Patents Assigned to Cataler Corporation
  • Patent number: 12270327
    Abstract: An exhaust gas purification catalyst apparatus has a honeycomb base material and a catalyst noble metal supported by the honeycomb base material, wherein: the honeycomb base material contains ceria-zirconia composite oxide particles as one of the constituent materials, is of a wall flow type, and includes inlet-side cells and outlet-side cells demarcated by porous partition walls; the catalyst noble metal is supported in inlet-side support regions and outlet-side support regions; each of the inlet-side support regions is formed with a specific length from the exhaust gas flow upstream end; the catalyst noble metal 70% support depth is not greater than 50% of the thickness of the porous partition walls; each of the outlet-side support regions is formed with a specific length from the exhaust gas flow downstream end; and the catalyst noble metal 70% support depth is greater than 50% of the thickness of the porous partition walls.
    Type: Grant
    Filed: June 17, 2020
    Date of Patent: April 8, 2025
    Assignees: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kana Iwata, Minoru Itou, Takeru Yoshida, Masaru Kakinohana, Hiromasa Suzuki, Atsushi Tanaka
  • Publication number: 20250083102
    Abstract: An exhaust gas purification catalyst includes a substrate and a catalyst layer on the substrate. The catalyst layer includes lower and upper catalyst layers. The lower catalyst layer includes a powder material containing a powdered carrier, and catalyst metal particles containing Rh on the carrier. The upper catalyst layer includes an upstream catalyst layer in an upstream side in an exhaust gas flow direction, and a downstream catalyst layer in a downstream side in the exhaust gas flow direction. At least the upstream catalyst layer of the upstream and downstream catalyst layers includes a powder material containing a powdered carrier, and catalyst metal particles containing Pd on the carrier. A cumulative 50% particle size D50 in a volume-based particle size distribution of the powder material included in at least the upstream catalyst layer of the upstream and downstream catalyst layers is 6 ?m or more and 10 ?m or less.
    Type: Application
    Filed: August 2, 2024
    Publication date: March 13, 2025
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Takahiro Nishio, Takumi Tojo, Nobuyuki Takagi, Sho Hoshino, Naoto Fujita, Yosuke Toda, Shun Sakamoto, Kengo Shimizu
  • Publication number: 20250073640
    Abstract: An exhaust gas purification device capable of reducing pressure loss and improving exhaust gas purification performance. Exhaust gas purification device including honeycomb substrate and outflow cell side catalyst. Honeycomb substrate includes porous partition wall defining plurality of cells extending from inflow side end surface to outflow side end surface. Plurality of cells include inflow and outflow cells adjacent across partition wall. Inflow cell has open inflow and sealed outflow side ends. Outflow cell side catalyst is disposed in inner region of partition wall at outflow cell side in outflow cell side catalyst-disposed range extending from outflow side end of partition wall to position apart by predetermined distance along extending direction. Minimum value of porosity in thickness direction of outflow cell side catalyst-disposed wall including outflow cell side catalyst-disposed range of partition wall and outflow cell side catalyst in range of 20% or more and 30% or less.
    Type: Application
    Filed: August 15, 2024
    Publication date: March 6, 2025
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Seiji NAKAHIGASHI, Koji SUGIURA, Eiji HARADA, Masatoshi IKEBE, Takaya OTA, Takeshi MORISHIMA, Ayano KIMURA
  • Patent number: 12239968
    Abstract: A particulate filter includes a base material having a wall-flow structure including porous partition walls partitioning inlet and outlet cells, and wash-coating layers held inside partition walls. The wash-coating layers include inlet layers each formed from vicinity of an end portion at exhaust gas inflow side to have predetermined length and thickness and outlet layers each formed from vicinity of end portion at exhaust gas outflow side to have a predetermined length and thickness. The inlet and the outlet layers partially overlap with each other. Inlet layers of particulate filter contain substantially no noble metal catalyst, and outlet layers contain noble metal catalyst. Accordingly, PM collection performance can be easily enhanced in inlet region, and high gas distributability (pressure loss suppression performance) can be maintained in outlet region.
    Type: Grant
    Filed: June 1, 2020
    Date of Patent: March 4, 2025
    Assignee: CATALER CORPORATION
    Inventors: Ryota Onoe, Ryo Tasaki, Momoko Iwai, Yamato Matsushita
  • Patent number: 12233404
    Abstract: The present invention provides an exhaust gas purification catalyst including a base material and a catalyst layer that is arranged on the base material. The catalyst layer includes a catalyst metal and a carrying material carrying the catalyst metal. The catalyst layer satisfies below: (1) in a pore distribution curve measured by a mercury porosimeter, a peak for the largest pore volume exists within a range of a pore diameter equal to or more than 1 ?m and not more than 10 ?m; and (2) on an electron microscopy observation image (with a 1000-fold magnification) of a surface of the catalyst layer, when areas of a plurality of voids comprised in the electron microscopy observation image are respectively calculated, a standard deviation for the areas of the plurality of voids is not more than 30 ?m2.
    Type: Grant
    Filed: August 20, 2020
    Date of Patent: February 25, 2025
    Assignee: Cataler Corporation
    Inventor: Chihiro Kasuya
  • Publication number: 20250058302
    Abstract: A supported catalyst particles include oxide carrier particles and noble metal particles supported on the oxide carrier particles, wherein the mass of the noble metal particles is less than or equal to 5 mass % based on the mass of the oxide carrier particles, and the average particle size of the noble metal particles measured by transmission electron microscopy is 1.0-2.0 nm, with the standard deviation ? less than or equal to 0.8 nm.
    Type: Application
    Filed: October 11, 2024
    Publication date: February 20, 2025
    Applicants: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Hiroki NIHASHI, Shogo KAWAMURA, Tomomasa AIKAWA, Isao NAITO, Shogo SHIRAKAWA, Masahide MIURA, Nobuyuki TAKAGI, Norimichi SHIMANO
  • Patent number: 12226755
    Abstract: An exhaust gas purification catalyst showing resistance to peeling and high purification performance is provided. The present invention is an exhaust gas purification catalyst including a base material and a catalyst layer disposed on the base material. The catalyst layer includes a catalytic metal, a first metal oxide, and a second metal oxide having a higher heat resistance than that of the first metal oxide. When Dx is an area-based average particle diameter of the first metal oxide determined from an arbitrary cross section of the catalyst layer and Dy is an area-based particle diameter of the second metal oxide 22 measured from the cross section of the catalyst layer, a ratio of the Dy to the Dx (Dy/Dx) is 5 or more, and the Dy is 7 ?m or more. In the catalyst layer, pore volume of pores having pore diameters 30 nm or more measured by a nitrogen adsorption method is 0.28 cm3/g or more.
    Type: Grant
    Filed: June 28, 2021
    Date of Patent: February 18, 2025
    Assignee: Cataler Corporation
    Inventors: Ryosuke Takasu, Shunsuke Oishi, Takaya Ota
  • Publication number: 20250052500
    Abstract: A ring tray for honeycomb substrate firing, the ring tray supporting a honeycomb substrate having cell flow channels partitioned by cell walls, so that the flow channel direction is vertical during substrate firing, the ring tray including a ring-shaped frame part, a support part further inside than the frame part, and a connecting part connecting the frame part and support part, and the ring tray being configured so that when the honeycomb substrate is mounted on the ring tray, the support part does not contact an outer peripheral edge of a lower end surface of the honeycomb substrate, and contacts a portion of an internal region of the lower end surface of the honeycomb substrate, and is thus able to support the lower end of the honeycomb substrate, and the frame part and the connecting part do not contact the lower end surface of the honeycomb substrate.
    Type: Application
    Filed: December 1, 2022
    Publication date: February 13, 2025
    Applicant: CATALER CORPORATION
    Inventors: Daiki SAKURAI, Katsuhiro OKABE, Shintaro SUZUKI
  • Publication number: 20250054997
    Abstract: A method for producing catalyst particles, which are for an electrochemical reaction and in which catalytic noble metal particles are carried on conductive oxide particles, includes: using metal atom-containing organic compounds as a precursor of the conductive oxide particles and a precursor of the catalytic noble metal particles, and dissolving the metal atom-containing organic compounds in an organic solvent to obtain a precursor solution; and spraying and combusting the precursor solution.
    Type: Application
    Filed: December 1, 2022
    Publication date: February 13, 2025
    Applicants: CATALER CORPORATION, HIROSHIMA UNIVERSITY
    Inventors: Aoi TAKANO, Yosuke HORIUCHI, Takashi OGI
  • Patent number: 12214334
    Abstract: A supported catalyst particles include oxide carrier particles and noble metal particles supported on the oxide carrier particles, wherein the mass of the noble metal particles is less than or equal to 5 mass % based on the mass of the oxide carrier particles, and the average particle size of the noble metal particles measured by transmission electron microscopy is 1.0-2.0 nm, with the standard deviation ? less than or equal to 0.8 nm.
    Type: Grant
    Filed: February 12, 2020
    Date of Patent: February 4, 2025
    Assignees: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Hiroki Nihashi, Shogo Kawamura, Tomomasa Aikawa, Isao Naito, Shogo Shirakawa, Masahide Miura, Nobuyuki Takagi, Norimichi Shimano
  • Patent number: 12201965
    Abstract: An exhaust gas purification catalyst provides excellent removal performance of methane, which is chemically stable. Exhaust gas purification catalyst includes a substrate that divides cells through which an exhaust gas flows and a catalyst layer that is provided on a surface of the substrate. The catalyst layer includes a palladium layer containing palladium that extends from a first end part which is an end part on the side into which an exhaust gas in the cells flows to a second end part which is an end part on the side from which an exhaust gas flows out, a platinum layer containing platinum that extends from the second end part to the first end part, and a rhodium layer containing rhodium that is laminated with both the palladium layer and the platinum layer.
    Type: Grant
    Filed: January 5, 2024
    Date of Patent: January 21, 2025
    Assignee: Cataler Corporation
    Inventors: Takahiro Noguchi, Ryota Onoe, Ryo Tasaki, Momoko Iwai, Yamato Matsushita
  • Patent number: 12201940
    Abstract: 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: Grant
    Filed: October 25, 2021
    Date of Patent: January 21, 2025
    Assignee: Cataler Corporation
    Inventors: Shu Miyasaka, Eriko Tanaka, Norihiko Aono, Mai Huong Tran, Keigo Hori, Daisuke Sugioka
  • Publication number: 20250018384
    Abstract: An exhaust gas purification catalyst device includes a substrate and one or more catalyst coating layers on the substrate, wherein the one or more catalyst coating layers include copper ion-exchanged zeolite and alkali-containing zeolite containing one or more metals selected from among alkali metals and alkaline earth metals, the exhaust gas purification catalyst device satisfying either of the following conditions (A) and (B): (A) both the copper ion-exchanged zeolite and the alkali-containing zeolite are contained in one of the catalyst coating layers, and (B) the catalyst coating layer includes a first catalyst coating layer containing the copper ion-exchanged zeolite and a second catalyst coating layer containing the alkali-containing zeolite, with the first catalyst coating layer and second catalyst coating layer being layered together in direct contact.
    Type: Application
    Filed: November 30, 2022
    Publication date: January 16, 2025
    Applicant: CATALER CORPORATION
    Inventors: Takehiro AMADA, Hiroto IMAI, Keigo HORI, Daisuke SUGIOKA, Akiya CHIBA
  • Publication number: 20250010282
    Abstract: A method for manufacturing an exhaust gas purification catalyst device includes: (A) holding a honeycomb base material, which has a plurality of cell flow paths divided by cell walls, so that the flow path direction of the cell flow paths is vertical, and placing a coating liquid for catalyst coating layer formation on the upper end surface of the base material; (B) suctioning the post-step (A) base material from the lower end surface by a decompression pump to apply the coating liquid on the cell walls and/or in the cell walls of the base material; and, (C) transferring the post-step (A) base material to the next step, wherein step (B) and step (C) are performed simultaneously by a transfer/suction device 100.
    Type: Application
    Filed: November 11, 2022
    Publication date: January 9, 2025
    Applicant: CATALER CORPORATION
    Inventors: Koji OGA, Hiroki OKADA, Masaki TAKAHASHI
  • Patent number: 12173634
    Abstract: The technology disclosed herein provides a particulate filter that can appropriately avoid PM from passing toward the outlet cell and can exhibit an excellent PM capturing performance. The particulate filter 1 disclosed herein includes: an outercoat layer 20 provided on an inlet surface 16a of a partition 16 of a base material 10. The outercoat layer 20 at least includes: a lower layer 22 provided on the inlet surface 16a of the partition 16; and an upper layer 24 provided to cover the lower layer 22. The mean particle diameter of granules contained in the upper layer 24 is higher than the mean particle diameter of granules contained in the lower layer. The mean particle diameter of the granules in the lower layer 22 is from 0.4 ?m to 2.0 ?m inclusive, and the mean particle diameter of the granules in the upper layer 24 is from 2.0 ?m to 7.0 ?m inclusive.
    Type: Grant
    Filed: December 9, 2021
    Date of Patent: December 24, 2024
    Assignee: Cataler Corporation
    Inventors: Ryo Tasaki, Ryota Onoe, Masaya Ito, Momoko Iwai, Yamato Matsushita
  • Publication number: 20240408589
    Abstract: A method for manufacturing an exhaust gas purification catalyst device includes: (A) placing a catalyst coating layer-forming coating liquid on the upper end surface of a honeycomb substrate having a plurality of cell flow paths partitioned by cell walls in a coating liquid placing station; (B) transferring the substrate from the coating liquid placing station to a suction station; and (C) suctioning the substrate from the lower end surface in the suction station to coat the cell walls of the substrate with the coating liquid, wherein the suction station comprises two or more suction devices, and step (B) comprises (B1) transferring the substrate, on which the coating liquid has been placed, from the coating liquid placing station to a branch station, and (B2) transferring the substrate, on which the coating liquid has been placed, to an empty suction device among the suction devices of the branch station.
    Type: Application
    Filed: November 14, 2022
    Publication date: December 12, 2024
    Applicant: CATALER CORPORATION
    Inventors: Hiroki OKADA, Koji OGA, Kazuhiro MIZOGUCHI, Hitomi SUZUKI, Yuji KAWARASAKI
  • Publication number: 20240396056
    Abstract: An electrocatalyst for hydrogen fuel cell anodes, including a conductive carrier and a noble metal supported on the conductive carrier, wherein the noble metal includes ruthenium and platinum, and a molar ratio Ru/Pt of the ruthenium relative to the platinum is 0.04 mol/mol or more and 0.20 mol/mol or less.
    Type: Application
    Filed: October 7, 2022
    Publication date: November 28, 2024
    Applicant: CATALER CORPORATION
    Inventors: Aoi TAKANO, Yosuke HORIUCHI
  • Publication number: 20240390853
    Abstract: Provided is an exhaust gas purification device having a high warm-up performance and a high NOx conversion performance. The exhaust gas purification device includes a substrate having an upstream end and a downstream end, a first catalyst layer disposed on the substrate in a first region extending between the downstream end and a first position and containing rhodium, a second catalyst layer disposed on the substrate in a second region extending between the upstream end and a second position and containing rhodium and an oxygen storage material, and a third catalyst layer disposed on the second catalyst layer in a third region extending between the upstream end and a third position and containing palladium. The oxygen storage material in the second catalyst layer contains a pyrochlore type Ce—Zr composite oxide and a fluorite type Ce—Zr composite oxide at a weight ratio of from 0.2:1 to 0.4:1.
    Type: Application
    Filed: May 13, 2024
    Publication date: November 28, 2024
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Takumi TOJO, Takahiro NISHIO, Nobuyuki TAKAGI, Sho HOSHINO, Yosuke TODA, Shun SAKAMOTO, Kengo SHIMIZU, Naoto FUJITA
  • Publication number: 20240375048
    Abstract: An exhaust gas purification catalyst device provided with: a base material having a plurality of exhaust gas flow paths that are partitioned from each other by a partitioning wall; and a noble metal catalyst particle-supporting layer and an inorganic oxide particle layer arranged on the partitioning wall or in the partitioning wall. In the exhaust gas purification catalyst device, the inorganic oxide particle layer is arranged nearer the exhaust gas flow path side than the noble metal catalyst particle-supporting layer and the primary particle diameter of inorganic oxide particles in the inorganic oxide particle layer is 5 nm to 200 nm inclusive.
    Type: Application
    Filed: August 29, 2022
    Publication date: November 14, 2024
    Applicant: CATALER CORPORATION
    Inventor: Fumitaka TERASAKI
  • Patent number: 12140060
    Abstract: Provided is an exhaust gas purification system that allows suppressing the emission of carbon monoxide (CO). An exhaust gas purification system includes a three-way catalyst and a particulate filter and a control device. The three-way catalyst and the particulate filter are arranged respectively on an upstream side and a downstream side of an exhaust channel connected to an internal combustion engine. The control device controls the internal combustion engine so as to execute fuel cut during a deceleration operation of the internal combustion engine. The particulate filter includes a honeycomb substrate and an outflow cell side catalyst layer. The honeycomb substrate includes a porous partition wall defining a plurality of cells extending from an inflow side end surface to an outflow side end surface. The plurality of cells include an inflow cell and an outflow cell adjacent across the partition wall. The inflow cell has an open inflow side end and a sealed outflow side end.
    Type: Grant
    Filed: July 6, 2023
    Date of Patent: November 12, 2024
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Koji Sugiura, Seiji Nakahigashi, Masatoshi Ikebe, Takaya Ota, Takeshi Morishima, Eiji Harada