Patents by Inventor Hirotaka Ori
Hirotaka Ori 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).
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Patent number: 11725556Abstract: Provided is an exhaust gas purification catalyst having an improved catalyst performance while securing an OSC in an air-fuel ratio (A/F) rich atmosphere where HC poisoning is likely to occur. The present disclosure relates to an exhaust gas purification catalyst including a substrate and a catalyst coating layer coated on the substrate. The catalyst coating layer has an upstream coat layer formed from an end portion in an upstream side with respect to an exhaust gas flow direction in the exhaust gas purification catalyst and a downstream coat layer formed from an end portion in a downstream side with respect to the exhaust gas flow direction in the exhaust gas purification catalyst. The downstream coat layer includes Rh as a catalytic metal, alumina-ceria-zirconia complex oxide, and alkaline earth metal.Type: GrantFiled: February 28, 2022Date of Patent: August 15, 2023Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Isao Chinzei, Takumi Tojo, Takahiro Nishio, Yosuke Toda, Hirotaka Ori, Minoru Ito, Sho Hoshino
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Patent number: 11660589Abstract: An exhaust gas purification device that allows suppressing an increase in pressure loss is provided. The exhaust gas purification device of the present disclosure includes a honeycomb substrate and an inflow cell side catalyst layer. The substrate includes a porous partition wall which defines inflow cells and outflow cells extending from an inflow side end to an outflow side end. The inflow cell side catalyst layer is disposed on a surface on the inflow cell side in an inflow cell side catalyst region from an inflow side end to a position close to an outflow side end of the partition wall. The permeability of a portion including an outflow side region from the position to the outflow side end of the partition wall is higher than a gas permeability of a portion including the inflow cell side catalyst region of the partition wall and the inflow cell side catalyst layer.Type: GrantFiled: May 1, 2020Date of Patent: May 30, 2023Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Koji Sugiura, Hiromasa Nishioka, Naoto Miyoshi, Akemi Sato, Masatoshi Ikebe, Ryota Nakashima, Yasutaka Nomura, Hirotaka Ori
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Patent number: 11602742Abstract: 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: GrantFiled: February 18, 2021Date of Patent: March 14, 2023Assignees: 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: 11559768Abstract: The present disclosure provides the exhaust gas purification catalyst with the improved purification performance under the high Ga condition and the transient state in which an A/F repeats rich and lean phases. The present disclosure relates to an exhaust gas purification catalyst comprising a catalyst coating layer on a substrate, the catalyst coating layer containing a noble metal, a composite oxide containing cerium oxide and zirconium oxide, and a composite oxide containing aluminum oxide, wherein in the catalyst coating layer: an average thickness of the coating layer is in a range from 20 ?m to 100 ?m; a porosity measured by a weight-in-water method is in a range from 50% by volume to 80% by volume; and high-aspect-ratio pores having an aspect ratio of 5 or more account for 0.Type: GrantFiled: April 17, 2020Date of Patent: January 24, 2023Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Isao Chinzei, Masahide Miura, Seiji Nakahigashi, Hiromasa Suzuki, Akira Morikawa, Toshio Yamamoto, Satoru Katoh, Takashi Onozuka, Hirotaka Ori, Mitsuyoshi Okada, Sho Hoshino
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Patent number: 11504700Abstract: The present invention provides an exhaust gas purification catalyst including an alkaline earth metal supported in a highly dispersed state on a porous carrier. A catalyst layer of the exhaust gas purification catalyst provided by the invention has an alkaline earth metal-supporting region including a porous carrier, a catalyst metal belonging to the platinum group, and a sulfate of at least one type of alkali earth metal supported on the porous carrier. In a cross-section of this region, a Pearson correlation coefficient RAe/M is at least 0.5 as calculated using ? and ? for each pixel obtained by carrying out area analysis by FE-EPMA under conditions of pixel size of 0.34 ?m×0.34 ?m, and measured pixel number 256×256, and by measuring the characteristic X-ray intensity (?:cps) of the alkaline earth metal element (Ae) and the characteristic X-ray intensity (?:cps) of the main constituent element of the inorganic compound constituting the porous carrier for each pixel.Type: GrantFiled: April 9, 2018Date of Patent: November 22, 2022Assignee: Cataler CorporationInventors: Shunsuke Oishi, Shogo Kawamura, Takahiro Nagata, Hirotaka Ori, Minoru Itou
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Patent number: 11473472Abstract: 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: GrantFiled: April 15, 2021Date of Patent: October 18, 2022Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Koji Sugiura, Hiromasa Nishioka, Naoto Miyoshi, Akemi Satou, Keisuke Murawaki, Masatoshi Ikebe, Takaya Ota, Ryota Nakashima, Hirotaka Ori
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Publication number: 20220298942Abstract: Provided is an exhaust gas purification catalyst having an improved catalyst performance while securing an OSC in an air-fuel ratio (A/F) rich atmosphere where HC poisoning is likely to occur. The present disclosure relates to an exhaust gas purification catalyst including a substrate and a catalyst coating layer coated on the substrate. The catalyst coating layer has an upstream coat layer formed from an end portion in an upstream side with respect to an exhaust gas flow direction in the exhaust gas purification catalyst and a downstream coat layer formed from an end portion in a downstream side with respect to the exhaust gas flow direction in the exhaust gas purification catalyst. The downstream coat layer includes Rh as a catalytic metal, alumina-ceria-zirconia complex oxide, and alkaline earth metal.Type: ApplicationFiled: February 28, 2022Publication date: September 22, 2022Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Isao CHINZEI, Takumi TOJO, Takahiro NISHIO, Yosuke TODA, Hirotaka ORI, Minoru ITO, Sho HOSHINO
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Patent number: 11286830Abstract: The exhaust gas cleaning catalyst according is provided with a substrate and a catalyst coat layer formed on a surface of the substrate. The catalyst coat layer is formed as a laminate structure having an upper layer and a lower layer. The upper layer is a Pd-free layer that does not contain Pd, and the lower layer is a Pd-containing layer. In addition, when a region of the lower layer that corresponds to 20% of the length of the exhaust gas cleaning catalyst from the exhaust gas inlet side end towards the exhaust gas outlet side of the exhaust gas cleaning catalyst is divided into four equal regions to be each 5% of the length, the relationship A>B>C is satisfied, where A, B, and C represents the Pd content in the first, second, and third region respectively.Type: GrantFiled: January 25, 2016Date of Patent: March 29, 2022Assignees: CATALER CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Yoshinori Saito, Hirotaka Ori, Shingo Sakagami, Isao Chinzei, Takeru Yoshida, Yuki Aoki
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Patent number: 11224840Abstract: An object of the present invention is to provide an exhaust gas purification catalyst which can exhibit sufficient purification performance even under a high Ga condition. The present invention relates to an exhaust gas purification catalyst comprising a substrate and a catalyst coating layer formed on the substrate, wherein the catalyst coating layer comprises catalyst particles, the catalyst coating layer having an upstream region extending by 40 to 60% of the entire length of the substrate from an upstream end of the catalyst in the direction of an exhaust gas flow and a downstream region corresponding to the remainder portion of the catalyst coating layer, the composition of the catalyst particle of the upstream region being different from that of the downstream region.Type: GrantFiled: March 24, 2016Date of Patent: January 18, 2022Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATAIER CORPORATIONInventors: Hiromasa Suzuki, Masahide Miura, Yoshinori Saito, Satoru Katoh, Toshitaka Tanabe, Tetsuhiro Hirao, Tatsuya Ohashi, Hiroaki Naito, Hirotaka Ori, Michihiko Takeuchi, Keiichi Narita
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Publication number: 20210324777Abstract: 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: ApplicationFiled: April 15, 2021Publication date: October 21, 2021Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Koji SUGIURA, Hiromasa NISHIOKA, Naoto MIYOSHI, Akemi SATOU, Keisuke MURAWAKI, Masatoshi IKEBE, Takaya OTA, Ryota NAKASHIMA, Hirotaka ORI
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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: 11053833Abstract: The present disclosure provides the exhaust gas purification catalyst with the improved purification performance under the high Ga condition and the atmosphere where the A/F is rich. The present disclosure relates to an exhaust gas purification catalyst including a catalyst coating layer on a substrate, the catalyst coating layer containing a noble metal and a metal oxide, wherein in the catalyst coating layer: an average thickness of the coating layer is in a range from 50 ?m to 100 ?m; a porosity measured by a weight-in-water method is in a range from 50% by volume to 80% by volume; and high-aspect-ratio pores having an aspect ratio of 5 or more account for 0.Type: GrantFiled: April 24, 2020Date of Patent: July 6, 2021Assignee: Toyota Jidosha Kabushiki KaishaInventors: Isao Chinzei, Masahide Miura, Seiji Nakahigashi, Hiromasa Suzuki, Toshio Yamamoto, Akira Morikawa, Satoru Katoh, Takashi Onozuka, Hirotaka Ori, Mitsuyoshi Okada, Sho Hoshino
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Publication number: 20210033009Abstract: An exhaust gas control apparatus includes: a honeycomb substrate including an inflow cell and an outflow cell adjacent to each other with a partition wall sandwiched between the inflow cell and the outflow cell; a first sealing part provided at an outflow side end of the inflow cell, and a second sealing part provided at an inflow side end of the outflow cell; and a catalyst layer provided on the partition wall, and at least one of the first sealing part and the second sealing part is an OSC material-containing sealing part containing an OSC material and a sealant, and a concentration of the OSC material in the OSC material-containing sealing part is uniform in an extending direction.Type: ApplicationFiled: June 17, 2020Publication date: February 4, 2021Inventors: Koji SUGIURA, Hiromasa NISHIOKA, Naoto MIYOSHI, Akemi SATO, Masatoshi IKEBE, Ryota NAKASHIMA, Yasutaka NOMURA, Hirotaka ORI
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Publication number: 20200368735Abstract: An exhaust gas purification device that allows suppressing an increase in pressure loss is provided. The exhaust gas purification device of the present disclosure includes a honeycomb substrate and an inflow cell side catalyst layer. The substrate includes a porous partition wall which defines inflow cells and outflow cells extending from an inflow side end to an outflow side end. The inflow cell side catalyst layer is disposed on a surface on the inflow cell side in an inflow cell side catalyst region from an inflow side end to a position close to an outflow side end of the partition wall. The permeability of a portion including an outflow side region from the position to the outflow side end of the partition wall is higher than a gas permeability of a portion including the inflow cell side catalyst region of the partition wall and the inflow cell side catalyst layer.Type: ApplicationFiled: May 1, 2020Publication date: November 26, 2020Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Koji SUGIURA, Hiromasa NISHIOKA, Naoto MIYOSHI, Akemi SATO, Masatoshi IKEBE, Ryota NAKASHIMA, Yasutaka NOMURA, Hirotaka ORI
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Publication number: 20200355106Abstract: The present disclosure provides the exhaust gas purification catalyst with the improved purification performance under the high Ga condition and the atmosphere where the A/F is rich. The present disclosure relates to an exhaust gas purification catalyst including a catalyst coating layer on a substrate, the catalyst coating layer containing a noble metal and a metal oxide, wherein in the catalyst coating layer: an average thickness of the coating layer is in a range from 50 ?m to 100 ?m; a porosity measured by a weight-in-water method is in a range from 50% by volume to 80% by volume; and high-aspect-ratio pores having an aspect ratio of 5 or more account for 0.Type: ApplicationFiled: April 24, 2020Publication date: November 12, 2020Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Isao JIDOSHA CHINZEI, Masahide MIURA, Seiji NAKAHIGASHI, Hiromasa SUZUKI, Toshio YAMAMOTO, Akira MORIKAWA, Satoru KATOH, Takashi ONOZUKA, Hirotaka ORI, Mitsuyoshi OKADA, Sho HOSHINO
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Publication number: 20200353411Abstract: The present disclosure provides the exhaust gas purification catalyst with the improved purification performance under the high Ga condition and the transient state in which an A/F repeats rich and lean phases. The present disclosure relates to an exhaust gas purification catalyst comprising a catalyst coating layer on a substrate, the catalyst coating layer containing a noble metal, a composite oxide containing cerium oxide and zirconium oxide, and a composite oxide containing aluminum oxide, wherein in the catalyst coating layer: an average thickness of the coating layer is in a range from 20 ?m to 100 ?m; a porosity measured by a weight-in-water method is in a range from 50% by volume to 80% by volume; and high-aspect-ratio pores having an aspect ratio of 5 or more account for 0.Type: ApplicationFiled: April 17, 2020Publication date: November 12, 2020Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Isao CHINZEI, Masahide MIURA, Seiji NAKAHIGASHI, Hiromasa SUZUKI, Akira MORIKAWA, Toshio YAMAMOTO, Satoru KATOH, Takashi ONOZUKA, Hirotaka ORI, Mitsuyoshi OKADA, Sho HOSHINO
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Publication number: 20200316578Abstract: There is provided a filter catalyst that has a wall-flow structure, and the filter catalyst has an excellent purification performance. The embodiment is a filter catalyst including a wall-flow type substrate that includes an inlet-side cell, an outlet-side cell, and a partition wall. The inlet-side cell has an open end portion on an exhaust gas flow-in side and a closed end portion on an exhaust gas flow-out side. The outlet-side cell is adjacent to the inlet-side cell and has an open end portion on the exhaust gas flow-out side and a closed end portion on the exhaust gas flow-in side. The partition wall has a porous structure and interposes between the inlet-side cell and the outlet-side cell. The filter catalyst includes an oxygen occlusion portion and a catalyst portion dispersed and disposed in the porous structure. The oxygen occlusion portion is disposed on a wall surface of the porous structure.Type: ApplicationFiled: March 13, 2020Publication date: October 8, 2020Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Naoto MIYOSHI, Koji SUGIURA, Hiromasa NISHIOKA, Akemi SATO, Masatoshi IKEBE, Ryota NAKASHIMA, Yasutaka NOMURA, Hirotaka ORI
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Patent number: 10731532Abstract: The problem of the present invention is to provide an exhaust gas purification catalyst which can exhibit sufficient purification performance under a high Ga condition while having a resistance to stress such as high-temperature and poisonous substances. The present invention relates to an exhaust gas purification catalyst comprising two or more catalyst coating layers on a substrate, wherein a lower catalyst coating layer that is present lower with respect to an uppermost catalyst coating layer has a structure where a large number of voids are included and high-aspect-ratio pores having an aspect ratio of 5 or more account for a certain proportion or more of the whole volume of voids, thereby to improve gas diffusivity in the lower catalyst coating layer.Type: GrantFiled: March 24, 2016Date of Patent: August 4, 2020Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Hiromasa Suzuki, Masahide Miura, Yoshinori Saito, Satoru Katoh, Toshitaka Tanabe, Tetsuhiro Hirao, Tatsuya Ohashi, Hiroaki Naito, Hirotaka Ori, Michihiko Takeuchi, Keiichi Narita
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Patent number: 10576420Abstract: The object of the present invention is to provide an exhaust gas purifying catalyst that can achieve high purification performance while suppressing H2S emissions. The object is solved by an exhaust gas purifying catalyst in which the lower layer of the catalyst coating layer comprises a ceria-zirconia composite oxide having a pyrochlore-type ordered array structure, in which the ceria-zirconia composite oxide contains at least one additional element selected from the group consisting of praseodymium, lanthanum, and yttrium at 0.5 to 5.0 mol % in relation to the total cation amount, and the molar ratio of (cerium+additional element):(zirconium) is within the range from 43:57 to 48:52.Type: GrantFiled: December 11, 2015Date of Patent: March 3, 2020Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Isao Chinzei, Hiromasa Suzuki, Takeru Yoshida, Masahide Miura, Yuki Aoki, Mitsuyoshi Okada, Toshitaka Tanabe, Akihiko Suda, Yoshinori Saito, Hirotaka Ori, Kosuke Iizuka, Akira Morikawa
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Patent number: 10556223Abstract: The object of the present invention is to provide an exhaust gas purifying catalyst that can achieve high purification performance while suppressing H2S emissions. The object is solved by an exhaust gas purifying catalyst in which the top layer of a catalyst coating layer comprises a ceria-zirconia composite oxide having a pyrochlore-type ordered array structure, in which the ceria-zirconia composite oxide contains at least one additional element selected from the group consisting of praseodymium, lanthanum, and yttrium at 0.5 to 5.0 mol % in relation to the total cation amount, and the molar ratio of (cerium+additional element):(zirconium) is within the range from 43:57 to 48:52.Type: GrantFiled: December 11, 2015Date of Patent: February 11, 2020Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATIONInventors: Hiromasa Suzuki, Takeru Yoshida, Masahide Miura, Yuki Aoki, Isao Chinzei, Yoshinori Saito, Daisuke Ochiai, Mitsuyoshi Okada, Toshitaka Tanabe, Akihiko Suda, Masanao Sato, Akiya Chiba, Akira Morikawa, Hirotaka Ori