Patents by Inventor Akimasa Hirai

Akimasa Hirai has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10279338
    Abstract: An exhaust gas-purifying catalyst includes a support and a catalytic metal supported thereby. The support includes a composite oxide represented by AO.xB2-?C?O3, wherein A represents at least one of an element having a valence of 1 and an element having a valence of 2, B represents an element having a valence of 3, C represents one or more elements selected from iridium, ruthenium, tantalum, niobium, molybdenum, and tungsten, x represents a numerical value of 1 to 6, and ? represents a numerical value greater than 0 and less than 2. The catalytic metal includes one or more precious metals selected from rhodium, palladium, and platinum.
    Type: Grant
    Filed: October 7, 2016
    Date of Patent: May 7, 2019
    Assignee: CATALER CORPORATION
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Sho Hoshino
  • Patent number: 10099204
    Abstract: An exhaust gas-purifying catalyst of the present invention comprises a substrate, and one or more catalytic layers provided on the substrate, wherein at least one of the catalytic layers (i) contains a precious metal, alumina, and an acidic oxide element, (ii) has a correlation coefficient ?Al,AE of 0.70 or more, and (iii) has a correlation coefficient ?PM,AE of 0.70 or more.
    Type: Grant
    Filed: April 10, 2017
    Date of Patent: October 16, 2018
    Assignee: CATALER CORPORATION
    Inventors: Sho Hoshino, Akimasa Hirai, Kenichi Taki, Satoshi Matsueda, Yuji Yabuzaki
  • Publication number: 20180280878
    Abstract: A catalyst for exhaust gas purification, which is capable of effectively purifying an exhaust gas. A catalyst for exhaust gas purification, which includes first catalyst particles, second catalyst particles and carrier particles that support the first catalyst particles and the second catalyst particles. The first catalyst particles are Pd particles or Pd—Rh alloy particles; and the second catalyst particles are Pd—Rh alloy particles. The molar ratio of Rh to the total of Pd and Rh in the first catalyst particles is 0.50 times or less the molar ratio of Rh to the total of Pd and Rh in the second catalyst particles.
    Type: Application
    Filed: September 23, 2016
    Publication date: October 4, 2018
    Applicant: CATALER CORPORATION
    Inventors: Satoru INODA, Satoshi MATSUEDA, Kenichi TAKI, Akimasa HIRAI
  • Patent number: 9855550
    Abstract: An exhaust gas-purifying catalyst includes a support and a catalytic metal as one or more precious metals supported by the support. The support includes a composite oxide having a composition represented by a general formula AB?C?O3, wherein A represents one or more elements selected from the group consisting of lanthanum, neodymium, and yttrium, B represents iron or a combination of iron and aluminum, C represents one or more elements selected from the group consisting of iridium, ruthenium, tantalum, niobium, molybdenum, and tungsten, ? and ? each represents a numerical value within a range of more than 0 and less than 1, and ? and ? satisfy relational formulae of ?>? and ?+??1.
    Type: Grant
    Filed: January 20, 2017
    Date of Patent: January 2, 2018
    Assignee: CATALER CORPORATION
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Sho Hoshino
  • Patent number: 9849441
    Abstract: The exhaust gas-purifying catalyst of the invention contains oxide particles having interdispersed therein A crystallites that are loaded with a noble metal and B crystallites that are not loaded with a noble metal. The A crystallites loaded with a noble metal are composed of an oxide containing at least one of zirconium (Zr) and cerium (Ce). The B crystallites not loaded with a noble metal are composed of a cerium (Ce)-containing oxide which has a higher Ce content (mol %) than the oxide making up the A crystallites. The oxide particles have a specific surface area after 5 hours of heat treatment at 1,150° C. in open air of 30 m2/g or more.
    Type: Grant
    Filed: December 4, 2014
    Date of Patent: December 26, 2017
    Assignee: CATALER CORPORATION
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki
  • Publication number: 20170297004
    Abstract: An exhaust gas-purifying catalyst of the present invention comprises a substrate, and one or more catalytic layers provided on the substrate, wherein at least one of the catalytic layers (i) contains a precious metal, alumina, and an acidic oxide element, (ii) has a correlation coefficient ?Al,AE of 0.70 or more, and (iii) has a correlation coefficient ?PM,AE of 0.70 or more.
    Type: Application
    Filed: April 10, 2017
    Publication date: October 19, 2017
    Applicant: Cataler Corporation
    Inventors: Sho Hoshino, Akimasa Hirai, Kenichi Taki, Satoshi Matsueda, Yuji Yabuzaki
  • Patent number: 9789469
    Abstract: An exhaust gas-purifying catalyst material includes first oxide particles having an average particle diameter Dav of 1 ?m to 95 ?m and having an oxygen storage capacity, second oxide particles having an average particle diameter Dav of 0.05 ?m to 0.5 ?m, containing a metal element, and having no oxygen storage capacity, precious metal particles, and acidic oxide particles. The material has a correlation coefficient ? of 0.45 or more obtained using first characteristic X-ray intensity for the metal element contained in the second oxide particle, second characteristic X-ray intensity for an element other than oxygen contained in the acidic oxide particle, and third characteristic X-ray intensity for a precious metal element contained in the precious metal particle.
    Type: Grant
    Filed: February 16, 2017
    Date of Patent: October 17, 2017
    Assignee: CATALER CORPORATION
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Yuji Yabuzaki, Sho Hoshino
  • Publication number: 20170239646
    Abstract: An exhaust gas-purifying catalyst material includes first oxide particles having an average particle diameter Dav of 1 ?m to 95 ?m and having an oxygen storage capacity, second oxide particles having an average particle diameter Dav of 0.05 ?m to 0.5 ?m, containing a metal element, and having no oxygen storage capacity, precious metal particles, and acidic oxide particles. The material has a correlation coefficient ? of 0.45 or more obtained using first characteristic X-ray intensity for the metal element contained in the second oxide particle, second characteristic X-ray intensity for an element other than oxygen contained in the acidic oxide particle, and third characteristic X-ray intensity for a precious metal element contained in the precious metal particle.
    Type: Application
    Filed: February 16, 2017
    Publication date: August 24, 2017
    Applicant: Cataler Corporation
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Yuji Yabuzaki, Sho Hoshino
  • Patent number: 9724644
    Abstract: The exhaust gas-purifying catalyst of the invention includes a noble metal, and crystallites that form CZ composite metal particles which serve as a carrier supporting the noble metal and contain at least zirconium (Zr) and cerium (Ce). The CZ composite oxide particles (crystallites) further contain crystal growth-suppressing fine particles which are fine metal particles comprising primarily a metallic element M that melts at 1,500° C. or above and which suppress crystal growth by the CZ composite oxide particles. The content of the metallic element M included in the CZ composite oxide particles, expressed in terms of the oxide thereof, is 0.5 mol % or less of the total oxide.
    Type: Grant
    Filed: December 4, 2014
    Date of Patent: August 8, 2017
    Assignee: CATALER CORPORATION
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki
  • Publication number: 20170209854
    Abstract: An exhaust gas-purifying catalyst includes a support and a catalytic metal as one or more precious metals supported by the support. The support includes a composite oxide having a composition represented by a general formula AB?C?O3, wherein A represents one or more elements selected from the group consisting of lanthanum, neodymium, and yttrium, B represents iron or a combination of iron and aluminum, C represents one or more elements selected from the group consisting of iridium, ruthenium, tantalum, niobium, molybdenum, and tungsten, ? and ? each represents a numerical value within a range of more than 0 and less than 1, and ? and ? satisfy relational formulae of ?>? and ?+??1.
    Type: Application
    Filed: January 20, 2017
    Publication date: July 27, 2017
    Applicant: Cataler Corporation
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Sho Hoshino
  • Patent number: 9694348
    Abstract: Provided is an exhaust catalyst that exhibits higher NOX-reducing activities at the time of engine restart while maintaining its catalytic activities during normal traveling. This invention provides an exhaust cleaning catalyst comprising a substrate and a catalyst coating layer that includes CeO2. Catalyst coating layer is constituted in its thickness direction with multiple coating layers. In a top coating layer located at the outermost surface, the CeO2 content in a top coating layer's upstream portion is less than the CeO2 content in a top coating layer's downstream portion; and the CeO2 content in the top coating layer's upstream portion is less than the CeO2 content in a lower coating layer. The CeO2 content per liter of catalyst volume in the entire coating layer is 10 g/L to 30 g/L.
    Type: Grant
    Filed: December 9, 2014
    Date of Patent: July 4, 2017
    Assignee: CATALER CORPORATION
    Inventors: Sho Hoshino, Akimasa Hirai, Kenichi Taki, Satoshi Matsueda
  • Patent number: 9675970
    Abstract: Provided is an exhaust cleaning catalyst that exhibits higher NOX-reducing activities at the time of engine restart while maintaining its catalytic activities during normal traveling. This invention provides an exhaust cleaning catalyst including a substrate and a catalyst coating layer including CeO2. Catalyst coating layer is constituted in its thickness direction with multiple coating layers. In a top coating layer located at the outermost surface, the CeO2 content in a top coating layer's upstream portion is less than the CeO2 content in a top coating layer's downstream portion. In a bottom coating layer near substrate, the CeO2 content in a bottom layer's downstream portion is less than the CeO2 content in a bottom coating layer's upstream portion.
    Type: Grant
    Filed: December 9, 2014
    Date of Patent: June 13, 2017
    Assignee: CATALER CORPORATION
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Sho Hoshino
  • Publication number: 20170100709
    Abstract: An exhaust gas-purifying catalyst includes a support and a catalytic metal supported thereby. The support includes a composite oxide represented by AO.xB2-?C?O3, wherein A represents at least one of an element having a valence of 1 and an element having a valence of 2, B represents an element having a valence of 3, C represents one or more elements selected from iridium, ruthenium, tantalum, niobium, molybdenum, and tungsten, x represents a numerical value of 1 to 6, and a represents a numerical value greater than 0 and less than 2. The catalytic metal includes one or more precious metals selected from rhodium, palladium, and platinum.
    Type: Application
    Filed: October 7, 2016
    Publication date: April 13, 2017
    Applicant: CATALER CORPORATION
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Sho Hoshino
  • Patent number: 9597663
    Abstract: An exhaust cleaning catalyst, with which precious metal sintering is inhibited and which has greater exhaust cleaning abilities, has a substrate and a catalyst coating layer provided on the substrate. The catalyst coating layer has a precious metal that serves as an oxidation and/or reduction catalyst. The precious metal has Rh-containing metal particles in which rhodium (Rh) coexists with a base metal selected among platinum group elements excluding rhodium. The Rh-containing metal particles have an average rhodium content of 0.1% to 5% by mole with the total amount of the base metal and rhodium being 100% by mole.
    Type: Grant
    Filed: December 8, 2014
    Date of Patent: March 21, 2017
    Assignee: CATALER CORPORATION
    Inventors: Satoru Inoda, Akimasa Hirai, Kenichi Taki, Satoshi Matsueda
  • Publication number: 20160288052
    Abstract: The exhaust gas-purifying catalyst of the invention includes a noble metal, and crystallites that form CZ composite metal particles which serve as a carrier supporting the noble metal and contain at least zirconium (Zr) and cerium (Ce). The CZ composite oxide particles (crystallites) further contain crystal growth-suppressing fine particles which are fine metal particles comprising primarily a metallic element M that melts at 1,500° C. or above and which suppress crystal growth by the CZ composite oxide particles. The content of the metallic element M included in the CZ composite oxide particles, expressed in terms of the oxide thereof, is 0.5 mol % or less of the total oxide.
    Type: Application
    Filed: December 4, 2014
    Publication date: October 6, 2016
    Applicant: CATALER CORPORATION
    Inventors: Satoshi MATSUEDA, Akimasa HIRAI, Kenichi TAKI
  • Publication number: 20160279607
    Abstract: The exhaust gas-purifying catalyst of the invention contains oxide particles having interdispersed therein A crystallites that are loaded with a noble metal and B crystallites that are not loaded with a noble metal. The A crystallites loaded with a noble metal are composed of an oxide containing at least one of zirconium (Zr) and cerium (Ce). The B crystallites not loaded with a noble metal are composed of a cerium (Ce)-containing oxide which has a higher Ce content (mol %) than the oxide making up the A crystallites. The oxide particles have a specific surface area after 5 hours of heat treatment at 1,150° C. in open air of 30 m2/g or more.
    Type: Application
    Filed: December 4, 2014
    Publication date: September 29, 2016
    Applicant: CATALER CORPORATION
    Inventors: Satoshi MATSUEDA, Akimasa HIRAI, Kenichi TAKI
  • Publication number: 20160236181
    Abstract: An exhaust cleaning catalyst, with which precious metal sintering is inhibited and which has greater exhaust cleaning abilities, has a substrate and a catalyst coating layer provided on the substrate. The catalyst coating layer has a precious metal that serves as an oxidation and/or reduction catalyst. The precious metal has Rh-containing metal particles in which rhodium (Rh) coexists with a base metal selected among platinum group elements excluding rhodium. The Rh-containing metal particles have an average rhodium content of 0.1% to 5% by mole with the total amount of the base metal and rhodium being 100% by mole.
    Type: Application
    Filed: December 8, 2014
    Publication date: August 18, 2016
    Applicant: CATALER CORPORATION
    Inventors: Satoru INODA, Akimasa HIRAI, Kenichi TAKI, Satoshi MATSUEDA
  • Publication number: 20160199815
    Abstract: Provided is an exhaust catalyst that exhibits higher NOX-reducing activities at the time of engine restart while maintaining its catalytic activities during normal traveling. This invention provides an exhaust cleaning catalyst comprising a substrate and a catalyst coating layer that includes CeO2. Catalyst coating layer is constituted in its thickness direction with multiple coating layers. In a top coating layer located at the outermost surface, the CeO2 content in a top coating layer's upstream portion is less than the CeO2 content in a top coating layer's downstream portion; and the CeO2 content in the top coating layer's upstream portion is less than the CeO2 content in a lower coating layer. The CeO2 content per liter of catalyst volume in the entire coating layer is 10 g/L to 30 g/L.
    Type: Application
    Filed: December 9, 2014
    Publication date: July 14, 2016
    Applicant: CATALER CORPORATION
    Inventors: Sho HOSHINO, Akimasa HIRAI, Kenichi TAKI, Satoshi MATSUEDA
  • Publication number: 20160199816
    Abstract: Provided is an exhaust cleaning catalyst that exhibits higher NOX-reducing activities at the time of engine restart while maintaining its catalytic activities during normal traveling. This invention provides an exhaust cleaning catalyst including a substrate and a catalyst coating layer including CeO2. Catalyst coating layer is constituted in its thickness direction with multiple coating layers. In a top coating layer located at the outermost surface, the CeO2 content in a top coating layer's upstream portion is less than the CeO2 content in a top coating layer's downstream portion. In a bottom coating layer near substrate, the CeO2 content in a bottom layer's downstream portion is less than the CeO2 content in a bottom coating layer's upstream portion.
    Type: Application
    Filed: December 9, 2014
    Publication date: July 14, 2016
    Applicant: CATALER CORPORATION
    Inventors: Satoshi MATSUEDA, Akimasa HIRAI, Kenichi TAKI, Sho HOSHINO
  • Patent number: 9364793
    Abstract: An exhaust gas-purifying catalyst includes a substrate, and a catalytic layer facing the substrate and including a precious metal, alumina, an oxygen storage material, and a sulfate of an alkaline-earth metal having an average particle diameter falling within a range of 0.01 to 0.70 ?m, the average particle diameter being obtained by observation using a scanning electron microscope. Another exhaust gas-purifying catalyst includes a substrate, and a catalytic layer formed on the substrate using slurry containing a precious metal, alumina, an oxygen storage material, and a sulfate of an alkaline-earth metal having an average particle diameter falling within a range of 0.01 to 0.70 ?m, the average particle diameter being obtained by observation using a scanning electron microscope.
    Type: Grant
    Filed: April 23, 2014
    Date of Patent: June 14, 2016
    Assignee: CATALER CORPORATION
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Yuji Yabuzaki