IP Library Granted Patent US 12,036,532
Granted Patent B2
US 12,036,532 · App. 17/614,913 · Granted Jul 16, 2024

Exhaust gas purification catalyst and exhaust gas purification system using the exhaust gas purification catalyst

Inventor: Hiroki Tanaka (Saitama, JP)
Assignee: MITSUI MINING & SMELTING CO., LTD.
B01J23/44B01J23/464B01J35/19B01J35/633B01J35/635B01J35/638B01J37/038F01N3/101F01N2570/10F01N2570/12F01N2570/14
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Quick Facts
Patent No.
US 12,036,532
App. No.
17/614,913
Granted
Jul 16, 2024
Kind
B2
Abstract

An exhaust gas purification catalyst comprises a substrate and a catalyst layer on the substrate, and has a first section upstream along a flow direction of the exhaust gas and a second section downstream from the first section. The catalyst layer in the first section comprises a first catalyst layer comprising palladium and a second catalyst layer comprising rhodium and covering the first catalyst layer. A pore volume proportion, which is a proportion of a total volume of the pores having a pore diameter of 0.06-30.0 μm as measured by mercury press-in method and existing in the substrate and the catalyst layer in the first section to a volume of a entire first section, is 12-18%. A wash coat amount, which is a mass per unit volume of the catalyst layer in the first section to the volume of the substrate existing in the first section, is 100-190 g/L.

Claims (19)

1. An exhaust gas purification catalyst comprising a substrate and a catalyst layer provided on the substrate, said catalyst having a first section located upstream along a flow direction of the exhaust gas and a second section located downstream from the first section, wherein

the catalyst layer in the first section comprises a first catalyst layer comprising palladium and a second catalyst layer comprising rhodium and covering the first catalyst layer;

a pore volume proportion is 12% or more and less than 18% wherein the pore volume proportion is a proportion of a total volume of the pores, which have a pore diameter of 0.06 μm to 30.0 μm as measured by mercury press-in method and existing in the substrate and the catalyst layer in the first section to a volume of the entire first section; and

a wash coat amount is 100 g/L to 190 g/L, wherein a wash coat amount is a mass per unit volume of the catalyst layer in the first section to the volume of the substrate existing in the first section.

2. The exhaust gas purification catalyst according to claim 1 , wherein said catalyst has a value of a1/a2 is 1.2 or more, wherein

when the first catalyst layer is divided into two equal portions along a thickness direction, a1 is defined as a mass of palladium existing on a surface side of the first catalyst layer, and a2 is defined as a mass of palladium existing on an opposite side to the surface side of the first catalyst layer when the first catalyst layer is divided into two equal portions along the thickness direction.

3. The exhaust gas purification catalyst according to claim 1 , wherein

a pore volume proportion is 8% to 25%, wherein the pore volume proportion is a proportion of a total volume of the pores, which have a pore diameter of 0.06 μm to 30.0 μm as measured by the mercury press-in method, existing in the substrate and the catalyst layer in the second section to a volume of the entire second section.

4. The exhaust gas purification catalyst according to claim 1 , wherein

the catalyst layer in the second section comprises a third catalyst layer comprising palladium and a fourth catalyst layer comprising rhodium and covering the third catalyst layer.

5. The exhaust gas purification catalyst according to claim 1 , wherein

the pore volume proportion of the substrate and the catalyst layer in the first section is not more than 90% of the pore volume proportion of the substrate and the catalyst layer in the second section.

6. The exhaust gas purification catalyst according to claim 1 , wherein

the wash coat amount which is the mass per unit volume of the catalyst layer in the second section relative to the volume of the substrate existing in the second section is 180 g/L to 300 g/L.

7. The exhaust gas purification catalyst according to claim 1 , wherein

the second catalyst layer has a through-hole having a width of 10 μm or more through which gas passes from a surface thereof to the first catalyst layer.

8. The exhaust gas purification catalyst according to claim 1 , wherein

a length of the flow direction of exhaust gas in the first section is 20% to 70% with respect to a length of the flow direction of exhaust gas in the substrate.

9. An exhaust gas purification system in which, in an exhaust path connected to an internal combustion engine, exhaust gas from the internal combustion engine is introduced into the exhaust gas purification catalyst according to claim 1 without passing through any other exhaust gas purification catalyst.

Assignments (2)
CHANGE OF NAME Recorded Mar 31, 2026
From: MITSUI MINING AND SMELTING COMPANY, LIMITED
To: MITSUI KINZOKU COMPANY, LIMITED
Reel/Frame 075357/0342 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 31, 2022
From: TANAKA, HIROKI
To: MITSUI MINING & SMELTING CO., LTD.
Reel/Frame 058825/0818 →
Priority Claims (1)
JP 2019-102987 · May 31, 2019 · national
Continuity (1)
Related Publication 20220234030A1 · Jul 28, 2022