公开(公告)号：US20240280038A1

公开(公告)日：2024-08-22

申请号：US18568875

申请日：2021-12-09

Applicant: Cataler Corporation

Inventor： Ryo Tasaki ,  Ryota Onoe ,  Masaya Ito ,  Momoko Iwai ,  Yamato Matsushita

IPC: F01N3/035 ,  F01N3/022

CPC classification number: F01N3/035 ,  F01N3/0224 ,  F01N2510/068

Abstract: 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 filter 1 disclosed herein includes: an outercoat layer 20 provided on an inlet surface 16a of a partition 16 of a base material 10. The outercoat layer 20 at least includes: a lower layer 22 provided on the inlet surface 16a of the partition 16; and an upper layer 24 provided to cover the lower layer 22. The mean particle diameter of granules contained in the upper layer 24 is higher than the mean particle diameter of granules contained in the lower layer. The mean particle diameter of the granules in the lower layer 22 is from 0.4 μm to 2.0 μm inclusive, and the mean particle diameter of the granules in the upper layer 24 is from 2.0 μm to 7.0 μm inclusive. With such a configuration, PM can be captured in an inlet cell 12, thereby suitably avoiding PM from passing toward an outlet cell 14 and exhibiting an excellent PM capturing performance.

公开(公告)号：US20240110496A1

公开(公告)日：2024-04-04

申请号：US18276298

申请日：2022-02-01

Applicant: Cataler Corporation

Inventor： Ryota Onoe ,  Junichi Hori ,  Ryosuke Takasu ,  Tatsuya Ohashi ,  Shunsuke Oishi

IPC: F01N3/20 ,  B01D53/94 ,  B01J23/46

CPC classification number: F01N3/2026 ,  B01D53/945 ,  B01D53/9495 ,  B01J23/464 ,  B01D2258/012 ,  B01D2258/014 ,  B01D2259/122 ,  B01D2259/4591

Abstract: The present invention provides an ohmic heating-type exhaust gas purification catalyst system. The ohmic heating-type exhaust gas purification catalyst system is configured to perform, based on information of temperature of a catalyst bed input from a temperature detector of an ohmic heating-type exhaust gas purification device, electric current pass control including controls of (1) causing an electric current to pass through a pair of electrodes when the temperature of the catalyst bed is equal to or lower than a first threshold temperature T1 set in a range of 350±25° C., (2) not causing an electric current to pass through the pair of electrodes when the temperature of the catalyst bed exceeds the first threshold temperature T1 and is equal to or lower than a second threshold temperature T2 set in a range of 450±25° C., (3) causing an electric current caused to pass through the pair of electrodes when the temperature of the catalyst bed exceeds the second threshold temperature T2 and is equal to or lower than a third threshold temperature T3 set to be equal to or higher than 550° C., and (4) not causing an electric current to pass through the pair of electrodes when the temperature of the catalyst bed exceeds the third threshold temperature T3.

公开(公告)号：US11808188B2

公开(公告)日：2023-11-07

申请号：US17618082

申请日：2020-06-26

Applicant: Cataler Corporation

Inventor： Ryo Tasaki ,  Ryota Onoe ,  Momoko Iwai ,  Yamato Matsushita

IPC: F01N3/022 ,  B01D46/82 ,  B01D46/24 ,  B01D53/94 ,  B01J21/04 ,  B01J23/02 ,  B01J23/58 ,  B01J35/00 ,  B01J35/04 ,  F01N3/035 ,  F01N3/023 ,  F01N9/00 ,  F01N3/021 ,  F01N3/025 ,  F01N3/28

CPC classification number: F01N3/022 ,  B01D46/2474 ,  B01D46/82 ,  B01D53/94 ,  B01J21/04 ,  B01J23/02 ,  B01J23/58 ,  B01J35/0006 ,  B01J35/04 ,  F01N3/035 ,  B01D2255/1023 ,  B01D2255/9022 ,  B01D2255/9155 ,  B01D2279/30 ,  F01N3/021 ,  F01N3/023 ,  F01N3/0253 ,  F01N3/2882 ,  F01N9/002 ,  F01N2250/02 ,  F01N2330/06 ,  F01N2370/24 ,  F01N2510/063 ,  F01N2510/0682 ,  F01N2510/0684

Abstract: A particulate filter disclosed herein includes a wall-flow structure substrate 10 and a wash coat layer 20 held inside a partition 16 of the substrate 10. The wash coat layer 20 includes an inlet layer 22 formed to have predetermined length LA and thickness TA from near an end thereof on an exhaust gas inflow side X1, and an outlet layer 24 formed to have predetermined length LB and thickness TB from near an end thereof on an exhaust gas outflow side X2. The inlet layer 22 and the outlet layer 24 partially overlap each other. In the particulate filter disclosed herein, the inlet layer 22 contains a precious metal catalyst, while the outlet layer 24 contains substantially no precious metal catalyst. The length LA of the inlet layer is 50% or more and 75% or less of a total length L of the partition 16. Thus, the particulate filter is capable of achieving both PM collection performance and pressure-drop reduction performance at high levels.

公开(公告)号：US20220316372A1

公开(公告)日：2022-10-06

申请号：US17618082

申请日：2020-06-26

Applicant: Cataler Corporation

Inventor： Ryo Tasaki ,  Ryota Onoe ,  Momoko Iwai ,  Yamato Matsushita

IPC: F01N3/022 ,  F01N3/035 ,  B01D46/24 ,  B01D46/82 ,  B01D53/94 ,  B01J23/02 ,  B01J21/04 ,  B01J23/58 ,  B01J35/04 ,  B01J35/00

Abstract: A particulate filter disclosed herein includes a wall-flow structure substrate 10 and a wash coat layer 20 held inside a partition 16 of the substrate 10. The wash coat layer 20 includes an inlet layer 22 formed to have predetermined length LA and thickness TA from near an end thereof on an exhaust gas inflow side X1, and an outlet layer 24 formed to have predetermined length LB and thickness TB from near an end thereof on an exhaust gas outflow side X2. The inlet layer 22 and the outlet layer 24 partially overlap each other. In the particulate filter disclosed herein, the inlet layer 22 contains a precious metal catalyst, while the outlet layer 24 contains substantially no precious metal catalyst. The length LA of the inlet layer is 50% or more and 75% or less of a total length L of the partition 16. Thus, the particulate filter is capable of achieving both PM collection performance and pressure-drop reduction performance at high levels.

公开(公告)号：US11420189B2

公开(公告)日：2022-08-23

申请号：US16623928

申请日：2018-06-07

Applicant: CATALER CORPORATION

Inventor： Kazunari Sawada ,  Ryota Onoe ,  Tetsuhiro Hirao

IPC: B01J23/00 ,  B01J23/44 ,  B01J23/46 ,  B01J23/63 ,  B01J35/04 ,  B01D53/94 ,  F01N3/022 ,  F01N3/035 ,  F01N3/10 ,  F01N3/28 ,  B01J35/00

Abstract: 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.

公开(公告)号：US11110435B2

公开(公告)日：2021-09-07

申请号：US16086083

申请日：2017-03-13

Applicant: CATALER CORPORATION

Inventor： Ryota Onoe ,  Kazuhiko Ito ,  Takahiro Harada ,  Chihiro Kasuya

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

Abstract: 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.

公开(公告)号：US10076725B2

公开(公告)日：2018-09-18

申请号：US15550078

申请日：2016-02-16

Applicant: CATALER CORPORATION ,  TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Ryota Onoe ,  Shingo Sakagami ,  Yasutaka Nomura ,  Yuta Morishita ,  Junji Kuriyama ,  Hiroshi Sekine ,  Daisuke Ochiai ,  Naoto Miyoshi ,  Masahiko Takeuchi ,  Akemi Sato

IPC: B01J23/10 ,  B01J23/44 ,  B01J23/46 ,  B01J23/63 ,  B01J35/00 ,  B01J35/04 ,  B01D53/94 ,  F01N3/10 ,  F01N3/08 ,  F01N3/28

CPC classification number: B01D53/945 ,  B01D53/94 ,  B01D2255/1023 ,  B01D2255/1025 ,  B01D2255/9022 ,  B01D2255/908 ,  B01D2255/9155 ,  B01J23/63 ,  B01J35/0006 ,  B01J35/04 ,  F01N3/0222 ,  F01N3/035 ,  F01N3/0864 ,  F01N3/10 ,  F01N3/281 ,  F01N2330/02 ,  F01N2510/0682 ,  F01N2510/0684

Abstract: 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 (D1/D2) of the coating density D1 of the first catalytic layer to the coating density D2 of the second catalytic layer is 1.1 to 1.8.

公开(公告)号：US10018095B2

公开(公告)日：2018-07-10

申请号：US15333769

申请日：2016-10-25

Applicant: CATALER CORPORATION

Inventor： Yasutaka Nomura ,  Shingo Sakagami ,  Ryota Onoe ,  Yuta Morishita ,  Junji Kuriyama ,  Hiroshi Sekine

IPC: F01N3/28 ,  B01D53/94 ,  B01D46/24 ,  B01J23/46 ,  B01J23/10 ,  B01J35/00 ,  B01J35/04

CPC classification number: F01N3/2842 ,  B01D46/2474 ,  B01D53/94 ,  B01D53/944 ,  B01D2255/1025 ,  B01D2255/2065 ,  B01D2255/407 ,  B01D2255/908 ,  B01D2255/9155 ,  B01D2258/014 ,  B01J23/10 ,  B01J23/462 ,  B01J23/464 ,  B01J23/63 ,  B01J35/0006 ,  B01J35/002 ,  B01J35/04 ,  F01N3/035 ,  F01N3/101 ,  F01N3/2828 ,  F01N2250/02 ,  F01N2330/06 ,  Y02T10/22

Abstract: The exhaust gas purification device according to the present invention includes a substrate of wall flow structure having a porous partition wall 16, and a catalyst layer held in internal pores of the partition wall 16. The catalyst layer contains, as a carrier, an OSC material having oxygen storage capacity. In the thickness direction of the partition wall 16, the porosity of the internal pores in inlet regions 16a is 25% or higher, and an average occupation ratio of the catalyst layer held in the internal pores is 75% or lower.

公开(公告)号：US09981216B2

公开(公告)日：2018-05-29

申请号：US15100747

申请日：2014-12-01

Applicant: CATALER CORPORATION

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

IPC: B01D50/00 ,  B01D59/50 ,  B01D46/24 ,  F01N3/022

CPC classification number: B01D46/247 ,  F01N3/0222 ,  F01N2330/30 ,  F01N2330/34 ,  F01N2330/38

Abstract: 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.