Patents Assigned to Cataler Corporation
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Patent number: 11135577Abstract: 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: GrantFiled: June 22, 2018Date of Patent: October 5, 2021Assignee: CATALER CORPORATIONInventors: Yuki Fujimura, Akio Kubota, Naoki Yokoyama, Junichi Hori
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Patent number: 11139498Abstract: 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: GrantFiled: June 21, 2018Date of Patent: October 5, 2021Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Toru Yamamoto, Nobuaki Mizutani, Kohei Koyamada, Kotaro Horiai, Mikihiro Kataoka, Kenji Yamamoto
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Publication number: 20210301706Abstract: 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: ApplicationFiled: March 24, 2021Publication date: September 30, 2021Applicants: 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: 20210283589Abstract: Provided is an exhaust gas purification device that ensures an improved purification performance and a suppressed pressure loss. An exhaust gas purification device of the present disclosure includes a honeycomb substrate and an inflow cell side catalyst layer. disposed on a surface on the inflow cell side in an inflow side region of the partition wall. When a gas permeability coefficient of an inflow side partition wall portion including the inflow side region of the partition wall and the inflow cell side catalyst layer is Ka and a gas permeability coefficient of an outflow side partition wall portion including an outflow side region at least from the predetermined position to an outflow side end of the partition wall is Kb, a ratio Ka/Kb of the gas permeability coefficients is within a range of 0.4 or more and 0.8 or less.Type: ApplicationFiled: February 18, 2021Publication date: September 16, 2021Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Koji SUGIURA, Hiromasa NISHIOKA, Naoto MIYOSHI, Akemi SATO, Ryota NAKASHIMA, Masatoshi IKEBE, Keisuke MURAWAKI, Hirotaka ORI
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Patent number: 11118495Abstract: An exhaust gas-purifying system includes an exhaust gas-purifying unit that includes one or more exhaust gas-purifying catalysts, is supplied with the exhaust gas from a combustion engine, and purifies the exhaust gas so that the exhaust gas can be released to the atmosphere, a sensor that detects a concentration of nitrogen oxides contained in the purified exhaust gas, and a processing section that makes a judgment with respect to at least one of the exhaust gas-purifying catalysts, as to whether or not a performance is maintained at a sufficient level, based on the concentration detected by the sensor.Type: GrantFiled: October 24, 2019Date of Patent: September 14, 2021Assignee: CATALER CORPORATIONInventors: Makoto Tsuji, Hiroto Imai, Kou Sugawara, Shintaro Kobayashi
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Publication number: 20210277814Abstract: 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: ApplicationFiled: September 9, 2019Publication date: September 9, 2021Applicants: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Shogo KAWAMURA, Tomomasa AIKAWA, Isao NAITO, Hiroki NIHASHI, Nobuyuki TAKAGI, Takeshi NOBUKAWA
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Patent number: 11110435Abstract: An exhaust gas purification catalyst comprises a substrate; a catalyst layer formed on the substrate and containing at least palladium (Pd) and rhodium (Rh) as a metal functioning as an oxidation and/or reduction catalyst. The catalyst also comprises a carrier that supports the metal, and an OSC material having oxygen storage capacity. The catalyst layer has, when disposed in the exhaust pipe, a front section positioned upstream in an exhaust gas flow direction within the exhaust pipe, and a rear section positioned downstream of the front section in the exhaust gas flow direction. The front section contains palladium (Pd) but does not contain the OSC material, and a proportion, at which the front section is formed from an upstream leading end in the exhaust gas flow direction, is 10% to 40% with respect to 100% of a total length of the substrate.Type: GrantFiled: March 13, 2017Date of Patent: September 7, 2021Assignee: Cataler CorporationInventors: Ryota Onoe, Kazuhiko Ito, Takahiro Harada, Chihiro Kasuya
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Patent number: 11084022Abstract: 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: GrantFiled: December 26, 2016Date of Patent: August 10, 2021Assignees: CATALER CORPORATION, SANTOKU CORPORATIONInventors: Kyosuke Murakami, Keiichi Narita, Satoshi Matsueda, Michio Tanaka, Tadatoshi Murota, Shigeru Ono, Tomonori Tahara
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Publication number: 20210205790Abstract: The present disclosure provides an exhaust gas purification catalyst having an improved Rh activation, 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 upstream portion contains Rh fine particles and Pt, 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, and wherein the downstream portion contains Rh.Type: ApplicationFiled: December 1, 2020Publication date: July 8, 2021Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Seiji NAKAHIGASHI, Isao CHINZEI, Shogo SHIRAKAWA, Hiromasa SUZUKI, Masahide MIURA, Takahiro NISHIO, Norimichi SHIMANO, Hiroki NIHASHI, Mitsuyoshi OKADA, Takashi ONOZUKA, Souta AKIYAMA, Hiromi TOGASHI, Takahiro NOGUCHI, Isao NAITO
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Publication number: 20210197175Abstract: The present disclosure relates to an exhaust gas control catalyst including a base and a catalyst coating layer having a two-layer structure on the base. The catalyst coating layer includes a lower layer on the base, and an upper layer on the lower layer. The upper layer of the catalyst coating layer contains Rh particles in which a mean particle diameter measured by observation using a transmission electron microscope is 1.0 nm or more and 2.0 nm or less and a particle-diameter standard deviation ? is 0.8 nm or less. A length of the upper layer from an end face on a downstream side in an exhaust gas flow direction falls within a range of 70% or more and 100% or less of a total length of the base.Type: ApplicationFiled: November 4, 2020Publication date: July 1, 2021Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Takahiro NISHIO, Shogo SHIRAKAWA, Masahide MIURA, Isao CHINZEI, Seiji NAKAHIGASHI, Norimichi SHIMANO, Hiromi TOGASHI, Hiroki NIHASHI, Mitsuyoshi OKADA, Takashi ONOZUKA, Souta AKIYAMA, Isao NAITO
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Publication number: 20210197176Abstract: The present disclosure provides an exhaust gas purification catalyst having an improved low-temperature activity, which comprises a substrate and a catalyst coat layer formed on the substrate, wherein the catalyst coat layer contains Rh fine particles and a promoter comprising a Ce—Zr-based composite oxide and a Zr-based composite oxide not containing cerium oxide, 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 a of the particle size of 0.8 nm or less, and wherein the Rh fine particles are supported on each of the Ce—Zr-based composite oxide and the Zr-based composite oxide not containing cerium oxide.Type: ApplicationFiled: November 30, 2020Publication date: July 1, 2021Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Isao CHINZEI, Seiji NAKAHIGASHI, Shogo SHIRAKAWA, Hiromasa SUZUKI, Masahide MIURA, Takahiro NISHIO, Norimichi SHIMANO, Hiroki NIHASHI, Hiromi TOGASHI, Mitsuyoshi OKADA, Takashi ONOZUKA, Souta AKIYAMA, Isao NAITO
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Publication number: 20210199037Abstract: 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 a of the particle size of 0.8 nm or less.Type: ApplicationFiled: December 14, 2020Publication date: July 1, 2021Applicants: 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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Publication number: 20210189930Abstract: 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: ApplicationFiled: March 30, 2018Publication date: June 24, 2021Applicant: CATALER CORPORATIONInventor: Ko SUGAWARA
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Publication number: 20210115828Abstract: 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: ApplicationFiled: February 23, 2018Publication date: April 22, 2021Applicant: CATALER CORPORATIONInventors: Yuki TANAKA, Shoko FUKUYO, Kazuma NAKADA, Eiichi YASUTOMI, Ryo NISHIMURA
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Patent number: 10981113Abstract: Provided is an exhaust gas purification catalyst body that can improve exhaust gas purification performance while maintaining favorable PM collection performance. The exhaust gas purification catalyst body includes a base of a wall flow structure having an inlet side cell, an outlet side cell, and porous partition wall, and a catalyst layer that is formed in the partition wall that is in contact with the inlet side cell or the outlet side cell. The catalyst layer is formed in a region of at least 50% of the thickness of the partition wall from a surface of the partition wall, and held on the surface of internal pores in the partition wall in the region.Type: GrantFiled: September 3, 2018Date of Patent: April 20, 2021Assignee: CATALER CORPORATIONInventors: Ryota Onoe, Yosuke Toda, Taku Miura
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Publication number: 20210094027Abstract: The exhaust gas purification catalyst device includes an upper layer which includes first carrier particles and rhodium, and a lower layer which includes second carrier particles, and the upper layer includes a rhodium enriched area in the range a, from the upstream end in the exhaust gas flow to 50% of the upper layer length, and a range b from the upper layer top surface to 18 ?m in the depth direction. The rhodium enriched area contains at least 50% and less than 100% of all the rhodium in the upper layer.Type: ApplicationFiled: January 25, 2019Publication date: April 1, 2021Applicants: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Shunsuke OISHI, Takaya OTA, Isao CHINZEI, Hiromasa SUZUKI, Yoshinori SAITO, Seiji NAKAHIGASHI
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Patent number: 10960389Abstract: An exhaust gas purification catalyst of the present invention is provided with a base 10 and a catalyst coat layer 30. The catalyst coat layer is provided with Rh and Pd as noble metal catalysts. Herein Rh is disposed in a first-stage upper layer A and a second-stage upper layer C, and Pd is disposed in the first-stage upper layer A and a first-stage lower layer B, and in a second-stage lower layer D. A mass ratio (APd/ARh) of Pd to Rh, disposed in first-stage upper layer A is 0.5?(APd/ARh)?3.Type: GrantFiled: May 12, 2017Date of Patent: March 30, 2021Assignee: CATALER CORPORATIONInventors: Yuki Takesue, Kyosuke Murakami, Ryota Onoe
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Publication number: 20210086133Abstract: A production method of an exhaust gas purification device includes the steps of supplying a solution containing a catalyst metal from a shower nozzle to an upper part of a honeycomb substrate, coating the honeycomb substrate with the solution, and firing the honeycomb substrate coated with the solution, wherein the shower nozzle has a plurality of discharge openings for discharging the solution and a guard which surrounds the plurality of discharge openings.Type: ApplicationFiled: November 8, 2019Publication date: March 25, 2021Applicant: CATALER CORPORATIONInventors: Yuki KIDO, Suguru MATSUI, Etsuko OHARA, Kazuma NAKADA
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Patent number: 10950869Abstract: An object of the present invention is to achieve both high initial performance and durability performance of a fuel cell. Such object can be achieved by using a fuel cell electrode catalyst that includes a solid carbon carrier and an alloy of platinum and cobalt supported on the carrier.Type: GrantFiled: October 23, 2015Date of Patent: March 16, 2021Assignees: Cataler Corporation, Toyota Jidosha Kabushiki KaishaInventors: Yousuke Horiuchi, Tomoaki Terada, Akihiro Hori, Nobuaki Mizutani, Hiroo Yoshikawa, Yusuke Itoh
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Publication number: 20210060487Abstract: Provided is an exhaust gas purification catalyst body that can improve exhaust gas purification performance while maintaining favorable PM collection performance. The exhaust gas purification catalyst body includes a base of a wall flow structure having an inlet side cell, an outlet side cell, and porous partition wall, and a catalyst layer that is formed in the partition wall that is in contact with the inlet side cell or the outlet side cell. The catalyst layer is formed in a region of at least 50% of the thickness of the partition wall from a surface of the partition wall, and held on the surface of internal pores in the partition wall in the region.Type: ApplicationFiled: September 3, 2018Publication date: March 4, 2021Applicant: CATALER CORPORATIONInventors: Ryota ONOE, Yosuke TODA, Taku MIURA
