Process for producing metal oxide particle and exhaust gas purifying catalyst

• US 20070197379A1
• Filed: 04/27/2005
• Published: 08/23/2007
• Est. Priority Date: 04/27/2004
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Miura, Masahide
• Granted Patent: US 7,989,387 B2
• Time in Patent Office: Days
• US Class Current: 502/304
• CPC Class Codes: B01D 2255/102 Platinum group metals
• CPC Class Codes: B01D 2255/206 Rare earth metals
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 21/063 Titanium; Oxides or hydroxides thereof
• CPC Class Codes: B01J 21/066 Zirconium or hafnium; Oxides or hydroxides thereof
• CPC Class Codes: B01J 23/10 of rare earths
• CPC Class Codes: B01J 23/63 with rare earths or actinides
• CPC Class Codes: B01J 35/19 Catalysts containing parts with different compositions
• CPC Class Codes: B01J 35/23 in a colloidal state
• CPC Class Codes: B01J 37/03 Precipitation; Co-precipitation
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

The present invention provides an exhaust gas purifying catalyst and a process for producing a metal oxide particle comprising multiple species of metal oxides and capable of satisfactorily exerting the properties of respective metal oxides. A process of the present invention comprises providing a sol containing at least a population of first colloid particles and a population of second colloid particles differing in the isoelectric point with each other; adjusting the pH of the sol to be closer to the isoelectric point of the population of first colloid particles than to the isoelectric point of the population of second colloid particles, thereby aggregating the population of first colloid particles; adjusting the pH of the sol, thereby aggregating the population of second colloid particles onto the population of first colloid particles aggregated; and drying and firing the obtained aggregate.

Claims

1. A process for producing a metal oxide particle comprising a core part and a surface layer differing in the composition, the process comprising:

providing a sol containing at least a population of first colloid particles and a population of second colloid particles differing in the isoelectric point with each other,

adjusting the pH of said sol to be closer to the isoelectric point of said population of first colloid particles than to the isoelectric point of said population of second colloid particles, thereby aggregating said population of first colloid particles,

adjusting the pH of said sol to be closer to the isoelectric point of said population of second colloid particles than to the isoelectric point of said population of first colloid particles, thereby aggregating said population of second colloid particles onto said population of first colloid particles aggregated, and

drying and firing the obtained aggregate.

2. The process according to claim 1, wherein the pH of said sol is changed to pass the isoelectric point of said population of first colloid particles, thereby aggregating said population of first colloid particles.

3. The process according to claim 1, wherein the pH of said sol is changed to pass the isoelectric point of said population of second colloid particles, thereby aggregating said population of second colloid particles.

4. The process according to claim 1, wherein said population of first colloid particles and said population of second colloid particles each is independently selected from the group consisting of alumina, ceria, zirconia and titania colloid particles.

5. The process according to claim 4, wherein said population of first colloid particles is zirconia, alumina or titania, and said population of second colloid particles is ceria.

6. An exhaust gas purifying catalyst for internal combustion engine, comprising a particulate support and a noble metal supported thereon,

wherein the particulate support comprises a core part and a surface layer, the molar fraction of the zirconium constituting the zirconia in the core part being higher than the molar fraction of the zirconium constituting the zirconia in the surface layer, and the molar fraction of the cerium constituting the ceria in the surface layer being higher than the molar fraction of the cerium constituting the ceria in the core part;

wherein said core part and said surface layer each comprises a plurality of primary particles;

wherein the composition of the boundary between said core part and said surface layer is gradually changing; and

wherein the content of ceria in the particulate support being 40 to 65 mol % or less.

7. The exhaust gas purifying catalyst for internal combustion engine according to claim 6, wherein the content of CeO₂ in the particulate support is 45 to 55 mol %.

8. The exhaust gas purifying catalyst for internal combustion engine according to claim 6, wherein the surface layer comprises at least one element selected from the group consisting of alkaline earth metals and rare earths.

9. The exhaust gas purifying catalyst for internal combustion engine according to claim 8, wherein the element comprised in the surface layer is at least one element of Y and Nd.

10. The exhaust gas purifying catalyst for internal combustion engine according to claim 6, wherein the core part comprises at least one element selected from the group consisting of alkaline earth metals and rare earths.

11. The exhaust gas purifying catalyst for internal combustion engine according to claim 10, wherein the element comprised in the core part is Y.