Patents Assigned to Cataler Corporation
  • Publication number: 20220062884
    Abstract: An exhaust gas purification device includes a substrate including an upstream end and a downstream end and having a length Ls; a first containing Pd particles, extending between the upstream end and a first position, and being in contact with the substrate; a second containing Rh particles, extending between the downstream end and a second position, and being in contact with the substrate; and a third catalyst layer containing Rh particles, extending between the upstream end and a third position, and being in contact with at least the first catalyst layer, wherein an average of a Rh particle size distribution is from 1.0 to 2.0 nm, and a standard deviation of the Rh particle size distribution is 0.8 nm or less in each of the second catalyst layer and the third catalyst layer.
    Type: Application
    Filed: August 24, 2021
    Publication date: March 3, 2022
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Isao CHINZEI, Takumi TOJO, Shogo SHIRAKAWA, Sho HOSHINO, Minoru ITO, Naoto FUJITA
  • Patent number: 11258076
    Abstract: The present invention relates to an electrode catalyst for a fuel cell that includes a carbon support (11) having pores (13) and catalyst particles containing platinum or a platinum alloy supported on the carbon support (11). The pores (13) of the carbon support (11) have a mode size of pores (13) in a range of 2.1 nm to 5.1 nm. A total pore volume of the pores (13) of the carbon support (11) is in a range of 21 cm3/g to 35 cm3/g. A distance between the catalyst particles and a surface of the carbon support (11) is in a range of 2.0 nm to 12 nm as a distance of a 50% cumulative frequency.
    Type: Grant
    Filed: December 11, 2017
    Date of Patent: February 22, 2022
    Assignees: Toyota Jidosha Kabushiki Kaisha, Cataler Corporation, Nippon Steel Chemical & Material Co., Ltd.
    Inventors: Nobuaki Mizutani, Yusuke Itoh, Toru Yamamoto, Kotaro Horiai, Mikihiro Kataoka, Yuki Makino
  • Patent number: 11236657
    Abstract: The purpose of the present invention is to provide a manufacturing method for an exhaust gas purification device that can uniformly coat a honeycomb substrate with slurry even when using a low viscosity slurry. The present invention pertains to a manufacturing method for an exhaust gas purification device that includes providing a slurry for catalyst layer formation from a shower nozzle onto a honeycomb substrate, coating the honeycomb substrate with the slurry, and firing the honeycomb substrate coated with the slurry, wherein the viscosity of the slurry at a shear rate of 4 s?1 is 800 mPA·s or less, the shower nozzle has a plurality of discharge openings for discharging the slurry, the relationship of the spacing a) of the discharge openings and the diameter b) of the liquid drops formed when starting supply of the slurry is 0.
    Type: Grant
    Filed: February 23, 2018
    Date of Patent: February 1, 2022
    Assignee: CATALER CORPORATION
    Inventors: Yuki Tanaka, Shoko Fukuyo, Kazuma Nakada, Eiichi Yasutomi, Ryo Nishimura
  • Publication number: 20220016601
    Abstract: An exhaust-gas purification apparatus includes: a honeycomb base material including a plurality of exhaust-gas flow paths partitioned by a porous wall; and one or more catalyst noble metals carried by the honeycomb base material. The catalyst noble metals are selected from the group consisting of platinum, palladium, and rhodium. The honeycomb base material has a noble metal concentrated surface section in which a 50%-by-mass noble metal carry depth for a specific noble metal that is one type among one or two catalyst noble metals is less than 50% of the distance from the surface to the center of the inside of the porous wall. The 50%-by-mass noble metal carry depth is the depth at which, when the amount of the specific noble metal carried between the surface and the center of the inside of porous wall is used as a reference, 50% by mass of specific noble metal is carried.
    Type: Application
    Filed: November 14, 2019
    Publication date: January 20, 2022
    Applicants: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Shunsuke OHISHI, Takaya OTA, Ryosuke TAKASU, Mitsuyoshi OKADA, Minoru ITOU, Kana IWATA, Takumi TOJO, Takeru YOSHIDA, Masaru KAKINOHANA, Hiromasa SUZUKI
  • Patent number: 11217796
    Abstract: An electrode catalyst and a method for producing the electrode catalyst are described, in which the electrode catalyst includes catalyst metal particles containing platinum or a platinum alloy, and carrier particles supporting the catalyst metal particles. The carrier particles are made of a carbonaceous material with a BET specific surface area of 700 m2/g or more. The catalyst metal particles have an average particle size of 2.5 to 4.5 nm, and a standard deviation of the particle size of the catalyst metal particles is 1.30 nm or less. The electrode catalyst has a high initial activity and is able to maintain that activity over a long period of time.
    Type: Grant
    Filed: April 17, 2018
    Date of Patent: January 4, 2022
    Assignees: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kotaro Horiai, Mikihiro Kataoka, Tomoaki Terada, Mikihiro Hori, Yuusuke Itou
  • Patent number: 11202991
    Abstract: This exhaust gas purifying catalyst is provided with a substrate 10 and a catalyst layer 20 formed on a surface of the substrate 10. The catalyst layer 20 contains zeolite particles 22 that support a metal, and a rare earth element-containing compound 24 that contains a rare earth element. The rare earth element-containing compound 24 is added in such an amount that the molar ratio of the rare earth element relative to Si contained in the zeolite 22 is 0.001 to 0.014 in terms of oxides.
    Type: Grant
    Filed: February 19, 2018
    Date of Patent: December 21, 2021
    Assignee: Cataler Corporation
    Inventors: Shu Miyasaka, Eriko Tanaka, Norihiko Aono, Mai Huong Tran, Keigo Hori, Daisuke Sugioka
  • Patent number: 11187129
    Abstract: An exhaust gas purification including: a base of wall flow structure having inlet side cells wherein an end on the exhaust gas inflow side is open and outlet side cells wherein an end on the exhaust gas outflow side is open, and a porous partition wall that partitions the side cells; and first and second catalyst layers disposed in the interior of the porous partition wall so as to be in contact with the side cells, wherein either of the catalyst layers contains an oxidation catalyst but does not contain a reduction catalyst, and the other contains the reduction catalyst but does not contain the oxidation catalyst; and a ratio of the lengths of the catalyst layers differs between a surface of the porous partition wall on the side in contact with the inlet side cells and a surface on the side in contact with the outlet side cells.
    Type: Grant
    Filed: September 11, 2018
    Date of Patent: November 30, 2021
    Assignees: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yasutaka Nomura, Satoru Inoda, Naoto Miyoshi, Akemi Sato
  • Patent number: 11179701
    Abstract: An exhaust gas purifying catalyst having first carrier particles, second carrier particles, and precious metal catalyst particles supported on the first and second carrier particles, wherein: the first carrier particles contain ceria, zirconia, and a rare-earth oxide other than ceria; the second carrier particles contain a rare-earth oxide other than ceria, and may contain ceria and zirconia; the contained proportion of ceria and zirconia in the first carrier particles is higher than the contained proportion of ceria and zirconia in the second carrier particles; the contained proportion of the rare-earth oxide in the second carrier particles is higher than the contained proportion of the rare-earth oxide in the first carrier particles; and the contained proportion of ceria in the first carrier particles is 45 wt % or less, while the precious metal catalyst particles include rhodium particles.
    Type: Grant
    Filed: March 9, 2017
    Date of Patent: November 23, 2021
    Assignee: CATALER CORPORATION
    Inventors: Yu Sakurada, Takahiro Harada, Ryota Nakashima
  • Publication number: 20210351419
    Abstract: An anode catalyst layer for a fuel cell includes: electrode catalyst particles; a carbon carrier carrying the electrode catalyst particles; water electrolysis catalyst particles; a proton-conductive binder; and a graphitized carbon, wherein the content of the graphitized carbon in the anode catalyst layer for a fuel cell is 3-70 mass % with respect to the total mass of the electrode catalyst particles, the carbon carrier, and the graphitized carbon.
    Type: Application
    Filed: September 4, 2019
    Publication date: November 11, 2021
    Applicant: CATALER CORPORATION
    Inventors: Akihiro HORI, Yosuke HORIUCHI
  • Patent number: 11167245
    Abstract: This exhaust gas purifying catalyst is provided with a substrate 10 and a catalyst layer 20 formed on a surface of the substrate 10. The catalyst layer 20 contains zeolite particles 22 that support a metal, and a rare earth element-containing compound 24 that contains a rare earth element. The rare earth element-containing compound 24 is added in such an amount that the molar ratio of the rare earth element relative to Si contained in the zeolite 22 is 0.001 to 0.014 in terms of oxides.
    Type: Grant
    Filed: February 19, 2018
    Date of Patent: November 9, 2021
    Assignee: Cataler Corporation
    Inventors: Shu Miyasaka, Eriko Tanaka, Norihiko Aono, Mai Huong Tran, Keigo Hori, Daisuke Sugioka
  • Publication number: 20210336276
    Abstract: An anode catalyst layer for a fuel cell includes: electrode catalyst particles; a carbon carrier carrying the electrode catalyst particles; water electrolysis catalyst particles; a proton-conductive binder; and a graphitized carbon, wherein the content of graphitized carbon in the anode catalyst layer for a fuel cell is 15-70 volume % with respect to the total volume of the electrode catalyst particles, the carbon carrier, and the graphitized carbon.
    Type: Application
    Filed: September 4, 2019
    Publication date: October 28, 2021
    Applicant: CATALER CORPORATION
    Inventors: Akihiro HORI, Yosuke HORIUCHI
  • Publication number: 20210336278
    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: Application
    Filed: September 4, 2019
    Publication date: October 28, 2021
    Applicant: CATALER CORPORATION
    Inventors: Akihiro HORI, Yosuke HORIUCHI
  • Patent number: 11154842
    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: Grant
    Filed: February 28, 2017
    Date of Patent: October 26, 2021
    Assignee: CATALER CORPORATION
    Inventors: Sho Hoshino, Noboru Sato, Keisuke Murawaki
  • Publication number: 20210322937
    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: Application
    Filed: September 9, 2019
    Publication date: October 21, 2021
    Applicants: CATALER CORPORATION, NATIONAL UNIVERSITY CORPORATION SHIZUOKA UNIVERSITY
    Inventors: Tomohito MIZUKAMI, Yusuke SAITO, Nobuyuki MASE
  • Publication number: 20210322947
    Abstract: A reaction device for reacting a liquid-phase reactant and a gas-phase reactant converted into fine bubbles includes: a porous body that includes a plurality of flow paths and in which the flow paths are separated by porous walls, the porous walls include continuous pores, and the porous body includes a reaction catalyst at least on the surface thereof; a solution supply section for supplying a solution containing a gas-phase reactant and a liquid-phase reactant to the continuous pores in the porous body; and a solution discharge section for discharging solution containing a reaction product obtained when the solution flows through the continuous pores of the porous body.
    Type: Application
    Filed: September 9, 2019
    Publication date: October 21, 2021
    Applicants: CATALER CORPORATION, NATIONAL UNIVERSITY CORPORATION SHIZUOKA UNIVERSITY
    Inventors: Tomohito MIZUKAMI, Yusuke SAITO, Nobuyuki MASE
  • Publication number: 20210324777
    Abstract: An exhaust gas control apparatus includes a honeycomb substrate and an inlet cell-side catalyst layer. The honeycomb substrate includes a porous partition wall that defines a plurality of cells extending from an inlet-side end face to an outlet-side end face. The cells include an inlet cell and an outlet cell that are adjacent to each other with the partition wall therebetween. The inlet cell is open at its inlet-side end and is sealed at its outlet-side end. The outlet cell is sealed at its inlet-side end and is open at its outlet-side end. The inlet cell-side catalyst layer is provided on a surface on the inlet cell side of the partition wall and extends from an inlet-side end of the partition wall. Porosity of the inlet cell-side catalyst layer is in a specific range.
    Type: Application
    Filed: April 15, 2021
    Publication date: October 21, 2021
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Koji SUGIURA, Hiromasa NISHIOKA, Naoto MIYOSHI, Akemi SATOU, Keisuke MURAWAKI, Masatoshi IKEBE, Takaya OTA, Ryota NAKASHIMA, Hirotaka ORI
  • Patent number: 11149604
    Abstract: An exhaust gas purification catalyst device includes a honeycomb base material and an inlet-side coat layer, wherein: the honeycomb base material includes a plurality of cells partitioned by porous partition walls, the plurality of cells including inlet-side cells and outlet-side cells and being configured such that exhaust gas that has flowed into the inlet-side cells passes through the partition walls and is exhausted from the outlet-side cells; and the inlet-side coat layer is present on the surface sides of the partition walls of the inlet-side cells, with the proportion of 4-9 ?m through-pores in the through-pore diameter distribution of the partition walls being at least 80 vol %, and the peak pore diameter measured using a mercury porosimeter being at least 3.0 ?m greater than the peak through-pore diameter measured using a perm porometer.
    Type: Grant
    Filed: March 30, 2018
    Date of Patent: October 19, 2021
    Assignee: CATALER CORPORATION
    Inventor: Ko Sugawara
  • Publication number: 20210310391
    Abstract: An exhaust gas purification catalyst device has catalyst coating layers, which extend from the upstream side to the downstream side of the exhaust gas flow. The catalyst coating layers each have at least three zones present in order from the upstream side to the downstream side of the exhaust gas flow, and each of these at least three zones is an oxidation catalyst zone or a reduction catalyst zone. In the uppermost layer of an oxidation catalyst zone, the total number of atoms of platinum and palladium is greater than the number of atoms of rhodium; in the upper most layer of a reduction catalyst zone, the number of atoms of rhodium is greater than the total number of atoms of platinum and palladium. The oxidation catalyst zones and the reduction catalyst zones alternate at least twice in the exhaust gas flow direction.
    Type: Application
    Filed: June 26, 2019
    Publication date: October 7, 2021
    Applicant: CATALER CORPORATION
    Inventors: Chihiro KASUYA, Yuji YABUZAKI, Masaaki KAWAI, Mitsuyoshi OKADA
  • Patent number: 11135577
    Abstract: The invention provides: an exhaust-gas-purifying metal substrate capable of achieving both low pressure loss and high purification performance; and an exhaust gas purification device using the metal substrate. The invention relates to an exhaust-gas-purifying perforated metal substrate in which a corrugated foil and a flat foil are layered and made into a cylindrical shape, wherein: the perforated metal substrate includes from 50/in2 to 800/in2 of cells; the corrugated foil includes a plurality of first holes having an area that is from 2.0 to 50 times the average opening area of the cells; the flat foil includes a plurality of second holes having an area that is from 3.0 to 100 times the average opening area of the cells; and the average value of the area of the first holes in the corrugated foil is smaller than the average value of the area of the second holes in the flat foil.
    Type: Grant
    Filed: June 22, 2018
    Date of Patent: October 5, 2021
    Assignee: CATALER CORPORATION
    Inventors: Yuki Fujimura, Akio Kubota, Naoki Yokoyama, Junichi Hori
  • Patent number: 11139498
    Abstract: An electrode catalyst for fuel cells that can inhibit an increase in gas diffusion resistance includes a carbon material having a ratio of a peak intensity IA derived from an amorphous structure to a peak intensity IG derived from a graphite structure in an X-ray diffraction spectrum (ratio IA/IG) of 0.90 or less as a catalyst-supporting carrier.
    Type: Grant
    Filed: June 21, 2018
    Date of Patent: October 5, 2021
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Toru Yamamoto, Nobuaki Mizutani, Kohei Koyamada, Kotaro Horiai, Mikihiro Kataoka, Kenji Yamamoto