公开(公告)号：US10156170B2

公开(公告)日：2018-12-18

申请号：US15100716

申请日：2014-12-01

Applicant: CATALER CORPORATION

Inventor： Ryota Onoe ,  Shingo Sakagami ,  Tsuyoshi Ito ,  Tatsuya Ohashi

IPC: F01N3/02 ,  F01N3/022 ,  F01N3/035 ,  B01D46/24

Abstract: 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.

公开(公告)号：US10112181B2

公开(公告)日：2018-10-30

申请号：US15553020

申请日：2016-02-17

Applicant: KABUSHIKI KAISHA TOYOTA CHUO KENKYUSHO ,  TOYOTA JIDOSHA KABUSHIKI KAISHA ,  CATALER CORPORATION

Inventor： Satoru Katoh ,  Toshitaka Tanabe ,  Masahide Miura ,  Hiromasa Suzuki ,  Hiroaki Naito ,  Hirotaka Ori ,  Keiichi Narita ,  Michihiko Takeuchi ,  Tatsuya Ohashi

IPC: B01J23/63 ,  B01D53/94 ,  B01J35/02 ,  B01J35/10 ,  B01J37/02 ,  B01J37/08 ,  B01J35/04 ,  F01N3/28

Abstract: A catalyst for purification of exhaust gas, wherein a substrate and a catalyst coat layer which is formed on a surface of the substrate and which comprises catalyst particles, wherein the catalyst coat layer has an average thickness in a range of 25 to 160 μm, and a void fraction in a range of 50 to 80% by volume as measured by a weight-in-water method, 0.5 to 50% by volume of all voids in the catalyst coat layer consist of high-aspect ratio pores which have equivalent circle diameters in a range of 2 to 50 μm in a cross-sectional image of a cross-section of the catalyst coat layer which the cross-section is perpendicular to a flow direction of exhaust gas in the substrate, and which have aspect ratios of 5 or higher, and the high-aspect ratio pores have an average aspect ratio in a range of 10 to 50.

公开(公告)号：US20250001406A1

公开(公告)日：2025-01-02

申请号：US18704504

申请日：2022-09-28

Applicant: Cataler Corporation

Inventor： Tatsuhiro Oshima ,  Tatsuya Ohashi ,  Ryo Tasaki

IPC: B01J37/02 ,  B01J21/06 ,  B01J21/18 ,  B01J23/44 ,  B01J35/00 ,  B01J37/08 ,  F01N3/28

Abstract: The present disclosure provides a technology of reducing migration of a noble metal catalyst in high temperature environments and reducing degradation of temperature characteristics. The production method disclosed herein includes: preparing an SiC base material 10 which has partitions 16 partitioning multiple cells and contains SiC; and forming a Pd catalyst layer 20 containing at least Pd particles 22 on surfaces of the partitions 16 of the SiC base material 10. In the production method disclosed herein, in the forming of the catalyst layer, the Pd catalyst layer 20 is formed by causing the Pd particles 22 to be carried directly on an Si member containing Si or SiC (for example, the partitions 16 of the SiC base material 10). Contacting between the Si member (SiC base material 10) and the Pd particles 22 in advance reduces migration and aggregation of the Pd particles 22 in high temperature environment and reduces degradation of temperature characteristics.

公开(公告)号：US11883797B2

公开(公告)日：2024-01-30

申请号：US17598994

申请日：2020-03-03

Applicant: CATALER CORPORATION

Inventor： Tatsuya Ohashi ,  Kohei Takasaki

IPC: B01J21/04 ,  B01J23/44 ,  B01J23/46 ,  B01J35/00 ,  B01J35/04 ,  F01N3/10 ,  B01J37/02

CPC classification number: B01J23/44 ,  B01J21/04 ,  B01J23/464 ,  B01J35/0006 ,  B01J37/0215 ,  F01N3/10 ,  F01N2510/0684

Abstract: An exhaust gas purification catalyst device having a substrate, a first catalyst coating layer on the substrate, and a second catalyst coating layer on the first catalyst coating layer. The first catalyst coating layer includes inorganic oxide particles, palladium carried on the inorganic oxide particles, and a barium compound. The second catalyst coating layer includes alumina particles and rhodium carried by the alumina particles. The ratio (MBa/MRh) between the mass (MBa) of barium in the first catalyst coating layer and the mass (MRh) of rhodium in the second catalyst coating layer is 5.0-60.0 inclusive.

公开(公告)号：US20230302438A1

公开(公告)日：2023-09-28

申请号：US18010525

申请日：2021-06-04

Applicant: Cataler Corporation

Inventor： Ryota Onoe ,  Takahiro Noguchi ,  Tatsuya Ohashi ,  Kohei Takasaki

IPC: B01J35/00 ,  B01J23/46 ,  B01J23/44 ,  B01J23/58 ,  B01J23/10 ,  B01J21/04 ,  B01J35/10 ,  F01N3/28 ,  B01D53/94

CPC classification number: B01J35/0006 ,  B01J23/464 ,  B01J23/44 ,  B01J23/58 ,  B01J23/10 ,  B01J21/04 ,  B01J35/1014 ,  F01N3/2828 ,  B01D53/9468 ,  F01N2370/02 ,  F01N2330/06 ,  B01D2255/908 ,  B01D2255/1021 ,  B01D2255/1023 ,  B01D2255/1025 ,  B01D2255/407 ,  B01D2255/9207 ,  B01D2255/2042 ,  B01D2255/9022 ,  B01D2258/01

Abstract: 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 m2/g or more and 60 m2/g or less.

公开(公告)号：US10413895B2

公开(公告)日：2019-09-17

申请号：US15560706

申请日：2016-03-24

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  CATALER CORPORATION

Inventor： Hiromasa Suzuki ,  Masahide Miura ,  Yoshinori Saito ,  Satoru Katoh ,  Toshitaka Tanabe ,  Tetsuhiro Hirao ,  Tatsuya Ohashi ,  Hiroaki Naito ,  Hirotaka Ori ,  Michihiko Takeuchi ,  Keiichi Narita

IPC: B01J23/54 ,  B01J23/63 ,  B01J35/10 ,  B01J37/00 ,  B01J37/02 ,  B01D53/94 ,  F01N3/28 ,  B01J37/08 ,  B01J35/02

Abstract: When the amount of coating is increased in a two-layer catalyst or the like containing two noble metals in respective different layers, gas diffusivity in the catalyst and use efficiency of a catalytic active site are reduced to thereby reduce purification performance. In view of this, an organic fiber having a predetermined shape is used as a pore-forming material in formation of an uppermost catalyst coating layer of a multi-layer catalyst, to thereby form an uppermost catalyst coating layer having a high-aspect-ratio pore excellent in connectivity and therefore excellent gas diffusivity.

公开(公告)号：US10413885B2

公开(公告)日：2019-09-17

申请号：US16151847

申请日：2018-10-04

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  CATALER CORPORATION

Inventor： Hiromasa Suzuki ,  Yoshinori Saito ,  Tatsuya Ohashi ,  Shunsuke Ohishi ,  Takaya Ota

IPC: B01J23/44 ,  B01J35/00 ,  B01J23/46 ,  B01D53/94 ,  F01N3/28

Abstract: 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.

公开(公告)号：US20230032414A1

公开(公告)日：2023-02-02

申请号：US17788020

申请日：2020-12-02

Applicant: Cataler Corporation

Inventor： Kohei Takasaki ,  Tatsuya Ohashi ,  Keiichi Narita

IPC: B01J23/44 ,  B01J27/224 ,  B01J21/04 ,  B01J23/10 ,  B01J35/04 ,  B01J35/10 ,  B01J35/00 ,  B01D53/94 ,  F01N3/20 ,  F01N3/28

Abstract: The present invention provides an exhaust gas purification catalyst in which platinum group metal migration from a catalyst layer to a base material during high temperature duration is suppressed. The exhaust gas purification catalyst disclosed herein includes a base material, a catalyst layer, and an intermediate layer arranged between the base material and the catalyst layer. The base material contains SiC. The catalyst layer contains a platinum group metal as a catalyst component. The intermediate layer contains substantially no platinum group metal. A product of a thickness of the intermediate layer (μm) and a specific surface area (m2/g) of the intermediate layer is 1100 or more.

公开(公告)号：US10450917B2

公开(公告)日：2019-10-22

申请号：US15560625

申请日：2016-03-24

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA ,  CATALER CORPORATION

Inventor： Hiromasa Suzuki ,  Masahide Miura ,  Yoshinori Saito ,  Satoru Katoh ,  Toshitaka Tanabe ,  Tetsuhiro Hirao ,  Tatsuya Ohashi ,  Hiroaki Naito ,  Hirotaka Ori ,  Michihiko Takeuchi ,  Keiichi Narita

IPC: F01N3/10 ,  B01J23/63 ,  B01D53/94 ,  B01J35/10 ,  F01N3/28 ,  B01J37/02 ,  B01J35/02 ,  B01J37/00 ,  B01J35/00 ,  B01J37/08

Abstract: An object of the present invention is to provide an exhaust gas purification catalyst which can exhibit high durability and warm-up performance. The present invention relates to an exhaust gas purification catalyst comprising a substrate and a catalyst coating layer formed on the substrate, wherein the catalyst coating layer comprises catalyst particles, the catalyst coating layer having an upstream region extending by 40 to 60% of the entire length of the substrate from an upstream end of the catalyst in the direction of an exhaust gas flow and a downstream region corresponding to the remainder portion of the catalyst coating layer, the composition of the catalyst particle of the upstream region being different from that of the downstream region. The upstream region in the direction of an exhaust gas flow has a structure where a void is included in a large number, and furthermore high-aspect-ratio pores having an aspect ratio of 5 or more account for a certain percentage or more of the whole volume of voids. Thus, the exhaust gas purification catalyst exhibits enhanced purification performance.

公开(公告)号：US10201805B2

公开(公告)日：2019-02-12

申请号：US15518086

申请日：2015-10-06

Applicant: CATALER CORPORATION

Inventor： Tatsuya Ohashi ,  Shingo Sakagami ,  Tsuyoshi Ito ,  Ryota Onoe ,  Naoto Miyoshi ,  Masahiko Takeuchi ,  Akemi Sato

IPC: B01J23/00 ,  B01J23/10 ,  B01J23/63 ,  B01D53/94 ,  B01J35/04 ,  F01N3/10 ,  F01N3/28 ,  F01N3/02 ,  F01N3/022 ,  F01N3/023 ,  F01N3/035 ,  B01J35/00 ,  B01J35/10 ,  B01J37/02 ,  F01N3/08

Abstract: 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.