Method of producing exhaust gas purifying catalyst and catalyst produced thereby

• US 6,432,859 B1
• Filed: 12/10/1999
• Issued: 08/13/2002
• Est. Priority Date: 12/11/1998
• Status: Expired due to Term

• Current Assignee: Mazda Motor Corporation
• Original Assignee: Mazda Motor Corporation
• Inventors: Takami, Akihide, Iwakuni, Hideharu, Yamada, Hiroshi, Kyogoku, Makoto
• Primary Examiner(s): Griffin, Steven P.
• Assistant Examiner(s): Nguyen, Cam N.
• Application Number:
  US09/458,949
• Time in Patent Office: 977 Days
• Field of Search: 502/302, 502/305, 502/306, 502/311, 502/313, 502/317, 502/325, 502/326, 502/328, 502/330, 502/339, 502/340, 502/344, 502/355, 502/60, 502/64, 502/66, 502/74, 502/304, 502/327, 502/333, 502/334, 502/341, 502/527.12, 423/213.2, 423/213.5, 423/239.1, 423/239.2
• US Class Current: 502/66
• CPC Class Codes: B01D 2255/1021 Platinum
• CPC Class Codes: B01D 2255/1023 Palladium
• CPC Class Codes: B01D 2255/202 Alkali metals
• CPC Class Codes: B01D 2255/2042 Barium
• CPC Class Codes: B01D 2255/50 Zeolites
• CPC Class Codes: B01D 2255/9022 Two layers
• CPC Class Codes: B01D 2255/908 O2-storage component incorporated in the catalyst
• CPC Class Codes: B01D 53/9422 for removing nitrogen oxides by NOx storage or reduction by cyclic switching between lean and rich exhaust gases (LNT, NSC, NSR)
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 37/0242 Coating followed by impregnation
• CPC Class Codes: B01J 37/0244 Coatings comprising several layers
• CPC Class Codes: B01J 37/0246 Coatings comprising a zeolite
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An exhaust gas purifying catalyst contains a NOx absorbing component which comprises at least one kind of element selected from a group of alkaline earth metals, a group of alkaline metals and a group of rare earth elements and a component, other than the NOx absorbing component, selected between K and Na. The catalyst has a such a structure that the component other than the NOx absorbing component is brought into contact with an exhaust gas before the NOx absorbing component is brought into contact with the exhaust gas.

Claims

1. A catalyst disposed in an exhaust passage of a lean burn engine for purifying an exhaust gas containing sulfur (S) and NOx, said catalyst comprising:

a substrate;

a first catalyst layer formed on said substrate, said first catalyst layer containing barium (Ba) as a NOx absorbing component which absorbs NOx in an exhaust gas having an excess oxygen concentration greater than 5%; and

a second catalyst layer formed over said first catalyst layer, said second catalyst layer containing one of potassium (K) and sodium (Na), and barium further comprising (Ba) at a higher concentration than that of said first catalyst layer.

2. A catalyst as defined in claim 1, wherein said first layer further contains a noble metal.

3. A catalyst as defined in claim 1, wherein said second layer contains zeolite on which a transition metal is carried.

4. A catalyst as defined in claim 1, wherein said first layer further contains ceria.

5. A catalyst disposed in an exhaust passage of a lean burn engine for purifying an exhaust gas containing sulfur (S) and NOx, said catalyst comprising:

a substrate;

a first catalyst layer formed on said substrate, said first catalyst layer containing barium (Ba) as a NOx absorbing component which absorbs NOx in an exhaust gas having an excess oxygen concentration greater than 5%; and

a second catalyst layer formed over said first catalyst layer, said second catalyst layer containing potassium (K) approximately three to four times in the number of moles as much as said barium (Ba) of said first catalyst layer and zeolite on which a transition metal is carried;

wherein said catalyst is structured such that said potassium (K) is brought into contact with sulfur (S) in an exhaust gas before said barium (Ba) is brought into contact with said sulfur (S) in said exhaust gas.