Cataler Corporation

Toyota Jidosha Kabushiki Kaisha

Kabushiki Kaisha Toyota Chuo Kenkyusho

Shingo Sakagami

Ryota Onoe

Tsuyoshi Ito

Naoto Miyoshi

Masahiko Takeuchi

Akemi Sato

Tatsuya Ohashi

Yuta Morishita

Yasutaka Nomura

Hiroshi Sekine

Junji Kuriyama

Takeru Yoshida

Yuki Aoki

Daisuke Ochiai

Naoki Takahashi

Hiromasa Suzuki

Toshitaka Tanabe

Isao Chinzei

Hirotaka Ori

Yoshinori Saito

Miho Hatanaka

Masaaki Kawai

Tomoyuki Goshima

Tamio Kosaka

Masahiro Nakahara

The exhaust gas cleaning catalyst according is provided with a substrate and a catalyst coat layer formed on a surface of the substrate. The catalyst coat layer is formed as a laminate structure having an upper layer and a lower layer. The upper layer is a Pd-free layer that does not contain Pd, and the lower layer is a Pd-containing layer. In addition, when a region of the lower layer that corresponds to 20% of the length of the exhaust gas cleaning catalyst from the exhaust gas inlet side end towards the exhaust gas outlet side of the exhaust gas cleaning catalyst is divided into four equal regions to be each 5% of the length, the relationship A&#x3e;B&#x3e;C is satisfied, where A, B, and C represents the Pd content in the first, second, and third region respectively.

Exhaust gas cleaning 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.

Exhaust gas purification catalyst

An exhaust gas purification device of the present invention is provided with: a substrate of wall flow structure having an inlet cell, an outlet cell and a porous partition wall; an upstream catalyst layer, provided inside the partition wall and disposed in an upstream portion of the substrate including an exhaust gas inflow end section; and a downstream catalyst layer, provided inside the partition wall and disposed in a downstream portion of the substrate including an exhaust gas outflow end section. The upstream catalyst layer and the downstream catalyst layer each contain a carrier and at least one noble metal from among Pt, Pd and Rh, supported on the carrier. The noble metal in the upstream catalyst layer and the noble metal in the downstream catalyst layer are different from each other.

Exhaust gas purification device

An exhaust gas purification catalyst having an excellent exhaust partition ability while reducing the increase in pressure loss. Exhaust gas purification catalyst includes a substrate having a wall-flow structure with partition wall, upstream coating section formed in portions of partition wall facing entrance cell, from exhaust inlet-side end in the extending direction of partition wall, and downstream coating section formed in portions of partition wall facing exit cell, from exhaust outlet-side end in the extending direction, having a length shorter than the entire length Lof the partition wall. In downstream coating section, a catalytic metal is concentrated in the surface layer in contact with exit cell.

A exhaust gas purification apparatus is provided with; a substrate having a wall-flow structure and including entry-side cells, exit-side cells, and a porous partition; a first catalyst region formed in small diameter pores having relatively small pore diameters among internal pores in the partition; and a second catalyst region formed in large diameter pores having relatively large pore diameters among the internal pores in the partition. The first catalyst region contains a support and any one or two species of precious metal selected from Pt, Pd, and Rh loaded on the support, while the second catalyst region contains a support and any one or two species of precious metal selected from Pt, Pd, and Rh loaded on the support and other than at least the precious metal present in the first catalyst region.

Exhaust gas purification apparatus

The exhaust gas purification device is provided with a wall flow structure substrate that has an entry-side cell, an exit-side cell and a porous partition, first catalyst parts which are formed in small pores having a relatively small pore diameter among internal pores in the partition, and second catalyst parts which are formed in large pores having a relatively large pore diameter among the internal pores in the partition. The first catalyst parts and the second catalyst parts each contain a carrier and at least one type of noble metal from among Pt, Pd and Rh supported on the carrier. The noble metal content in the first catalyst parts is smaller than the noble metal content in the second catalyst parts per 1 liter of substrate volume.

An exhaust gas purification catalyst having an excellent exhaust gas purification ability while reducing the increase in pressure loss. Exhaust gas purification catalyst includes entrance cell, exit cell, and a wall-flow substrate having partition wall to separate these cell, a catalytic layer formed from exhaust inlet-side ends in the extending direction in sections of the interior of partition wall facing entrance cell, and a catalytic layer formed on the surface of partition wall facing exit cell from exhaust outlet-side ends in the extending direction of partition wall, having a length shorter than the entire partition wall length.

The exhaust gas purification device provided with a particulate filter disposed in an exhaust passage of an internal combustion engine and capturing particulate matter in exhaust gas discharged from the internal combustion engine. The particulate filter is provided with a wall-flow part having an inlet-side cell that is open only at an end on an exhaust gas inflow side, an outlet-side cell that is adjacent to this inlet-side cell and is open only at an end on an exhaust gas outflow side, and a porous wall that partitions the inlet-side cell from the outlet-side cell, and is also provided with a straight-flow part having a through cell that penetrates the filter in an axial direction thereof and is open at the end on the exhaust gas inflow side as well as the end on the exhaust gas outflow side.

Exhaust gas purification device and particulate filter

An exhaust gas purification catalyst that has an excellent exhaust gas purification performance while suppressing pressure loss increases. The exhaust gas purification catalyst is provided with a substrate having a wall-flow structure and having a partition; a first catalyst layer formed, in a region of an interior part of the partition that is in contact with an entrance cell, along the extending direction of the partition from an exhaust gas inflow-side end for less than the total length Lof the partition; and a second catalyst layer formed, in a region of an interior part of the partition that is in contact with an exit cell, along the extending direction of the partition from the exhaust gas outflow-side end for less than the total length Lof the partition. The first catalyst layer and the second catalyst layer are configured to partially overlap with each other in the extending direction.

A wall-flow-type exhaust gas purification catalyst with an oxygen storage material that has an increased OSC and exhibits its OSC without a compromise provides an exhaust gas purification catalyst having a wall-flow-type substrate, a first catalytic layer and a second catalytic layer. The first catalytic layer is provided to an internal portion of a partition wall in contact with an entrance cell. The second catalytic layer is provided to an internal portion of a partition wall in contact with an exit cell. Each of the first and second catalytic layers has an oxygen storage material. The ratio (D/D) of the coating density Dof the first catalytic layer to the coating density Dof the second catalytic layer is 1.1 to 1.8.

An exhaust gas purification catalyst capable of stably maintaining and exhibiting excellent catalytic performance includes a wall-flow-type substrate, a first catalytic layer and a second catalytic layer. The first catalytic layer is provided to an internal portion of a partition wall in contact with an entrance cell. The second catalytic layer is provided to an internal portion of a partition wall in contact with an exit cell. The ratio (D/D) of the coating density Dof the second catalytic layer to the coating density Dof the first catalytic layer is 1.01 to 1.4.

The exhaust gas purification device according to the present invention includes a substrate of wall flow structure having a porous partition wall, and a catalyst layer held in internal pores of the partition wall. The catalyst layer contains, as a carrier, an OSC material having oxygen storage capacity. In the thickness direction of the partition wall, the porosity of the internal pores in inlet regionsis 25% or higher, and an average occupation ratio of the catalyst layer held in the internal pores is 75% or lower.

Particulate filter provided in the exhaust gas purification device includes: a wall-flow part having an inlet-side cell that is open only at an end on an exhaust gas inflow side, outlet-side cell adjacent to this inlet-side cell and is open only at an end on an exhaust gas outflow side, a porous wall partitions the inlet-side cell from the outlet-side cell; a straight-flow part having a through cell that penetrates the filter in axial direction and is open at the end on the exhaust gas inflow side as well as the end on the exhaust gas outflow side. In a cross section of the filter orthogonal to its axial direction, cross-sectional areas of the inlet-side cell and outlet-side cell present in an outer peripheral region of the cross section are larger than cross-sectional areas of the inlet-side cells and the outlet-side cell in a central region of the cross section.

An exhaust gas purifying catalyst includes a substrate that defines an exhaust gas passage; a lower catalyst layer formed over the substrate, and an upper catalyst layer formed over the lower catalyst layer. The lower catalyst layer has a lower catalytic precious metal that contains at least one of Pt and Pd, and a lower-layer carrier that supports the lower catalytic precious metal. The upper catalyst layer has an upper catalytic precious metal that contains Rh, and an upper-layer carrier that supports the upper catalytic precious metal. The upper-layer carrier includes an inorganic mixed oxide that contains Ce, Zr, Al, Nd, and at least one element selected from the group consisting of rare earth elements other than Ce and alkaline earth elements. The Nd is unevenly distributed in covering layers that covers surfaces of interior regions within the inorganic mixed oxide.

Exhaust gas purifying catalyst

In a method of coating a substrate, inner walls of flow channels of the substrate are coated with a slurry. A plurality of flow channels each opened at both end faces are formed in the substrate. The method includes a step of storing a predetermined amount of slurry in a slurry container in which the end of the substrate, where the flow channels of the substrate are opened, can be inserted under pressure into the slurry container. A step of inserting the substrate with the end of the substrate being downward in the slurry container and dipping the substrate under pressure to the slurry liquid surface, and a step of extending the slurry along the inner wall of the flow channels by blow-opening the respective flow channels in a state of up-turning the slurry container together with the substrate.

Growing community of inventors

Kakegawa, Japan

Shingo Sakagami