Cataler Corporation

Toyota Jidosha Kabushiki Kaisha

Takaya Ota

Koji Sugiura

Masatoshi Ikebe

Shunsuke Oishi

Keisuke Murawaki

Takeshi Morishima

Hiromasa Suzuki

Yoshinori Saito

Seiji Nakahigashi

Kohei Takasaki

Takeshi Hirabayashi

Ryosuke Takasu

Akemi Satou

Isao Chinzei

Taku Miura

Hiromasa Nishioka

Ryota Onoe

Naoto Miyoshi

Tatsuya Ohashi

Hirotaka Ori

Sho Hoshino

Akemi Sato

Ryota Nakashima

Hiromi Togashi

Yuki Takesue

Shunsuke Ohishi

Eiji Harada

In accordance with the technology herein disclosed, an exhaust gas purification catalyst exhibiting a high exhaust gas purifying performance using a new rare earth-containing material is provided. The exhaust gas purification catalyst herein disclosed includes a base material and a catalyst layer formed on the surface of the base material. The catalyst layer of such an exhaust gas purification catalyst includes rare earth-carrying alumina 50 including a primary particle of a rare earth particle 40 including at least one rare earth element carried on the surface of an alumina carrier 30 including alumina, and the average particle diameter Dbased on TEM observation of the rare earth particle 40 in the rare earth-carrying alumina 50 is 10 nm or less. As a result of this, it is possible to provide an exhaust gas purification catalyst having high NOx adsorption performance and CO adsorption performance.

Exhaust gas purification catalyst

An exhaust gas purification catalyst showing resistance to peeling and high purification performance is provided. The present invention is an exhaust gas purification catalyst including a base material and a catalyst layer disposed on the base material. The catalyst layer includes a catalytic metal, a first metal oxide, and a second metal oxide having a higher heat resistance than that of the first metal oxide. When Dx is an area-based average particle diameter of the first metal oxide determined from an arbitrary cross section of the catalyst layer and Dy is an area-based particle diameter of the second metal oxide 22 measured from the cross section of the catalyst layer, a ratio of the Dy to the Dx (Dy/Dx) is 5 or more, and the Dy is 7 μm or more. In the catalyst layer, pore volume of pores having pore diameters 30 nm or more measured by a nitrogen adsorption method is 0.28 cm/g or more.

The present invention provides an exhaust gas purification catalyst including a base materialand a catalyst layerprovided on the base material. The catalyst layerincludes: a catalyst metal; and a carrying materialcarrying the catalyst metal. The carrying materialincludes: an OSC materialhaving an oxygen storage capacity; and a carrierother than the OSC material. The OSC materialhas a mean particle diameter Dx of 1.5 μm or more which is larger than the mean particle diameter Dy of the carrierother than the OSC material

Provided is an exhaust gas purification system that allows suppressing the emission of carbon monoxide (CO). An exhaust gas purification system includes a three-way catalyst and a particulate filter and a control device. The three-way catalyst and the particulate filter are arranged respectively on an upstream side and a downstream side of an exhaust channel connected to an internal combustion engine. The control device controls the internal combustion engine so as to execute fuel cut during a deceleration operation of the internal combustion engine. The particulate filter includes a honeycomb substrate and an outflow cell side catalyst layer. The honeycomb substrate includes a porous partition wall defining a plurality of cells extending from an inflow side end surface to an outflow side end surface. The plurality of cells include an inflow cell and an outflow cell adjacent across the partition wall. The inflow cell has an open inflow side end and a sealed outflow side end. The outflow cell has a sealed inflow side end and an open outflow side end. The outflow cell side catalyst layer is disposed on an outflow cell side catalyst region extending from an outflow side end to a position apart toward an inflow side of the partition wall along an extending direction.

Exhaust gas purification system

An exhaust gas purification device suppresses a pressure loss increase and includes a honeycomb substrate and inflow cell side catalyst layer. The substrate includes a porous partition wall defining several cells extending from an inflow side end surface to an outflow side end surface. The cells include an inflow and outflow cell adjacent across the wall. The inflow cell has an open inflow side end and sealed outflow side end. The outflow cell has a sealed inflow side end and open outflow side end. The catalyst layer is on an inflow cell side surface in an region extending from the inflow side end positioned 10% or more of the partition wall length. At this position, a filled portion of the inflow cell side catalyst layer pores are 40% or less. The pores are present to a depth of 50% of a thickness of the partition wall.

Exhaust gas purification device

There is provided an exhaust gas purification device that shows a high HC removal performance under a condition in which a rich air-fuel mixture is introduced. The exhaust gas purification device includes a substrate, a first catalyst layer, and a second catalyst layer. The substrate includes an upstream end and a downstream end. The first catalyst layer is disposed on a surface of the partition wall in an upstream region including the upstream end of the substrate. The second catalyst layer is disposed inside the partition wall in a downstream region including the downstream end of the substrate. The first catalyst layer contains a first metal catalyst and alumina-zirconia composite oxide. The second catalyst layer contains a second metal catalyst.

The exhaust gas purification device includes a substrate, a first catalyst layer, and a second catalyst layer. The substrate includes an upstream end, a downstream end, and a porous partition wall defining a plurality of cells extending between the upstream end and the downstream end. The plurality of cells include an inlet cell opening at the upstream end and sealed at the downstream end, and an outlet cell adjacent to the inlet cell sealed at the upstream end and opening at the downstream end. The first catalyst layer is disposed on a surface of the partition wall in an upstream region. In a downstream region, the second catalyst layer is disposed inside the partition wall, and a second catalyst-containing wall including the partition wall and the second catalyst layer has a porosity of 35% or more.

Methods for exhaust gas purification, including the steps of: attaching an exhaust gas purification catalyst to an exhaust system of an internal combustion engine, and supplying an exhaust gas to the exhaust gas purification catalyst, where the exhaust gas purification catalyst includes an upper layer containing first carrier particles which are particles of an inorganic oxide and rhodium, and a lower layer containing second carrier particles which are particles of an inorganic oxide, the upper layer includes a rhodium-rich portion near the surface of the upper layer on the upstream side of the exhaust gas flow, and the existence range of the rhodium-rich portion is in a range of greater than 50% to 80% of the length of the upper layer from a downstream side end of an exhaust gas flow and of less than 20 &#x3bc;m in the depth direction from an outermost surface of the upper layer.

Methods for exhaust gas purification

The exhaust gas purification catalyst device includes an upper layer which includes first carrier particles and rhodium, and a lower layer which includes second carrier particles, and the upper layer includes a rhodium enriched area in the range a, from the upstream end in the exhaust gas flow to 50% of the upper layer length, and a range b from the upper layer top surface to 18 &#x3bc;m in the depth direction. The rhodium enriched area contains at least 50% and less than 100% of all the rhodium in the upper layer.

Exhaust gas purification catalyst device

An exhaust gas control apparatus includes a honeycomb substrate and an inlet cell-side catalyst layer. The honeycomb substrate includes a porous partition wall that defines a plurality of cells extending from an inlet-side end face to an outlet-side end face. The cells include an inlet cell and an outlet cell that are adjacent to each other with the partition wall therebetween. The inlet cell is open at its inlet-side end and is sealed at its outlet-side end. The outlet cell is sealed at its inlet-side end and is open at its outlet-side end. The inlet cell-side catalyst layer is provided on a surface on the inlet cell side of the partition wall and extends from an inlet-side end of the partition wall. Porosity of the inlet cell-side catalyst layer is in a specific range.

Exhaust gas control apparatus and manufacturing method thereof

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

The exemplary embodiments relate to an exhaust gas purification catalyst that is excellent in terms of HC purification capacity and warm-up performance. Such exhaust gas purification catalyst comprises a substrate and a catalyst coating layer formed on the surface of the substrate, wherein the catalyst coating layer comprises an upper and lower layer comprising a lower layer being closer to the surface of the substrate and an upper layer being relatively remote from the surface of the substrate, the upper layer of the catalyst coating layer comprises Rh, Pd, and a carrier, the upper layer of the catalyst coating layer comprises an uppermost surface Pd layer having a Pd concentration relatively higher than that in any other portion in the upper layer within an area extending over a length of 20 mm or more from one end on the upstream side in the downstream direction on the surface of the upper layer, the lower layer of the catalyst coating layer comprises at least one noble metal selected from Pd and Pt and a carrier, and 60% or more of Pd by mass in the uppermost surface Pd layer exists in a layer up to 50% of the upper layer in a thickness direction from the surface of the uppermost surface Pd layer being relatively remote from the surface of the substrate.

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Kakegawa, Japan

Takaya Ota