Patents by Inventor Mitsuyoshi Okada

Mitsuyoshi Okada 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).

  • Publication number: 20230201770
    Abstract: A catalyst for purification of exhaust gas including a substrate, and a catalyst coat layer which is formed on a surface of the substrate and contains catalyst particles, wherein the catalyst coat layer has an average thickness ranging 25 to 150 ?m, a void fraction, as determined by scanning electron microscope observation of a cross-section of the catalyst coat layer, ranging 1.5 to 8.0% by volume, 60 to 90% by volume of all voids in the catalyst coat layer are high-aspect ratio pores which have equivalent circle diameters ranging 2 to 50 ?m in a cross-sectional image of a cross-section of the catalyst coat layer perpendicular to a flow direction of exhaust gas in the substrate, and which ratios of 5 or higher, the high-aspect ratio pores have an average aspect ratio ranging 10 to 50, and a noble metal is supported on the entire catalyst coat layer.
    Type: Application
    Filed: June 8, 2021
    Publication date: June 29, 2023
    Applicant: CATALER CORPORATION
    Inventors: Toshio YAMAMOTO, Akira MORIKAWA, Satoru KATOH, Masahide MIURA, Nobusuke KABASHIMA, Nobuyuki TAKAGI, Takashi ONOZUKA, Mitsuyoshi OKADA
  • Patent number: 11577226
    Abstract: 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: Grant
    Filed: December 1, 2020
    Date of Patent: February 14, 2023
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: 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
  • Patent number: 11559768
    Abstract: 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: Grant
    Filed: April 17, 2020
    Date of Patent: January 24, 2023
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Isao Chinzei, Masahide Miura, Seiji Nakahigashi, Hiromasa Suzuki, Akira Morikawa, Toshio Yamamoto, Satoru Katoh, Takashi Onozuka, Hirotaka Ori, Mitsuyoshi Okada, Sho Hoshino
  • Patent number: 11426710
    Abstract: 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: Grant
    Filed: November 4, 2020
    Date of Patent: August 30, 2022
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Takahiro Nishio, Shogo Shirakawa, Masahide Miura, Isao Chinzei, Seiji Nakahigashi, Norimichi Shimano, Hiromi Togashi, Hiroki Nihashi, Mitsuyoshi Okada, Takashi Onozuka, Souta Akiyama, Isao Naito
  • Patent number: 11400436
    Abstract: 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 ? 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: Grant
    Filed: November 30, 2020
    Date of Patent: August 2, 2022
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: 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
  • Patent number: 11352924
    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: Grant
    Filed: June 26, 2019
    Date of Patent: June 7, 2022
    Assignee: CATALER CORPORATION
    Inventors: Chihiro Kasuya, Yuji Yabuzaki, Masaaki Kawai, Mitsuyoshi Okada
  • 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
  • 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
  • Publication number: 20210205790
    Abstract: 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: Application
    Filed: December 1, 2020
    Publication date: July 8, 2021
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: 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
  • Patent number: 11053833
    Abstract: 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: Grant
    Filed: April 24, 2020
    Date of Patent: July 6, 2021
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Isao Chinzei, Masahide Miura, Seiji Nakahigashi, Hiromasa Suzuki, Toshio Yamamoto, Akira Morikawa, Satoru Katoh, Takashi Onozuka, Hirotaka Ori, Mitsuyoshi Okada, Sho Hoshino
  • Publication number: 20210197175
    Abstract: 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: Application
    Filed: November 4, 2020
    Publication date: July 1, 2021
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Takahiro NISHIO, Shogo SHIRAKAWA, Masahide MIURA, Isao CHINZEI, Seiji NAKAHIGASHI, Norimichi SHIMANO, Hiromi TOGASHI, Hiroki NIHASHI, Mitsuyoshi OKADA, Takashi ONOZUKA, Souta AKIYAMA, Isao NAITO
  • Publication number: 20210197176
    Abstract: 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: Application
    Filed: November 30, 2020
    Publication date: July 1, 2021
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: 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
  • Publication number: 20200355106
    Abstract: 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: Application
    Filed: April 24, 2020
    Publication date: November 12, 2020
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Isao JIDOSHA CHINZEI, Masahide MIURA, Seiji NAKAHIGASHI, Hiromasa SUZUKI, Toshio YAMAMOTO, Akira MORIKAWA, Satoru KATOH, Takashi ONOZUKA, Hirotaka ORI, Mitsuyoshi OKADA, Sho HOSHINO
  • Publication number: 20200353411
    Abstract: 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: Application
    Filed: April 17, 2020
    Publication date: November 12, 2020
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Isao CHINZEI, Masahide MIURA, Seiji NAKAHIGASHI, Hiromasa SUZUKI, Akira MORIKAWA, Toshio YAMAMOTO, Satoru KATOH, Takashi ONOZUKA, Hirotaka ORI, Mitsuyoshi OKADA, Sho HOSHINO
  • Patent number: 10576420
    Abstract: 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: Grant
    Filed: December 11, 2015
    Date of Patent: March 3, 2020
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Isao Chinzei, Hiromasa Suzuki, Takeru Yoshida, Masahide Miura, Yuki Aoki, Mitsuyoshi Okada, Toshitaka Tanabe, Akihiko Suda, Yoshinori Saito, Hirotaka Ori, Kosuke Iizuka, Akira Morikawa
  • Patent number: 10556223
    Abstract: 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: Grant
    Filed: December 11, 2015
    Date of Patent: February 11, 2020
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: 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
  • Patent number: 10384163
    Abstract: 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: Grant
    Filed: December 11, 2015
    Date of Patent: August 20, 2019
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Isao Chinzei, Hiromasa Suzuki, Takeru Yoshida, Masahide Miura, Yuki Aoki, Mitsuyoshi Okada, Toshitaka Tanabe, Akihiko Suda, Yoshinori Saito, Hirotaka Ori, Kosuke Iizuka, Akira Morikawa
  • Patent number: 10322406
    Abstract: 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: Grant
    Filed: December 11, 2015
    Date of Patent: June 18, 2019
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: 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
  • Patent number: 10307736
    Abstract: An exhaust gas purification catalyst, excellent in the NOx purification capacity and the HC purification capacity, includes a substrate and a catalyst coating layer formed on the surface of the substrate, wherein the catalyst coating layer comprises the upper and lower layer including a lower layer being closer to the surface of the substrate and an upper layer being relatively remote from the surface of the substrate. The upper layer of the catalyst coating layer includes Rh, Pd, and a carrier. The lower layer of the catalyst coating layer includes at least one noble metal selected from Pd and Pt and a carrier. 65% by mass or more of Pd in the upper layer exists in a layer up to 50% of the upper layer in a thickness direction from the surface of the upper layer being relatively remote from the surface of the substrate. The ratio of Pd to Rh by mass (Pd/Rh) is 0.5 to 7.0 in the upper layer.
    Type: Grant
    Filed: March 27, 2018
    Date of Patent: June 4, 2019
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Yoshinori Saito, Hiromasa Suzuki, Tatsuya Ohashi, Keiichi Narita, Ryota Nakashima, Mitsuyoshi Okada, Ryosuke Takasu, Shunsuke Oishi
  • Patent number: 10143968
    Abstract: The object of the present invention is to provide a high-performance exhaust gas purifying catalyst that can achieve oxygen absorption/release capacity and NOx purification performance. The object is solved by an exhaust gas purifying catalyst, which comprises a ceria-zirconia composite oxide having a pyrochlore-type ordered array structure in the upstream part of the catalyst coating layer, 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 % of the total cation amount, and has a molar ratio of (cerium+the additional element):(zirconium) of 43:57 to 48:52.
    Type: Grant
    Filed: December 11, 2015
    Date of Patent: December 4, 2018
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Hiromasa Suzuki, Takeru Yoshida, Masahide Miura, Isao Chinzei, Mitsuyoshi Okada, Toshitaka Tanabe, Akihiko Suda, Hirotaka Ori, Akiya Chiba, Kosuke Iizuka, Akira Morikawa