Patents Assigned to Cataler Corporation
  • Publication number: 20190336945
    Abstract: A Pd-supporting Zr-based composite oxide wherein by having a Zr-containing composite oxide support and Pd supported thereon and by showing, upon XAFS (X-ray absorption fine structure) analysis, a maximum peak in a Pd bond distance range of 2.500-3.500 ?, the maximum peak being located in a position of 3.050-3.110 ?.
    Type: Application
    Filed: December 26, 2016
    Publication date: November 7, 2019
    Applicants: CATALER CORPORATION, SANTOKU CORPORATION
    Inventors: Kyosuke MURAKAMI, Keiichi NARITA, Satoshi MATSUEDA, Michio TANAKA, Tadatoshi MUROTA, Shigeru ONO, Tomonori TAHARA
  • Patent number: 10450917
    Abstract: An object of the present invention is to provide an exhaust gas purification catalyst which can exhibit high durability and warm-up performance. The present invention relates to an exhaust gas purification catalyst comprising a substrate and a catalyst coating layer formed on the substrate, wherein the catalyst coating layer comprises catalyst particles, the catalyst coating layer having an upstream region extending by 40 to 60% of the entire length of the substrate from an upstream end of the catalyst in the direction of an exhaust gas flow and a downstream region corresponding to the remainder portion of the catalyst coating layer, the composition of the catalyst particle of the upstream region being different from that of the downstream region. The upstream region in the direction of an exhaust gas flow has a structure where a void is included in a large number, and furthermore high-aspect-ratio pores having an aspect ratio of 5 or more account for a certain percentage or more of the whole volume of voids.
    Type: Grant
    Filed: March 24, 2016
    Date of Patent: October 22, 2019
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Hiromasa Suzuki, Masahide Miura, Yoshinori Saito, Satoru Katoh, Toshitaka Tanabe, Tetsuhiro Hirao, Tatsuya Ohashi, Hiroaki Naito, Hirotaka Ori, Michihiko Takeuchi, Keiichi Narita
  • Publication number: 20190299139
    Abstract: An exhaust gas purification filter that suppresses an increase in pressure loss associated with the formation of a catalyst layer and is excellent in PM burning quality. The exhaust gas purification filter includes a base and a catalyst layer provided on the base. The catalyst layer contains a carrier and a metal catalyst. Large pores having a circle equivalent diameter greater than 5 ?m occupy, when an area of the catalyst layer is 100% in an electron microscope observation image of a cross section of the catalyst layer, 45% or more of the area.
    Type: Application
    Filed: May 30, 2017
    Publication date: October 3, 2019
    Applicant: CATALER CORPORATION
    Inventor: Eriko TANAKA
  • Patent number: 10413885
    Abstract: The exemplary embodiments relate to an exhaust gas purification catalyst that is excellent in terms of HC purification capacity and warm-up performance.
    Type: Grant
    Filed: October 4, 2018
    Date of Patent: September 17, 2019
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Hiromasa Suzuki, Yoshinori Saito, Tatsuya Ohashi, Shunsuke Ohishi, Takaya Ota
  • Patent number: 10413895
    Abstract: When the amount of coating is increased in a two-layer catalyst or the like containing two noble metals in respective different layers, gas diffusivity in the catalyst and use efficiency of a catalytic active site are reduced to thereby reduce purification performance. In view of this, an organic fiber having a predetermined shape is used as a pore-forming material in formation of an uppermost catalyst coating layer of a multi-layer catalyst, to thereby form an uppermost catalyst coating layer having a high-aspect-ratio pore excellent in connectivity and therefore excellent gas diffusivity.
    Type: Grant
    Filed: March 24, 2016
    Date of Patent: September 17, 2019
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Hiromasa Suzuki, Masahide Miura, Yoshinori Saito, Satoru Katoh, Toshitaka Tanabe, Tetsuhiro Hirao, Tatsuya Ohashi, Hiroaki Naito, Hirotaka Ori, Michihiko Takeuchi, Keiichi Narita
  • Patent number: 10408102
    Abstract: An oxidation catalyst device for exhaust gas purification, having a first catalyst coating layer on the exhaust gas flow's upstream side, second catalyst coating layer of an upper layer on exhaust gas flow's downstream side, and third catalyst coating layer of a lower layer on exhaust gas flow's downstream side, on a substrate, wherein the weight ratio of platinum to palladium in the first catalyst coating layer is 0.75 to 4.50, weight ratio of platinum to palladium in second catalyst coating layer is greater than 4.50 to 25.0, weight ratio of platinum to palladium in third catalyst coating layer is 0.12 or less, the length of first catalyst coating layer is 8% to 55% of the substrate's length, length of second catalyst coating layer is 45% to 95% of the substrate's length, and length of third catalyst coating layer is 45% to 95% of the substrate's length.
    Type: Grant
    Filed: June 1, 2018
    Date of Patent: September 10, 2019
    Assignees: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Takahiro Noguchi, Makoto Tsuji, Hiroto Imai, Yusuke Shimmyo, Hiroyuki Matsubara
  • Patent number: 10384163
    Abstract: The object of the present invention is to provide an exhaust gas purifying catalyst that can achieve high purification performance while suppressing H2S emissions. The object is solved by an exhaust gas purifying catalyst in which the lower layer of the catalyst coating layer comprises a ceria-zirconia composite oxide having a pyrochlore-type ordered array structure, in which the ceria-zirconia composite oxide contains at least one additional element selected from the group consisting of praseodymium, lanthanum, and yttrium at 0.5 to 5.0 mol % in relation to the total cation amount, and the molar ratio of (cerium+additional element):(zirconium) is within the range from 43:57 to 48:52.
    Type: Grant
    Filed: December 11, 2015
    Date of Patent: August 20, 2019
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Isao Chinzei, Hiromasa Suzuki, Takeru Yoshida, Masahide Miura, Yuki Aoki, Mitsuyoshi Okada, Toshitaka Tanabe, Akihiko Suda, Yoshinori Saito, Hirotaka Ori, Kosuke Iizuka, Akira Morikawa
  • Patent number: 10369520
    Abstract: The exhaust gas cleaning catalyst according to the present invention is provided with a cylindrical substrate 10 and a catalyst coat layer 20 formed on the surface of the substrate 10. A ratio of the length L in the cylindrical axis direction of the substrate 10 and the diameter D of a cross section orthogonal to the cylindrical axis direction is denoted by (L/D)?0.8. The coat density of the catalyst coat layer 20 differs between an upstream side portion 10a that includes the exhaust gas inlet-side end 16 of the substrate 10 and a downstream side portion 10b that includes the exhaust gas outlet-side end 18 of the substrate 10. The coat density A in the upstream side portion 10a is lower than the coat density B in the downstream side portion 10b (A<B).
    Type: Grant
    Filed: January 8, 2016
    Date of Patent: August 6, 2019
    Assignee: Cataler Corporation
    Inventors: Ryota Onoe, Tsuyoshi Ito, Yuki Takesue, Masatoshi Ikebe, Chihiro Kasuya, Yuta Morishita
  • Patent number: 10357744
    Abstract: An exhaust gas purification device of the present invention is provided with: a substrate of wall flow structure having an inlet cell, an outlet cell and a porous partition wall; an upstream catalyst layer, provided inside the partition wall and disposed in an upstream portion of the substrate including an exhaust gas inflow end section; and a downstream catalyst layer, provided inside the partition wall and disposed in a downstream portion of the substrate including an exhaust gas outflow end section. The upstream catalyst layer and the downstream catalyst layer each contain a carrier and at least one noble metal from among Pt, Pd and Rh, supported on the carrier. The noble metal in the upstream catalyst layer and the noble metal in the downstream catalyst layer are different from each other.
    Type: Grant
    Filed: October 6, 2015
    Date of Patent: July 23, 2019
    Assignee: CATALER CORPORATION
    Inventors: Tatsuya Ohashi, Shingo Sakagami, Tsuyoshi Ito, Ryota Onoe, Naoto Miyoshi, Masahiko Takeuchi, Akemi Sato
  • Publication number: 20190209967
    Abstract: An exhaust gas purifying catalyst for 2-stroke general-purpose engines, which is characterized in that: the exhaust gas purifying catalyst includes a base and a coat layer on the base; the coat layer contains noble metals and metal oxides; the noble metals include palladium and one or more elements selected from among platinum and rhodium; the zirconia content in the coat layer is 0.07 mole or less per 100 g of the metal oxides contained in the coat layer; and the total content of one or more metal oxides selected from among lanthana and alkaline earth metal oxides in the coat layer is 0.05 mole or more per 100 g of the metal oxides contained in the coat layer.
    Type: Application
    Filed: May 17, 2017
    Publication date: July 11, 2019
    Applicant: CATALER CORPORATION
    Inventors: Yoritsugu SHINO, Tsuyoshi ITO, Keisuke MURASHIGE, Akio KUBOTA
  • Patent number: 10344655
    Abstract: An exhaust gas purification catalyst having an excellent exhaust partition ability while reducing the increase in pressure loss. Exhaust gas purification catalyst includes a substrate having a wall-flow structure with partition wall, upstream coating section formed in portions of partition wall facing entrance cell, from exhaust inlet-side end in the extending direction of partition wall, and downstream coating section formed in portions of partition wall facing exit cell, from exhaust outlet-side end in the extending direction, having a length shorter than the entire length Lw of the partition wall. In downstream coating section, a catalytic metal is concentrated in the surface layer in contact with exit cell.
    Type: Grant
    Filed: October 7, 2015
    Date of Patent: July 9, 2019
    Assignees: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Ryota Onoe, Shingo Sakagami, Tsuyoshi Ito, Yuta Morishita, Masahiko Takeuchi, Naoto Miyoshi, Akemi Sato, Daisuke Ochiai
  • Patent number: 10344641
    Abstract: An exhaust gas purifying catalyst includes an inlet-side catalyst layer formed on an inner side of the partition wall from a surface of the partition wall in contact with an inlet-side cell and formed along an extension direction from an end portion on the exhaust gas inflow side, and an outlet-side catalyst layer formed on the inner side of the partition wall from a surface of the partition wall in contact with an outlet-side cell and formed along the extension direction from an end portion on the exhaust gas outflow side. Here, a sum of the lengths of the inlet-side catalyst layer and the outlet-side catalyst layer is larger than the entire length of the partition wall, and a total amount of an SCR catalyst body present in the outlet-side catalyst layer is larger than a total amount of an SCR catalyst body present in the inlet-side catalyst layer.
    Type: Grant
    Filed: March 6, 2018
    Date of Patent: July 9, 2019
    Assignees: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Makoto Tsuji, Hiroto Imai, Shintaro Kobayashi, Yusuke Shimmyo, Hiroyuki Matsubara
  • Publication number: 20190201884
    Abstract: The exemplary embodiments relate to an exhaust gas purification catalyst, in which exhaust gas purification performance is secured and an increase in pressure loss is suppressed, which is an exhaust gas purification catalyst, in which a porous filter wall of a substrate having a wall-flow structure is coated with a catalyst material containing an OSC material having oxygen storage capacity and a catalyst metal, wherein the density of percolation paths having percolation path diameters of 4 ?m or more per unit area inside of the filter wall coated with the catalyst material is 100 paths/mm2 to 1000 paths/mm2.
    Type: Application
    Filed: December 7, 2018
    Publication date: July 4, 2019
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Atsushi TANAKA, Takeru YOSHIDA, Naoto MIYOSHI, Akemi SATO, Yasutaka NOMURA, Satoru INODA
  • Patent number: 10335736
    Abstract: An exhaust gas purification material according to the present invention is provided with a particulate filter 10 that traps particulate matter in exhaust gas and contains an SCR catalyst for adsorbing ammonia and reducing NOx in the exhaust gas. A maximum allowable adsorption amount of ammonia adsorbable by the filter 10 differs between an upstream portion 10a of the filter 10 including an exhaust gas inlet-side end 10c, and a downstream portion 10b of the filter 10 including an exhaust gas outlet-side end 10d. The SCR catalyst contained in the upstream portion 10a and the SCR catalyst contained in the downstream portion 10b are qualitatively different. A ratio (B/A) of a maximum allowable adsorption amount of ammonia A in the upstream portion 10a and a maximum allowable adsorption amount of ammonia B in the downstream portion 10b satisfies the relationship 1.1?(B/A)?2.
    Type: Grant
    Filed: June 21, 2018
    Date of Patent: July 2, 2019
    Assignee: CATALER CORPORATION
    Inventors: Makoto Tsuji, Hiroto Imai, Shintaro Kobayashi
  • Publication number: 20190193057
    Abstract: An exhaust gas purifying catalyst includes a catalyst layer formed inside a partition wall of a base material having a wall flow structure, and has an upstream-side and a downstream-side catalyst layer. The upstream-side catalyst layer includes Rh and a Ce-containing oxide, and the downstream-side catalyst layer includes Pd and a Ce-containing oxide. The mass of the catalyst layer per unit volume of the base material is from 105 g/L to 210 g/L, the mass of the upstream-side catalyst layer per unit volume in an upstream-side portion is from 50 g/L to 100 g/L, the mass of the downstream-side catalyst layer per unit volume in a downstream-side portion is from 100 g/L to 150 g/L, the Ce amount per unit volume of the base material is from 14 g/L to 35 g/L, and the Ce amount per unit volume in the upstream-side portion is from 5 g/L to 20 g/L.
    Type: Application
    Filed: September 19, 2017
    Publication date: June 27, 2019
    Applicant: CATALER CORPORATION
    Inventors: Sho HOSHINO, Yuki TAKESUE, Ryota ONOE, Taku MIURA, Takaya OTA
  • Patent number: 10328387
    Abstract: A method of manufacturing an exhaust gas-purifying catalyst comprising: moving a gas-flow control tool from a first position where the gas-flow control tool faces the first end face with the slurry in the reservoir interposed therebetween and is spaced apart from the slurry in the reservoir to a second position where the gas-flow control tool faces the first end face with a distance from the first end face shorter than that in the first position, in a period during which the slurry flows from the first end face's side toward the second end face's side, the gas-flow control tool being configured to generate a distribution of linear velocities of gas flows when the gas-flow control tool faces the first end face and gas is passed therethrough toward the first end face.
    Type: Grant
    Filed: May 7, 2018
    Date of Patent: June 25, 2019
    Assignee: CATALER CORPORATION
    Inventors: Shoko Fukuyo, Minoru Ito
  • Patent number: 10323554
    Abstract: The present invention is directed to address the following problem: in an exhaust gas purification catalyst comprising a dual catalyst of a combination of a startup catalyst and an underfloor catalyst, reduction in the gas diffusivity of the underfloor catalyst results in reduction in the use efficiency of a catalytic active site, resulting in reduction in purification performance. The present invention relates to an exhaust gas purification catalyst comprising a dual catalyst of a combination of a startup catalyst and an underfloor catalyst having a catalyst coating where a large number of voids are included, wherein high-aspect-ratio pores having an aspect ratio of 5 or more account for a certain rate or more of the whole volume of the voids, to thereby enhance the purification performance of the catalyst.
    Type: Grant
    Filed: March 24, 2016
    Date of Patent: June 18, 2019
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Hiromasa Suzuki, Masahide Miura, Yoshinori Saito, Satoru Katoh, Toshitaka Tanabe, Tetsuhiro Hirao, Tatsuya Ohashi, Hiroaki Naito, Hirotaka Ori, Michihiko Takeuchi, Keiichi Narita
  • Patent number: 10322406
    Abstract: The object of the present invention is to provide an exhaust gas purifying catalyst that can achieve high purification performance while suppressing H2S emissions. The object is solved by an exhaust gas purifying catalyst in which the top layer of a catalyst coating layer comprises a ceria-zirconia composite oxide having a pyrochlore-type ordered array structure, in which the ceria-zirconia composite oxide contains at least one additional element selected from the group consisting of praseodymium, lanthanum, and yttrium at 0.5 to 5.0 mol % in relation to the total cation amount, and the molar ratio of (cerium+additional element):(zirconium) is within the range from 43:57 to 48:52.
    Type: Grant
    Filed: December 11, 2015
    Date of Patent: June 18, 2019
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Hiromasa Suzuki, Takeru Yoshida, Masahide Miura, Yuki Aoki, Isao Chinzei, Yoshinori Saito, Daisuke Ochiai, Mitsuyoshi Okada, Toshitaka Tanabe, Akihiko Suda, Masanao Sato, Akiya Chiba, Akira Morikawa, Hirotaka Ori
  • Patent number: 10307736
    Abstract: An exhaust gas purification catalyst, excellent in the NOx purification capacity and the HC purification capacity, includes a substrate and a catalyst coating layer formed on the surface of the substrate, wherein the catalyst coating layer comprises the upper and lower layer including a lower layer being closer to the surface of the substrate and an upper layer being relatively remote from the surface of the substrate. The upper layer of the catalyst coating layer includes Rh, Pd, and a carrier. The lower layer of the catalyst coating layer includes at least one noble metal selected from Pd and Pt and a carrier. 65% by mass or more of Pd in the upper layer exists in a layer up to 50% of the upper layer in a thickness direction from the surface of the upper layer being relatively remote from the surface of the substrate. The ratio of Pd to Rh by mass (Pd/Rh) is 0.5 to 7.0 in the upper layer.
    Type: Grant
    Filed: March 27, 2018
    Date of Patent: June 4, 2019
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Yoshinori Saito, Hiromasa Suzuki, Tatsuya Ohashi, Keiichi Narita, Ryota Nakashima, Mitsuyoshi Okada, Ryosuke Takasu, Shunsuke Oishi
  • Publication number: 20190151829
    Abstract: An exhaust gas purification underfloor catalyst characterized in having a catalyst layer having a lower layer and an upper layer, the lower layer containing alumina and CeO2, the noble metal content of the lower layer being at most 0.5 mass % in relation to the mass of the lower layer, the upper layer containing Rh, alumina, and CeO2, the amount of noble metals other than Rh contained being 1 mol % or less in relation to the total amount of noble metals contained in the upper layer, the total amount of CeO2 contained in the lower layer and the upper layer being 14 g/L to 30 g/L, the amount of CeO2 contained in the upper layer being 7 g/L to 25 g/L, and the amount of CeO2 contained in the lower layer being 20% or more of the amount of CeO2 contained in the upper layer.
    Type: Application
    Filed: February 28, 2017
    Publication date: May 23, 2019
    Applicant: Cataler Corporation
    Inventors: Sho HOSHINO, Noboru SATO, Keisuke MURAWAKI