Patents Assigned to Cataler Corporation
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Publication number: 20230372917Abstract: The exhaust gas purification device includes: a substrate including an upstream end through which an exhaust gas is introduced and a downstream end through which the exhaust gas is discharged; a first catalyst layer containing a rhodium-containing catalyst containing a metal oxide carrier and rhodium particles supported on the metal oxide carrier, the first catalyst layer extending across a first region; and a second catalyst layer containing palladium particles and a material having a basicity higher than a basicity of the metal oxide carrier, the second catalyst layer extending across a second region. A mean of a particle size distribution of the rhodium particles is from 1.5 nm to 18 nm.Type: ApplicationFiled: May 16, 2023Publication date: November 23, 2023Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Takahiro NISHIO, Shogo Shirakawa, Hiroki Shirakawa, Nobuyuki Takagi, Tomomasa Aikawa, Hiroki Nihashi, Takahiro Noguchi
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Publication number: 20230372907Abstract: Provided are a method for producing an exhaust gas purification material and a method for manufacturing an exhaust gas purification device that allow efficient removal of a harmful component even after exposure to a high temperature environment. The method for producing the exhaust gas purification material includes the steps, in this order, of: (a) impregnating a metal oxide carrier with a rhodium compound solution; (b) drying the metal oxide carrier impregnated with the rhodium compound solution to obtain a rhodium-containing catalyst containing the metal oxide carrier and rhodium particles supported on the metal oxide carrier; (c) heating the rhodium-containing catalyst at a temperature within a range from 700° C. to 900° C. under an inert atmosphere; and (d) mixing the rhodium-containing catalyst with a material having a basicity higher than a basicity of the metal oxide carrier.Type: ApplicationFiled: May 16, 2023Publication date: November 23, 2023Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Takahiro NISHIO, Shogo SHIRAKAWA, Nobuyuki TAKAGI, Tomomasa AIKAWA, Hiroki NIHASHI, Takahiro NOGUCHI
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Patent number: 11821349Abstract: An exhaust gas purification catalyst including an alkaline-earth metal carried on a porous carrier in a highly dispersed state. The catalyst layer of the exhaust gas purification catalyst has an alkaline-earth metal carrying region including a porous carrier, Pt, and a sulfuric acid salt of at least one alkaline-earth metal carried on the porous carrier, wherein a value of RAe/Pt is 0.5 or more, where RAe/Pt represents the Pearson's correlation coefficient calculated using ? and ? in each pixel obtained by, for a cross section of the region, performing the area analysis by FE-EPMA under the conditions of: pixel size 0.34 ?m×0.34 ?m; and number of measured pixels 256×256; and measuring an intensity (?: cps) of a characteristic X ray of an element (Ae) of the alkaline-earth metal and an intensity (?: cps) of a characteristic X ray of Pt for each pixel.Type: GrantFiled: September 9, 2019Date of Patent: November 21, 2023Assignees: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Shogo Kawamura, Tomomasa Aikawa, Isao Naito, Hiroki Nihashi, Nobuyuki Takagi, Takeshi Nobukawa
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Publication number: 20230364589Abstract: An exhaust gas-purifying catalyst includes a catalyst-coated filter. The catalyst-coated filter includes a filter substrate and a catalyst layer on a pore wall of the filter substrate. The exhaust gas-purifying catalyst has a first end, a second end, a porous wall, a first cell, and a second cell. The first cell is closed at the second end, the second cell is closed at the first end, and the first cell and the second cell are adjacent to each other with the porous wall interposed therebetween. At a surface of the porous wall on the first cell side, a proportion SS/S of a total area SS of pores having an opening diameter of less than 40 ?m in a total area S of all pores is 65% or more.Type: ApplicationFiled: July 13, 2023Publication date: November 16, 2023Applicant: CATALER CORPORATIONInventors: Ryo Tasaki, Ryota Onoe, Momoko Iwai, Yamato Matsushita
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Publication number: 20230356205Abstract: An exhaust gas-purifying catalyst includes a catalyst-coated filter and inorganic particles in a powder form. The catalyst-coated filter includes a filter substrate and a catalyst layer on a pore wall of the filter substrate. The catalyst-coated filter has a first end portion, a second end portion, a filter wall, an entry-side cell, and an exit-side cell. The filter wall is porous. The entry-side cell is opened at the first end portion and closed at the second end portion. The exit-side cell is opened at the second end portion and closed at the first end portion. The entry-side cell and the exit-side cell are adjacent to each other with the filter wall interposed therebetween. The inorganic particles in a powder form are localized at a surface of the filter wall adjacent to the entry-side cell at a cross section parallel to the thickness direction of the filter wall.Type: ApplicationFiled: July 19, 2023Publication date: November 9, 2023Applicant: CATALER CORPORATIONInventors: Ryo Tasaki, Ryota Onoe, Momoko Iwai, Yamato Matsushita
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Publication number: 20230356192Abstract: The present disclosure provides an oxygen storage/release material that has achieved both the improved oxygen storage/release capacity at low temperature and heat tolerance, which comprises a ceria-zirconia-based composite oxide, wherein the ceria-zirconia-based composite oxide further comprises praseodymium (Pr) or neodymium (Nd), and has, in at least a part thereof, at least one ordered phase of ? phase and a pyrochlore phase, a proportion of primary particles having particle diameters of 0.4 ?m to 1.5 ?m is 40% to 100% on a particle number basis, and, when heated for 5 hours in the air at 1,100° C., I(14/29) value is 0.015 or more and I(28/29) value is 0.08 or less. The present disclosure also relates to a method for producing such oxygen storage/release material.Type: ApplicationFiled: April 13, 2023Publication date: November 9, 2023Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Eriko YOSHIMOTO, Nobuyuki TAKAGI, Takuya OKUDA, Yuhei UDAGAWA, Takahiro HARADA
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Patent number: 11808188Abstract: A particulate filter disclosed herein includes a wall-flow structure substrate 10 and a wash coat layer 20 held inside a partition 16 of the substrate 10. The wash coat layer 20 includes an inlet layer 22 formed to have predetermined length LA and thickness TA from near an end thereof on an exhaust gas inflow side X1, and an outlet layer 24 formed to have predetermined length LB and thickness TB from near an end thereof on an exhaust gas outflow side X2. The inlet layer 22 and the outlet layer 24 partially overlap each other. In the particulate filter disclosed herein, the inlet layer 22 contains a precious metal catalyst, while the outlet layer 24 contains substantially no precious metal catalyst. The length LA of the inlet layer is 50% or more and 75% or less of a total length L of the partition 16. Thus, the particulate filter is capable of achieving both PM collection performance and pressure-drop reduction performance at high levels.Type: GrantFiled: June 26, 2020Date of Patent: November 7, 2023Assignee: Cataler CorporationInventors: Ryo Tasaki, Ryota Onoe, Momoko Iwai, Yamato Matsushita
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Publication number: 20230343971Abstract: To provide a carbon support for catalysts for fuel cells, which increases the power generation performance of fuel cells, a catalyst for fuel cells, a catalyst layer for fuel cells, and a method for producing the carbon support. A carbon support for catalysts for fuel cells, wherein the carbon support includes at least one pore; wherein a thickness of a carbon wall of the carbon support, which is derived from a three-dimensional pore structure of a silica mold obtained by pore volume measurement of the silica mold by nitrogen adsorption analysis, is 3.3 nm or more and 11.2 nm or less; and wherein a carbon wall content is more than 60.3 ml/g and less than 190.8 ml/g.Type: ApplicationFiled: April 20, 2023Publication date: October 26, 2023Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Yunan WANG, Rui IMOTO, Kumiko NOMURA, Naoki HASEGAWA, Tomohiro TAKESHITA, Kazuhisa YANO, Hironobu NANBU, Yuuki KASAMA, Keisuke ASAKURA, Takanobu KUROKI, Hitohiko SATO, Tsubasa YONEUCHI, Akihiro HORI
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Patent number: 11795855Abstract: Provided is an exhaust gas purification catalyst capable of reducing a noble metal amount while maintaining a catalyst performance, which comprises a substrate and at least three catalyst coating layers formed on the substrate, the first and third catalyst coating layers contain Pd as a catalyst metal and are formed in a range of a predetermined length from an upstream end surface in an exhaust gas flow direction, and the second catalyst coating layer contains Rh as a catalyst metal and is formed in a range of a predetermined length from a downstream end surface in the exhaust gas flow direction.Type: GrantFiled: March 24, 2021Date of Patent: October 24, 2023Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Isao Chinzei, Takahiro Nishio, Shogo Shirakawa, Masahide Miura, Hiromasa Suzuki, Yuki Kido, Minoru Ito, Sho Hoshino, Shin Nakayama
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Publication number: 20230302406Abstract: An gas purification catalyst device having a catalyst coated layer formed on at least one base material, wherein: the catalyst coated layer includes a first catalyst coated layer on the upstream side of an exhaust gas flow, and a second catalyst coated layer on the downstream side of the exhaust gas flow; the first catalyst coated layer includes a hydrocarbon adsorbent and a catalytic precious metal; and the second catalyst coated layer includes a nitrogen oxide adsorbent and a catalytic precious metal.Type: ApplicationFiled: August 23, 2021Publication date: September 28, 2023Applicant: CATALER CORPORATIONInventors: Shunsuke OISHI, Naruya INADA, Ryoichi OGAWA
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Publication number: 20230294078Abstract: Provided is an exhaust gas purification catalyst improved in warm-up performance while suppressing HC poisoning of a noble metal in an atmosphere in which an air-fuel ratio (A/F) is rich and the HC poisoning easily occurs. The present disclosure relates to an exhaust gas purification catalyst that includes a substrate and a catalyst coating layer coated on the substrate. The catalyst coating layer includes a lower coating layer coated on the substrate and an upper coating layer coated on the lower coating layer. The lower coating layer contains a noble metal. The upper coating layer contains Pd and/or Pt. The Pd and/or Pt contained in the upper coating layer is supported on A12O3 by a certain amount or more. A thickness of the upper coating layer is adjusted.Type: ApplicationFiled: March 2, 2023Publication date: September 21, 2023Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Nobusuke Kabashima, Tetsuya Shinozaki
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Publication number: 20230294044Abstract: Provided is an exhaust gas purification catalyst system comprising, in the following order, from the upstream side of an exhaust gas flow: a first exhaust gas purification catalyst apparatus 100 including a metal honeycomb substrate 110 and a first catalyst coat layer 120 on the metal honeycomb substrate 110; a heater 300; and a second exhaust purification catalyst apparatus 200 including a cordierite honeycomb substrate 210 and a second catalyst coat layer 220 on the cordierite honeycomb substrate 210, wherein the first catalyst coat layer 120 contains an adsorbent 130 that can adsorb one or two or more among NOx, HC and CO, and the second catalyst coat layer 220 contains inorganic oxide particles 230 and catalyst precious metal particles 240 supported on the inorganic oxide particles 230.Type: ApplicationFiled: July 6, 2021Publication date: September 21, 2023Applicant: CATALER CORPORATIONInventors: Kohei TAKASAKI, Tatsuya OHASHI, Shunsuke OISHI, Ryota ONOE, Junichi HORI, Ryosuke TAKASU, Chihiro KASUYA
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Patent number: 11759769Abstract: Provided is an exhaust gas purification device that allows improving an exhaust gas purification performance. An exhaust gas purification device of the present disclosure includes a substrate and a catalyst layer disposed on the substrate. The catalyst layer contains a porous carrier, a catalytic metal that is supported by the porous carrier and belongs to platinum group, an alkaline earth metal supported by the porous carrier, and an alkaline earth metal not supported by the porous carrier. At least a part of the alkaline earth metal supported by the porous carrier is supported inside the porous carrier.Type: GrantFiled: October 7, 2021Date of Patent: September 19, 2023Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Isao Chinzei, Seiji Nakahigashi, Takumi Tojo, Masahide Miura, Nobuyuki Takagi, Yoshiteru Yazawa, Sho Hoshino, Minoru Ito, Naoto Fujita, Tomomasa Aikawa
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Publication number: 20230285924Abstract: A honeycomb substrate holder for holding a honeycomb substrate, the honeycomb substrate holder comprising: an elastically deformable cylindrical inner circumferential wall; a cylindrical outer circumferential wall located outside the cylindrical inner circumferential wall with a cylindrical gap from the cylindrical inner circumferential wall; and two end faces sealing the cylindrical gap together with the cylindrical inner circumferential wall and the cylindrical outer circumferential wall, A honeycomb substrate can be inserted on the axial side of the cylindrical inner circumferential wall. Fluid can be circulated or held in the cylindrical gap. The cylindrical inner circumferential wall can be elastically deformed and pressed against an outer circumferential surface of the honeycomb substrate by pressurizing the fluid in the cylindrical gap.Type: ApplicationFiled: July 13, 2021Publication date: September 14, 2023Applicant: CATALER CORPORATIONInventors: Tamio KOSAKA, Tomohito MIZUKAMI, Yusuke SAITO
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Patent number: 11725556Abstract: Provided is an exhaust gas purification catalyst having an improved catalyst performance while securing an OSC in an air-fuel ratio (A/F) rich atmosphere where HC poisoning is likely to occur. The present disclosure relates to an exhaust gas purification catalyst including a substrate and a catalyst coating layer coated on the substrate. The catalyst coating layer has an upstream coat layer formed from an end portion in an upstream side with respect to an exhaust gas flow direction in the exhaust gas purification catalyst and a downstream coat layer formed from an end portion in a downstream side with respect to the exhaust gas flow direction in the exhaust gas purification catalyst. The downstream coat layer includes Rh as a catalytic metal, alumina-ceria-zirconia complex oxide, and alkaline earth metal.Type: GrantFiled: February 28, 2022Date of Patent: August 15, 2023Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Isao Chinzei, Takumi Tojo, Takahiro Nishio, Yosuke Toda, Hirotaka Ori, Minoru Ito, Sho Hoshino
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Patent number: 11719144Abstract: The present disclosure provides an exhaust gas purification catalyst having improved durability, which comprises a substrate and a catalyst coat layer formed on the substrate, the catalyst coat layer having a two-layer structure, wherein the catalyst coat layer includes an upstream portion on an upstream side and a downstream portion on a downstream side in an exhaust gas flow direction, and a part or all of the upstream portion is formed on a part of the downstream portion, wherein the downstream portion contains Rh fine particles, and wherein the Rh fine particles have an average particle size measured by a transmission electron microscope observation of 1.0 nm or more to 2.0 nm or less, and a standard deviation ? of the particle size of 0.8 nm or less.Type: GrantFiled: December 14, 2020Date of Patent: August 8, 2023Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Norimichi Shimano, Shogo Shirakawa, Masahide Miura, Isao Chinzei, Seiji Nakahigashi, Hiroki Nihashi, Hiromi Togashi, Tomomasa Aikawa, Isao Naito
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Patent number: 11715833Abstract: A fuel cell electrode catalyst includes catalyst metal particles and electrically conductive support particles supporting the catalyst metal particles. In the fuel cell electrode catalyst, a proportion of a surface area occupied by the catalyst metal particles with particle sizes of 4.5 nm or less to a surface area of the catalyst metal particles calculated from a transmission electron microscope image is 5% or less.Type: GrantFiled: March 8, 2022Date of Patent: August 1, 2023Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Toshihiro Ikai, Tomohiro Ishida, Godai Kitayama, Yousuke Horiuchi
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Patent number: 11710833Abstract: This anode catalyst layer for a fuel cell contains electrode catalyst particles, a carbon carrier on which the electrode catalyst particles are loaded, water electrolysis catalyst particles, a proton-conducting binder, and graphitized carbon. The graphitized carbon has a bulk density of 0.50/cm3 or less.Type: GrantFiled: September 4, 2019Date of Patent: July 25, 2023Assignee: CATALER CORPORATIONInventors: Akihiro Hori, Yosuke Horiuchi
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Patent number: 11701615Abstract: This exhaust gas purifying catalyst is provided with a substrate and a catalyst layer formed on a surface of the substrate. The catalyst layer contains zeolite particles that support a metal, and a rare earth element-containing compound that contains a rare earth element. The rare earth element-containing compound is added in such an amount that the molar ratio of the rare earth element relative to Si contained in the zeolite is 0.001 to 0.014 in terms of oxides.Type: GrantFiled: October 26, 2021Date of Patent: July 18, 2023Assignee: Cataler CorporationInventors: Shu Miyasaka, Eriko Tanaka, Norihiko Aono, Mai Huong Tran, Keigo Hori, Daisuke Sugioka
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Publication number: 20230201770Abstract: A catalyst for purification of exhaust gas including a substrate, and a catalyst coat layer which is formed on a surface of the substrate and contains catalyst particles, wherein the catalyst coat layer has an average thickness ranging 25 to 150 ?m, a void fraction, as determined by scanning electron microscope observation of a cross-section of the catalyst coat layer, ranging 1.5 to 8.0% by volume, 60 to 90% by volume of all voids in the catalyst coat layer are high-aspect ratio pores which have equivalent circle diameters ranging 2 to 50 ?m in a cross-sectional image of a cross-section of the catalyst coat layer perpendicular to a flow direction of exhaust gas in the substrate, and which ratios of 5 or higher, the high-aspect ratio pores have an average aspect ratio ranging 10 to 50, and a noble metal is supported on the entire catalyst coat layer.Type: ApplicationFiled: June 8, 2021Publication date: June 29, 2023Applicant: CATALER CORPORATIONInventors: Toshio YAMAMOTO, Akira MORIKAWA, Satoru KATOH, Masahide MIURA, Nobusuke KABASHIMA, Nobuyuki TAKAGI, Takashi ONOZUKA, Mitsuyoshi OKADA