Cataler Corporation

Toyota Jidosha Kabushiki Kaisha

Ryota Onoe

Shingo Sakagami

Tsuyoshi Ito

Naoto Miyoshi

Masahiko Takeuchi

Akemi Sato

Yuta Morishita

Ryo Tasaki

Tatsuya Ohashi

Yasutaka Nomura

Momoko Iwai

Yamato Matsushita

Mamoru Yoshioka

Takahiko Fujiwara

Takahiro Tsukagoshi

Hiroshi Sekine

Fumito Chiba

Junji Kuriyama

Makoto Tomimatsu

Daisuke Ochiai

Takahiro Noguchi

Junichi Suzuki

Yuki Takesue

Yuki Aoki

Sho Hoshino

Chihiro Kasuya

Taku Miura

Hiromasa Suzuki

Shuntaro Okazaki

Koichi Kimura

Keiichi Narita

Oji Kuno

Koichi Kitaura

Takaya Ota

Masatoshi Ikebe

Atsushi Tanaka

Tetsuhiro Hirao

Shunsuke Oishi

Ichiro Kitamura

Nobusuke Kabashima

Kohei Takasaki

Satoru Inoda

Kyosuke Murakami

Takahiro Harada

Kazunari Sawada

Yosuke Toda

Haruka Makino

Kazuhiko Ito

Akihito Inoue

Jun Sawada

Yuuji Miyoshi

Masaya Ito

Koki Aono

An exhaust gas purifying catalyst includes a base material and a catalyst layer. A first catalyst region including the catalyst layer formed therein is provided on an entry side surface of a partition wall of the base material. A second catalyst region including the catalyst layer formed on a wall surface of a pore is provided in a prescribed region from an exit side surface of the partition wall toward an entry side cell. A catalyst unformed region in which a catalyst layer is substantially not formed is provided between the first and second catalyst regions in the thickness direction Y of the partition wall. Thus, it is possible to prevent the deposition of PMs in the second catalyst region including the catalyst layer formed in the pore, and to establish the compatibility between the noxious gas purifying performance and the pressure loss suppressing performance at a high level.

Exhaust gas purification catalyst

According to a technique disclosed herein, provided is an exhaust gas purification catalyst, which both suppresses OSC when using a new vehicle and maintains OSC during life cycles. The exhaust gas purification catalyst disclosed herein is an exhaust gas purification catalyst includes a substrate, and a catalyst coated layer formed on the surface of the substrate, wherein the catalyst coated layer contains an OSC material having an oxygen storage capacity. The catalyst coated layer includes a Rh layer mainly containing Rh as a catalyst metal, and a Pd/Pt layer mainly containing Pd and/or Pt as a catalyst metal. At least a portion of the Pd/Pt layer in the catalyst coated layer contains, as the OSC material, a low specific surface area OSC material, including a ceria-zirconia composite oxide and having a specific surface area of 40 m/g or more and 60 m/g or less.

A particulate filter includes a base material having a wall-flow structure including porous partition walls partitioning inlet and outlet cells, and wash-coating layers held inside partition walls. The wash-coating layers include inlet layers each formed from vicinity of an end portion at exhaust gas inflow side to have predetermined length and thickness and outlet layers each formed from vicinity of end portion at exhaust gas outflow side to have a predetermined length and thickness. The inlet and the outlet layers partially overlap with each other. Inlet layers of particulate filter contain substantially no noble metal catalyst, and outlet layers contain noble metal catalyst. Accordingly, PM collection performance can be easily enhanced in inlet region, and high gas distributability (pressure loss suppression performance) can be maintained in outlet region. Accordingly, it is possible to provide particulate filter capable of achieving high levels of PM collection performance and pressure loss suppression performance.

Particulate filter

An exhaust gas purification catalyst provides excellent removal performance of methane, which is chemically stable. Exhaust gas purification catalyst includes a substrate that divides cells through which an exhaust gas flows and a catalyst layer that is provided on a surface of the substrate. The catalyst layer includes a palladium layer containing palladium that extends from a first end part which is an end part on the side into which an exhaust gas in the cells flows to a second end part which is an end part on the side from which an exhaust gas flows out, a platinum layer containing platinum that extends from the second end part to the first end part, and a rhodium layer containing rhodium that is laminated with both the palladium layer and the platinum layer.

The technology disclosed herein provides a particulate filter that can appropriately avoid PM from passing toward the outlet cell and can exhibit an excellent PM capturing performance. The particulate filterdisclosed herein includes: an outercoat layerprovided on an inlet surfaceof a partitionof a base material. The outercoat layerat least includes: a lower layerprovided on the inlet surfaceof the partition; and an upper layerprovided to cover the lower layer. The mean particle diameter of granules contained in the upper layeris higher than the mean particle diameter of granules contained in the lower layer. The mean particle diameter of the granules in the lower layeris from 0.4 μm to 2.0 μm inclusive, and the mean particle diameter of the granules in the upper layeris from 2.0 μm to 7.0 μm inclusive. With such a configuration, PM can be captured in an inlet cell, thereby suitably avoiding PM from passing toward an outlet celland exhibiting an excellent PM capturing performance.

A particulate filter disclosed herein includes a wall-flow structure substrateand a wash coat layerheld inside a partitionof the substrate. The wash coat layerincludes an inlet layerformed to have predetermined length Land thickness Tfrom near an end thereof on an exhaust gas inflow side X, and an outlet layerformed to have predetermined length Land thickness Tfrom near an end thereof on an exhaust gas outflow side X. The inlet layerand the outlet layerpartially overlap each other. In the particulate filter disclosed herein, the inlet layercontains a precious metal catalyst, while the outlet layercontains substantially no precious metal catalyst. The length Lof the inlet layer is 50% or more and 75% or less of a total length L of the partition. Thus, the particulate filter is capable of achieving both PM collection performance and pressure-drop reduction performance at high levels.

Provided is a particulate filter in which a PM collection rate is stably increased. The particulate filter according to the present invention includes a substratehaving a wall flow structure having a porous partition wallthat partitions an inlet cell and an outlet cell, and a wash coat layer held on surfaces of internal pores of the partition wall. In addition, average filling rates A, B, and C of the wash coat layer measured for each predetermined pore diameter range in the internal pores satisfy specific relationships. Further, the wash coat layer is formed in a region that occupies 50% or more of a thickness of the partition wall, and an amount of a noble metal catalyst carried by the wash coat layer is 0 g/L or more but 0.2 g/L or less.

An exhaust gas purification catalyst having a substrate having a wall flow structure, and a catalyst layer. The catalyst layer has: an A section provided in the interior of the partition wall, along an extension direction X of the partition wall, from an exhaust gas inflow end section; a C section provided in the interior of the partition wall, along the extension direction X of the partition wall, from an exhaust gas outflow end section; and a B section disposed between the A section and the C section in the extension direction X of the partition wall, and provided over the surface of the partition wall on the side in contact with the inlet cell, the interior of the partition wall, and the surface of the partition wall on the side in contact with the outlet cell.

An exhaust gas purification catalyst comprises a substrate; a catalyst layer formed on the substrate and containing at least palladium (Pd) and rhodium (Rh) as a metal functioning as an oxidation and/or reduction catalyst. The catalyst also comprises a carrier that supports the metal, and an OSC material having oxygen storage capacity. The catalyst layer has, when disposed in the exhaust pipe, a front section positioned upstream in an exhaust gas flow direction within the exhaust pipe, and a rear section positioned downstream of the front section in the exhaust gas flow direction. The front section contains palladium (Pd) but does not contain the OSC material, and a proportion, at which the front section is formed from an upstream leading end in the exhaust gas flow direction, is 10% to 40% with respect to 100% of a total length of the substrate.

Provided is an exhaust gas purification catalyst body that can improve exhaust gas purification performance while maintaining favorable PM collection performance. The exhaust gas purification catalyst body includes a base of a wall flow structure having an inlet side cell, an outlet side cell, and porous partition wall, and a catalyst layer that is formed in the partition wall that is in contact with the inlet side cell or the outlet side cell. The catalyst layer is formed in a region of at least 50% of the thickness of the partition wall from a surface of the partition wall, and held on the surface of internal pores in the partition wall in the region.

Exhaust gas purification catalyst body

An exhaust gas purification catalyst of the present invention is provided with a baseand a catalyst coat layer. The catalyst coat layer is provided with Rh and Pd as noble metal catalysts. Herein Rh is disposed in a first-stage upper layer A and a second-stage upper layer C, and Pd is disposed in the first-stage upper layer A and a first-stage lower layer B, and in a second-stage lower layer D. A mass ratio (A/A) of Pd to Rh, disposed in first-stage upper layer A is 0.5&#x2264;(A/A)&#x2264;3.

An exhaust gas cleaning catalyst that has: a substrate having a wall flow structure, wherein an entry side cell, in which the end part on an exhaust gas inflow side is open, and an exit side cell, in which the end part on the exhaust gas outflow side is open, are divided by a porous dividing wall; and a first catalyst layer that includes a metal catalyst and is disposed within the dividing wall so as to be in contact with the exit side cell and not in contact with the entry side cell, and no catalyst layer is provided in the region in contact with the entry side cell.

Exhaust gas cleaning catalyst

An exhaust gas purifying catalyst includes a catalyst layer formed inside a partition wall of a base material having a wall flow structure, and has an upstream-side and a downstream-side catalyst layer. The upstream-side catalyst layer includes Rh and a Ce-containing oxide, and the downstream-side catalyst layer includes Pd and a Ce-containing oxide. The mass of the catalyst layer per unit volume of the base material is from 105 g/L to 210 g/L, the mass of the upstream-side catalyst layer per unit volume in an upstream-side portion is from 50 g/L to 100 g/L, the mass of the downstream-side catalyst layer per unit volume in a downstream-side portion is from 100 g/L to 150 g/L, the Ce amount per unit volume of the base material is from 14 g/L to 35 g/L, and the Ce amount per unit volume in the upstream-side portion is from 5 g/L to 20 g/L.

Exhaust gas purifying catalyst

Provided is an exhaust gas purification catalyst in which the performance of a catalyst metal can be brought out properly, the purification catalyst boasting excellent purification performance during warm-up of an internal combustion engine. The exhaust gas purification catalystis provided with a substrateand a catalyst layer. A leading end sectionpositioned upstream in the direction of exhaust gas flow (arrow) has a portion in which the flow rate of exhaust gas is relatively high and a portion in which the flow rate of exhaust gas is relatively low during warm-up of the internal combustion engine. The catalyst, layer in the portion of relatively high flow rate of exhaust gas has a high density sectionin which a noble metal, is supported at relatively high density. The high density sectionis formed to be shorter than the total length of the exhaust gas purification catalystfrom the leading end sectionin the direction of exhaust gas flow.

Growing community of inventors

Kakegawa, Japan

Ryota Onoe