which exhaust gas flows; and
a catalyst layer formed on a cell wall surface of the substrate,
wherein:
the catalyst layer has a lower catalyst layer arranged on a surface of the substrate, and an upper catalyst layer arranged on a surface of the lower catalyst layer,
the upper catalyst layer includes a support containing an Al 2 O 3 —CeO 2 —ZrO 2 ternary composite oxide and an Al 2 O 3 —ZrO 2 binary composite oxide, and at least Rh that is a noble metal catalyst carried on the support,
the lower catalyst layer includes a support, and Pd or Pt that is a noble metal catalyst carried on the support,
in the support in the upper catalyst layer, a mass proportion of the Al 2 O 3 —CeO 2 —ZrO 2 ternary composite oxide/(the Al 2 O 3 —CeO 2 —ZrO 2 ternary composite oxide+the Al 2 O 3 —ZrO 2 binary composite oxide) is in a range of 0.33 to 0.5, and
in the upper catalyst layer, greater than or equal to 75 mass % Rh is carried on the Al 2 O 3 —ZrO 2 binary composite oxide of the support.

Assignees

• Toyota Motor Co Ltd

Inventors

• Yoshida Takeru
• Suzuki Hiromasa
• Aoki Yuki
• Chinzei Isao

Classifications

• B01J35/57

  Honeycombs · CPC title

• B01D2255/1021

  Platinum · CPC title

• B01D2255/2092

  Aluminium · CPC title

• B01D2255/9025

  Three layers · CPC title

• B01D2255/20715

  Zirconium · CPC title