Catalyst for purifying an exhaust gas and process for producing the same

• US 6,372,688 B1
• Filed: 12/06/1999
• Issued: 04/16/2002
• Est. Priority Date: 12/28/1998
• Status: Expired due to Fees

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Yamashita, Kouichi, Tsuji, Shinji
• Primary Examiner(s): Griffin, Steven P.
• Assistant Examiner(s): Nguyen, Cam N.
• Application Number:
  US09/455,453
• Time in Patent Office: 862 Days
• Field of Search: 502/326, 502/327, 502/328, 502/332, 502/334, 502/339, 502/340, 502/355, 502/439, 502/524, 502/527.15, 423/22, 423/111, 423/155, 423/213.5
• US Class Current: 502/326
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 23/005 Spinels
• CPC Class Codes: B01J 23/58 with alkali- or alkaline earth metals
• CPC Class Codes: B01J 37/0221 of particles
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10S 502/524 Spinel

Abstract

A catalyst for purifying an exhaust gas includes a composite oxide support and a platinum structural layer. The composite oxide support has a spinel structure expressed by M.Al₂O₄ in which M is an alkaline-earth metal. The platinum structural layer is formed on a surface of the composite oxide support and includes a matrix composed mainly of an alkaline-earth metal oxide in which platinum clusters are dispersed uniformly. A composite oxide layer can be interposed between the composite oxide support and the platinum structural layer. Also disclosed is an optimum process for producing the catalyst.

Claims

1. A catalyst for purifying an exhaust gas, comprising:

a composite oxide support having a spinel structure expressed by M.Al₂O₄ in which M is an alkaline-earth metal; and

a platinum structural layer formed on a surface of said composite oxide support and including a matrix composed mainly of an alkaline-earth metal oxide in which platinum clusters are dispersed uniformly, a particle diameter of said platinum clusters being 10 nm or less.

2. The catalyst according to claim 1, wherein the alkaline-earth metal M is at least one member selected from the group consisting of Mg, Ca, Sr and Ba.

3. The catalyst according to claim 2, wherein the alkaline-earth metal M is at least one member selected from the group consisting of Sr and Ba.

4. The catalyst according to claim 1, wherein the alkaline-earth metal oxide of said platinum structural layer is at least one oxide selected from the group consisting of oxides of Mg, Ca, Sr and Ba.

5. The catalyst according to claim 1, in said platinum structural layer, the ratio of alkaline-earth metal with respect to platinum falls in the range of from 2:

1 to 70;

1 by a molar ratio.

6. The catalyst according to claim 1, wherein a thickness of said platinum structural layer is 0.05 μ

m or less.

7. A catalyst for purifying an exhaust gas, comprising:

a composite oxide support having a spinel structure expressed by M.Al₂O₄ in which M is an alkaline-earth metal;

a composite oxide layer formed on a surface of said composite oxide support containing at least two kinds of an alkaline-earth metal comprising the M contained in said composite oxide support and an alkaline-earth metal other than the M; and

a platinum structural layer formed on a surface of said composite oxide layer and including a matrix composed mainly of an alkaline-earth metal oxide in which platinum clusters are dispersed uniformly.

8. The catalyst according to claim 7, wherein the alkaline-earth metal other than the M is identical with the alkaline-earth metal of said platinum structural layer.

9. The catalyst according to claim 7, wherein a thickness of said composite oxide