Toyota Jidosha Kabushiki Kaisha

Ibiden Company Limited

Cataler Corporation

Takumi Tojo

Hiromasa Suzuki

Takeru Yoshida

Shinnosuke Goto

Isao Chinzei

Masaru Kakinohana

Minoru Ito

Sho Hoshino

Naoto Fujita

Masahide Miura

Takahiro Nishio

Kenta Nomura

Yoshiteru Yazawa

Hiroya Yamamoto

Hirotaka Ori

Shogo Shirakawa

Nobuyuki Takagi

Seiji Nakahigashi

Nobusuke Kabashima

Tomomasa Aikawa

Misako Makino

Yosuke Toda

Daisuke Mori

Shun Sakamoto

An exhaust gas purification device includes a substrate including an upstream end and a downstream end, the substrate having a length Ls between the upstream end and the downstream end; a first catalyst layer containing first catalyst particles, extending across a first region, and being in contact with the substrate, the first region extending between the upstream end and a first position, the first position being at a first distance La from the upstream end toward the downstream end; and a second catalyst layer containing second catalyst particles, extending across a second region, and being in contact with the substrate, the second region extending between the downstream end and a second position, the second position being at a second distance Lb from the downstream end toward the upstream end. The first catalyst layer has an inner surface defining macropores.

Exhaust gas purification device

The present disclosure provides an exhaust gas purification catalyst improved in OSC performance while maintaining an exhaust gas purification performance, which comprises a substrate and at least one catalyst layer formed on the substrate, wherein an uppermost catalyst layer contains a catalyst metal, a first OSC material having a pyrochlore structure, and a second OSC material having a higher oxygen storage/release rate than the first OSC material, wherein the uppermost catalyst layer consists of an upstream catalyst layer and a downstream catalyst layer, and wherein a proportion of a mass of the second OSC material based on a total mass of the first OSC material and the second OSC material is in a specific range in each of the upstream catalyst layer and the downstream catalyst layer.

Exhaust gas purification catalyst

Provided is an exhaust gas purification device that allows improving an exhaust gas purification performance. An exhaust gas purification device of the present disclosure includes a substrate and a catalyst layer disposed on the substrate. The catalyst layer contains a porous carrier, a catalytic metal that is supported by the porous carrier and belongs to platinum group, an alkaline earth metal supported by the porous carrier, and an alkaline earth metal not supported by the porous carrier. At least a part of the alkaline earth metal supported by the porous carrier is supported inside the porous carrier.

Provided is an exhaust gas purification catalyst having an improved catalyst performance while securing an OSC in an air-fuel ratio (A/F) rich atmosphere where HC poisoning is likely to occur. The present disclosure relates to an exhaust gas purification catalyst including a substrate and a catalyst coating layer coated on the substrate. The catalyst coating layer has an upstream coat layer formed from an end portion in an upstream side with respect to an exhaust gas flow direction in the exhaust gas purification catalyst and a downstream coat layer formed from an end portion in a downstream side with respect to the exhaust gas flow direction in the exhaust gas purification catalyst. The downstream coat layer includes Rh as a catalytic metal, alumina-ceria-zirconia complex oxide, and alkaline earth metal.

The present invention relates to a honeycomb catalytic converter, including: a honeycomb structured body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween; and Pd and Rh supported on the partition walls of the honeycomb structured body, wherein the honeycomb structured body is an extrudate containing a ceria-zirconia complex oxide and alumina, a Pd-carrying region where only Pd is supported is formed on the partition walls within a predetermined width from one end of the honeycomb structured body, and a Rh-carrying region where only Rh is supported is formed on the partition walls within a predetermined width from the other end of the honeycomb structured body, and the Pd-carrying region extends to at least 50% of the length of the honeycomb structured body, and the Rh-carrying region extends to at least 20% of the length of the honeycomb structured body.

Honeycomb catalytic converter

The present invention provides a method of producing a honeycomb structured body having excellent mechanical strength. The present invention relates to a method of producing a honeycomb structured body including a honeycomb fired body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween, the method including: a raw material mixing step of preparing a raw material paste containing ceria-zirconia composite oxide particles, alumina particles, an inorganic binder, and alumina fibers; a molding step of molding the raw material paste into a honeycomb molded body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween; a drying step of drying the honeycomb molded body obtained in the molding step; and a firing step of firing the honeycomb molded body dried in the drying step into a honeycomb fired body, wherein the percentage of amorphous alumina fibers in the alumina fibers for use in the raw material mixing step is 50 to 100 wt %.

Method of producing honeycomb structured body

The present invention provides a method of producing a honeycomb structured body having excellent mechanical strength. The present invention relates to a method of producing a honeycomb structured body including a honeycomb fired body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween, the method including: a raw material mixing step of preparing a raw material paste containing ceria-zirconia composite oxide particles, alumina particles, an inorganic binder, and inorganic fibers; a molding step of molding the raw material paste into a honeycomb molded body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween; a drying step of drying the honeycomb molded body obtained in the molding step; and a firing step of firing the honeycomb molded body dried in the drying step into a honeycomb fired body, wherein the raw material mixing step includes pre-mixing of the inorganic binder and the inorganic fibers.

An exhaust gas purification device includes a substrate including an upstream end and a downstream end and having a length Ls; a first containing Pd particles, extending between the upstream end and a first position, and being in contact with the substrate; a second containing Rh particles, extending between the downstream end and a second position, and being in contact with the substrate; and a third catalyst layer containing Rh particles, extending between the upstream end and a third position, and being in contact with at least the first catalyst layer, wherein an average of a Rh particle size distribution is from 1.0 to 2.0 nm, and a standard deviation of the Rh particle size distribution is 0.8 nm or less in each of the second catalyst layer and the third catalyst layer.

The present invention relates to a honeycomb catalytic converter including: a honeycomb structured body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween; a noble metal supported on the honeycomb structured body; and an inlet-side end face and on outlet-side end face, wherein each partition wall includes a substrate portion in the form of an extrudate containing a ceria-zirconia complex oxide and alumina, and a coat layer formed on a surface of the substrate portion and containing the noble metal, and the inlet-side end face has a higher aperture ratio than the outlet-side end face.

The present invention provides a honeycomb catalytic converter including: a honeycomb structured body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween; and a noble metal supported on the honeycomb structured body, wherein the honeycomb structured body contains a ceria-zirconia composite oxide and alumina, and cerium on a surface of each partition wall has a lower concentration than cerium in a central portion of the partition wall in a thickness direction.

The present invention relates to a honeycomb catalytic converter including: a honeycomb structured body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween; and a noble metal supported on the honeycomb structured body, wherein the honeycomb structured body contains a ceria-zirconia complex oxide and alumina, each partition wall includes a first carrier layer defining a surface layer of the partition wall and carrying Pd, and a second carrier layer located more inwardly of the partition wall than the first carrier layer and carrying Rh.

A honeycomb structured body includes a honeycomb fired body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween. The honeycomb fired body contains ceria-zirconia composite oxide particles and inorganic fibers. 60 to 80% of inorganic fibers observed in a cross-sectional image of the honeycomb structured body cut in a cross-sectional direction perpendicular to a longitudinal direction have a ratio of the length of a long axis to the length of a short axis (long axis/short axis) of 1.00 to 1.30. The length of the long axis is the length of a long axis of a cross section of an inorganic fiber shown in the cross-sectional image. The length of the short axis is the length of a perpendicular bisector of the long axis.

Honeycomb structured body

The present invention provides a honeycomb structured body containing a ceria-zirconia composite oxide and being less susceptible to ring-off cracking. The honeycomb structured body of the present invention includes a honeycomb fired body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween, wherein the honeycomb fired body contains ceria-zirconia composite oxide particles and inorganic fibers, and a b-axis thermal expansion coefficient measured in a direction along a b-axis representing a direction perpendicular to a longitudinal direction of the honeycomb structured body is higher than an a-axis thermal expansion coefficient measured in a direction along an a-axis representing the longitudinal direction of the honeycomb structured body.

The present invention relates to a honeycomb structured body including a honeycomb fired body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween, wherein the honeycomb fired body is an extrudate containing ceria-zirconia composite oxide particles, &#x3b8;-alumina particles, &#x3b3;-alumina, and &#x3b1;-alumina fibers, and the honeycomb fired body has a porosity of 55 to 70%.

Honeycomb structure and production method for said honeycomb structure

The present invention provides a honeycomb structured body capable of achieving more effective use of a catalyst in partition walls and having excellent exhaust gas conversion performance. The present invention relates to a honeycomb structured body including: a honeycomb fired body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween, wherein the honeycomb fired body contains ceria-zirconia composite oxide particles and alumina particles, the partition wall of the honeycomb fired body contains macropores having a pore size of 2 to 50 &#x3bc;m, and in an electron microscope image of a cross section of the partition wall, the percentage of the area occupied by pores having a pore size of 5 to 15 &#x3bc;m is at least 85% of the total area of the macropores.

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Toyota, Japan

Takumi Tojo