Patents Assigned to Cataler Corporation
  • Patent number: 11949113
    Abstract: An electrode catalyst for a fuel cell, the electrode catalyst having high initial activity and being capable of long-term retention of said activity; and a fuel cell using the electrode catalyst for a fuel cell. The electrode catalyst for a fuel cell includes catalyst metal particles that include platinum or a platinum alloy, and carrier particles that carry said catalyst metal particles, wherein the carrier particles are a carbonaceous material having a cumulative pore volume of 0.10 cc/g or less in the diameter range of 2 nm or less, and a BET specific surface area of greater than 900 m2/g; and a fuel cell comprising the electrode catalyst for a fuel cell.
    Type: Grant
    Filed: March 13, 2019
    Date of Patent: April 2, 2024
    Assignees: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Mikihiro Kataoka, Kotaro Horiai, Tomoaki Terada, Yusuke Itoh, Mikihiro Hori
  • Publication number: 20240097146
    Abstract: A fuel cell electrode catalyst in which catalytic metal particles made of Pt or a Pt alloy are supported on a carbon carrier, wherein the number of the catalytic metal particles per unit surface area of the carbon carrier is 4.3/100 nm2 to 16.0/100 nm2.
    Type: Application
    Filed: January 14, 2022
    Publication date: March 21, 2024
    Applicant: CATALER CORPORATION
    Inventors: Akihiro HORI, Yuko MATSUMURA
  • Publication number: 20240075463
    Abstract: Particles for an exhaust gas purification catalyst including: inorganic oxide particles; and an inorganic coating layer covering the inorganic oxide particles. The particles for an exhaust gas purification catalyst have reduced cumulative pore volume in a pore diameter range of 0.1-20 ?m compared to a cumulative pore volume in a pore diameter range of 0.1-20 ?m of inorganic oxide particles before being coated with the inorganic coating layer. Accordingly, the particles for an exhaust gas purification catalyst have a higher thermal conductivity than the inorganic oxide particles before being coated with the inorganic coating layer.
    Type: Application
    Filed: December 27, 2021
    Publication date: March 7, 2024
    Applicant: CATALER CORPORATION
    Inventors: Yukiko YAMASHITA, Satoshi MATSUEDA, Isao NAITO
  • Patent number: 11918986
    Abstract: There is provided an exhaust gas purification device that shows a high HC removal performance under a condition in which a rich air-fuel mixture is introduced. The exhaust gas purification device includes a substrate, a first catalyst layer, and a second catalyst layer. The substrate includes an upstream end and a downstream end. The first catalyst layer is disposed on a surface of the partition wall in an upstream region including the upstream end of the substrate. The second catalyst layer is disposed inside the partition wall in a downstream region including the downstream end of the substrate. The first catalyst layer contains a first metal catalyst and alumina-zirconia composite oxide. The second catalyst layer contains a second metal catalyst.
    Type: Grant
    Filed: May 24, 2022
    Date of Patent: March 5, 2024
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Koji Sugiura, Takeshi Hirabayashi, Akemi Satou, Keisuke Murawaki, Takaya Ota, Masatoshi Ikebe, Kohei Takasaki, Takeshi Morishima
  • Patent number: 11901567
    Abstract: 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. At least part of the carbon carrier has a crystallite size La of 3.0 nm or more.
    Type: Grant
    Filed: September 4, 2019
    Date of Patent: February 13, 2024
    Assignee: CATALER CORPORATION
    Inventors: Akihiro Hori, Yosuke Horiuchi
  • Patent number: 11901568
    Abstract: To provide an electrocatalyst for fuel cells, which is configured to ensure both the initial performance and durability of fuel cells. An electrocatalyst for fuel cells, wherein the electrocatalyst comprises a carbon support including a mesopore and a catalyst alloy supported on the carbon support, and the catalyst alloy is a catalyst alloy of platinum and a transition metal; wherein the mesopore includes at least one throat; wherein an average effective diameter of the at least one throat is 1.8 nm or more and less than 3.2 nm; and wherein a transition metal ratio of the catalyst alloy supported on a deeper-side region than the at least one throat, is lower than the transition metal ratio of the catalyst alloy supported on a nearer-side region than the at least one throat.
    Type: Grant
    Filed: March 3, 2022
    Date of Patent: February 13, 2024
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Ryo Shimizu, Kumiko Nomura, Tomohiro Takeshita, Shu Miyasaka, Kenji Yamamoto
  • Patent number: 11901565
    Abstract: A fuel cell electrode catalyst includes: catalyst metal particles containing at least one of platinum or a platinum alloy; and support particles supporting the catalyst metal particles. The crystallite size 2r obtained from an X-ray diffraction image of the catalyst metal particles is 3.8 nm or less, where r represents a crystallite radius of the catalyst metal particles obtained from the X-ray diffraction image. The amount of CO adsorption Y (mL/g-Pt) on the fuel cell electrode catalyst satisfies Y?40.386/r+1.7586.
    Type: Grant
    Filed: March 9, 2022
    Date of Patent: February 13, 2024
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Toshihiro Ikai, Tomohiro Ishida, Godai Kitayama, Yousuke Horiuchi
  • Patent number: 11890586
    Abstract: A device produces fine bubbles that has a simple configuration and that is capable of generating fine bubbles. This fine bubble generation device includes: a porous body having continuous pores; a liquid supply section that supplies a liquid to the porous body and causes the liquid to circulate through the continuous pores; and a liquid discharge section for discharging liquid that has circulated through the continuous pores.
    Type: Grant
    Filed: September 9, 2019
    Date of Patent: February 6, 2024
    Assignees: CATALER CORPORATION, NATIONAL UNIVERSITY CORPORATION SHIZUOKA UNIVERSITY
    Inventors: Tomohito Mizukami, Yusuke Saito, Nobuyuki Mase
  • Patent number: 11883797
    Abstract: An exhaust gas purification catalyst device having a substrate, a first catalyst coating layer on the substrate, and a second catalyst coating layer on the first catalyst coating layer. The first catalyst coating layer includes inorganic oxide particles, palladium carried on the inorganic oxide particles, and a barium compound. The second catalyst coating layer includes alumina particles and rhodium carried by the alumina particles. The ratio (MBa/MRh) between the mass (MBa) of barium in the first catalyst coating layer and the mass (MRh) of rhodium in the second catalyst coating layer is 5.0-60.0 inclusive.
    Type: Grant
    Filed: March 3, 2020
    Date of Patent: January 30, 2024
    Assignee: CATALER CORPORATION
    Inventors: Tatsuya Ohashi, Kohei Takasaki
  • Publication number: 20240017246
    Abstract: The exhaust gas purification device includes: a substrate including an upstream and a downstream ends; a first catalyst layer extending across a first region and containing a first rhodium-containing catalyst and a first cerium-containing oxide, the first rhodium-containing catalyst containing a first metal oxide carrier and first rhodium particles supported on the first metal oxide carrier, a mean of a particle size distribution of the first rhodium particles being 1.5 nm to 18 nm; and a second catalyst layer extending across a second region and containing a second rhodium-containing catalyst containing a second metal oxide carrier and second rhodium particles supported on the second metal oxide carrier, a cerium content in the first catalyst layer based on a volume capacity of the substrate in the first region being higher than a cerium content in the second catalyst layer based on a volume capacity of the substrate in the second region.
    Type: Application
    Filed: May 16, 2023
    Publication date: January 18, 2024
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Takahiro NISHIO, Shogo Shirakawa, Hiroki Shirakawa, Nobuyuki Takagi, Tomomasa Aikawa, Hiroki Nihashi, Takahiro Noguchi
  • Publication number: 20240018891
    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: Application
    Filed: July 6, 2023
    Publication date: January 18, 2024
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Koji SUGIURA, Seiji NAKAHIGASHI, Masatoshi IKEBE, Takaya OTA, Takeshi MORISHIMA, Eiji HARADA
  • Publication number: 20230420695
    Abstract: A catalyst for fuel cells that contains a carbon powder carrier and catalyst particles carried on the carbon powder carrier, the catalyst particles being Pt alloy particles, the catalyst for fuel cells having 0.65 mmol/g or more of hydrophilic groups, and a Pt elution amount when 0.5 g of the catalyst for fuel cells is immersed in 30 ml of a 0.5 mol/L aqueous sulfuric acid solution and retained for 100 hours at room temperature under stirring being 0.625 mg or less per g of the catalyst for fuel cells.
    Type: Application
    Filed: November 24, 2021
    Publication date: December 28, 2023
    Applicant: CATALER CORPORATION
    Inventor: Kosuke MIYAZAKI
  • Patent number: 11850573
    Abstract: This exhaust gas cleaning catalytic device includes a base material and a first catalyst coat layer on the base material. The first catalyst coat layer has a pre-stage section on an exhaust gas flow upstream side, and a post-stage section on an exhaust gas flow downstream side. The first catalyst coat layer pre-stage section and post-stage section each contain inorganic oxide particles and rhodium supported by the inorganic oxide particles, while at least some of the inorganic oxide particles contain ceria. The ceria amount per unit length of the first catalyst coat layer post-stage section is larger than the ceria amount per unit length of the first catalyst coat layer pre-stage section. The first catalyst coat layer pre-stage section is disposed in such a manner that the end portion on the exhaust gas flow upstream side thereof is in direct contact with the exhaust gas flow.
    Type: Grant
    Filed: March 23, 2020
    Date of Patent: December 26, 2023
    Assignee: CATALER CORPORATION
    Inventors: Tomohiro Chiba, Kyosuke Murakami, Kenichi Taki, Shunsuke Haga
  • Publication number: 20230405569
    Abstract: Provided is an exhaust gas purification catalyst having a catalyst performance and an OSC performance in a compatible manner in an air-fuel ratio (A/F) rich atmosphere where HC poisoning is likely to occur. The exhaust gas purification catalyst includes a substrate and a catalyst coating layer coated on the substrate. The catalyst coating layer includes a first catalyst coating layer containing Pd and/or Pt as a catalyst metal and a second catalyst coating layer containing Rh as a catalyst metal. The first catalyst coating layer is formed from an end portion in an upstream side with respect to an exhaust gas flow direction in the exhaust gas purification catalyst. The second catalyst coating layer includes a high specific surface area OSC material having a specific surface area of more than 40 m2/g, a medium specific surface area OSC material having a specific surface area of 4 m2/g to 40 m2/g, and a low specific surface area OSC material having a specific surface area of less than 4 m2/g.
    Type: Application
    Filed: June 19, 2023
    Publication date: December 21, 2023
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Takahiro NISHIO, Shogo SHIRAKAWA, Takumi TOJO, Nobuyuki TAKAGI, Yosuke TODA, Sho HOSHINO, Shun SAKAMOTO
  • Publication number: 20230381748
    Abstract: An exhaust gas purification catalyst device having a base material, an upstream-side lower coat layer, an upstream-side upper coat layer, a downstream-side lower coat layer, and a downstream-side upper coat layer, the exhaust gas purification catalyst device satisfying conditions (i) and (ii). (i) The concentration of Pt and/or Pd in the upstream-side upper coat layer and the downstream-side lower coat layer is greater than the concentration of Pt and/or Pd in the upstream-side lower coat layer, and is greater than the concentration of Pt and/or Pd in the downstream-side upper coat layer. (ii) The concentration of Rh in the upstream-side lower coat layer and the downstream-side upper coat layer is greater than the concentration of Rh in the upstream-side upper coat layer, and is greater than the concentration of Rh in the downstream-side lower coat layer.
    Type: Application
    Filed: October 21, 2021
    Publication date: November 30, 2023
    Applicant: CATALER CORPORATION
    Inventors: Tetsuhiro HIRAO, Yosuke TODA, Daiki SAITO
  • Publication number: 20230372917
    Abstract: 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: Application
    Filed: May 16, 2023
    Publication date: November 23, 2023
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Takahiro NISHIO, Shogo Shirakawa, Hiroki Shirakawa, Nobuyuki Takagi, Tomomasa Aikawa, Hiroki Nihashi, Takahiro Noguchi
  • Publication number: 20230372907
    Abstract: 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: Application
    Filed: May 16, 2023
    Publication date: November 23, 2023
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Takahiro NISHIO, Shogo SHIRAKAWA, Nobuyuki TAKAGI, Tomomasa AIKAWA, Hiroki NIHASHI, Takahiro NOGUCHI
  • Patent number: 11821349
    Abstract: 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: Grant
    Filed: September 9, 2019
    Date of Patent: November 21, 2023
    Assignees: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Shogo Kawamura, Tomomasa Aikawa, Isao Naito, Hiroki Nihashi, Nobuyuki Takagi, Takeshi Nobukawa
  • Publication number: 20230364589
    Abstract: 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: Application
    Filed: July 13, 2023
    Publication date: November 16, 2023
    Applicant: CATALER CORPORATION
    Inventors: Ryo Tasaki, Ryota Onoe, Momoko Iwai, Yamato Matsushita
  • Publication number: 20230356205
    Abstract: 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: Application
    Filed: July 19, 2023
    Publication date: November 9, 2023
    Applicant: CATALER CORPORATION
    Inventors: Ryo Tasaki, Ryota Onoe, Momoko Iwai, Yamato Matsushita