Catalyst for purifying exhaust gases

• US 7,737,077 B2
• Filed: 11/25/2004
• Issued: 06/15/2010
• Est. Priority Date: 11/25/2004
• Status: Expired due to Fees

• Current Assignee: Cataler Corporation (Toyota Motor Corporation)
• Original Assignee: Cataler Corporation (Toyota Motor Corporation)
• Inventors: Taki, Kenichi, Kitamura, Ichiro, Hirai, Akimasa
• Primary Examiner(s): Nguyen; Cam N
• Application Number:
  US11/791,141
• Publication Number:
  US 20080081762A1
• Time in Patent Office: 2,028 Days
• Field of Search: 502/326, 502/327, 502/332, 502/333, 502/334, 502/339, 502/415, 502/439, 502/527.19, 502/258, 502/261, 502/262, 502/263, 502/303, 502/304, 502/349, 502/355, 502/527.13, 502/527.18
• US Class Current: 502/326
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 23/40 of the platinum group metals
• CPC Class Codes: B01J 23/464 Rhodium
• 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 37/0242 Coating followed by impregnation
• CPC Class Codes: B01J 37/0244 Coatings comprising several layers
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

This is to provide a catalyst for purifying exhaust gases, catalyst which are good in terms of the purifying performance.

A catalyst according to the present invention for purifying exhaust gases comprises: a catalytic support substrate (1); a first catalytic layer (2) having a first loading layer formed on an upstream side of the catalytic support substrate (1) and made of a fire-resistant inorganic oxide, and Rh loaded in the first loading layer; a second catalytic layer (3) having a second loading layer formed on a surface of the catalytic support substrate (1) on an downstream side of the first catalytic layer (2) and made of a fire-resistant inorganic oxide, and Pd and/or Pt loaded in the second loading layer; and a third catalytic layer (4) having a third loading layer formed on a surface of the second catalytic layer (3) and made of a fire-resistant inorganic oxide, and Rh loaded in the third loading layer; and is characterized in that: the first catalytic layer (2) is such that, when taking Rh loaded in the first catalytic layer as 100% by weight, Rh is loaded in an amount of 70% by weight or more within such a range that the distance from the surface is 20 μm; and the loading amount of Rh loaded in the first catalytic layer (2) is from 1.5 to 15 times as much as the loading amount of Rh loaded in the third loading layer. Because of the fact that Rh is loaded in a great loading amount in the superficial layer portion on an upstream side of exhaust-gas flow, it turns into a catalyst for purifying exhaust gases, catalyst which is good in terms of the purifying characteristics.

Claims

1. A catalyst for purifying exhaust gases, the catalyst comprising:

a catalytic substrate;

a first catalytic layer having a first loading layer formed on an upstream side of the catalytic substrate and made of a fire-resistant inorganic oxide, and Rh loaded in the first loading layer;

a second catalytic layer having a second loading layer formed on a surface of the catalytic substrate on a downstream side of the first catalytic layer and made of a fire-resistant inorganic oxide, and Pd and/or Pt loaded in the second loading layer; and

a third catalytic layer having a third loading layer formed on a surface of the second catalytic layer and made of a fire-resistant inorganic oxide, and Rh loaded in the third loading layer

wherein the first catalytic layer is such that, when taking Rh loaded in the first catalytic layer as 100% by weight, Rh is loaded in an amount of 70% by weight or more in a distance from the surface measured in a thickness direction that is not greater than 20 μ

m, and

the loading amount of Rh loaded in the first catalytic layer is from 1.5 to 15 times as much as the loading amount of Rh loaded in the third loading layer.

2. The catalyst for purifying exhaust gases set forth in claim 1, wherein a length of said first catalytic layer in the flowing direction of exhaust gases is from 0.1 to 0.5 times as long as a length of said catalytic substrate.

3. The catalyst for purifying exhaust gases set forth in claim 1, wherein said second catalytic layer is such that, when taking Pd and/or Pt loaded in the second catalytic layer as 100% by weight, Pd and/or Pt are loaded in an amount of 70% by weight or more in a distance from the surface measured in a thickness direction that is not greater than 20 μ

m.

4. The catalyst for purifying exhaust gases set forth in claim 1, wherein the third catalytic layer is such that, when taking Rh loaded in the third catalytic layer as 100% by weight, Rh is loaded in an amount of 70% by weight or more in a distance from the surface measured in a thickness direction that is not greater than 20 μ

m.