Patents by Inventor Yuji Yabuzaki

Yuji Yabuzaki 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: 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: 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: 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: 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
  • Publication number: 20160319722
    Abstract: A catalytic converter capable of uniformizing an exhaust gas flow velocity to realize uniform temperature distribution and improved purification performance, and a method for designing the catalytic converter. A catalytic converter includes a catalyst base composed of an inner base material part having inner cell holes and an outer base material part having outer cell holes, and an exhaust pipe composed of an upstream-side pipe, a catalyst housing pipe and a downstream-side pipe. In the catalytic converter, a flow path cross-sectional area of the upstream-side pipe defined as S1, a cross-sectional area of the inner base material part defined as S2, a cross-sectional area of the catalyst base defined as S3, a hydraulic diameter of the inner cell holes defined as d1 and a hydraulic diameter of the outer cell holes defined as d2, satisfy the relationship, S1?S2?S3(?0.2242 (d12/d22)2+0.1141 (d12/d22)+0.617).
    Type: Application
    Filed: December 16, 2014
    Publication date: November 3, 2016
    Applicant: Toyota Jidosha Kabushiki Kaisha
    Inventors: Yuki AOKI, Takahiko FUJIWARA, Ryosuke KAYANUMA, Yuji YABUZAKI, Naohiro HAYASHI, Hiroyuki MATSUBARA
  • Publication number: 20160288096
    Abstract: Provided is an exhaust gas control catalyst in which a catalyst layer containing at least one of Pd and Pt is formed on a substrate (1), the exhaust gas control catalyst including a first OSC material having a pyrochlore structure and an OSC material whose oxygen storage rate is faster than that of the first OSC material having a pyrochlore structure in a catalyst layer front stage (21) which is in a range from an exhaust gas upstream end of the catalyst layer to a length position which is 50% or lower of a total length of the catalyst layer.
    Type: Application
    Filed: November 10, 2014
    Publication date: October 6, 2016
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, CATALER CORPORATION
    Inventors: Takahiko FUJIWARA, Yuki AOKI, Hiromasa SUZUKI, Isao CHINZEI, Yuji YABUZAKI
  • 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
  • Publication number: 20160102591
    Abstract: A catalytic converter (10) includes i) an outer tube (1) that includes a cylindrical portion (1a), an upstream-side cone portion (1b), and a downstream-side cone portion (1c), and ii) a substrate (2) having a cell structure that is arranged in the cylindrical portion (1a) of the outer tube (1). The substrate (2) has a center region (2a) where a cell density is relatively high and a peripheral region (2b) where the cell density is relatively low, in a cross-section that is orthogonal to a length direction of the substrate (2). A projection portion when a connecting portion (5) of the exhaust duct (4) and the downstream-side cone portion (1c) is projected onto the substrate (2) is within the center region (2a).
    Type: Application
    Filed: April 23, 2014
    Publication date: April 14, 2016
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Ryosuke Kayanuma, Takahiko Fujiwara, Yuki Aoki, Hiroyuki Matsubara, Naohiro Hayashi, Yuji Yabuzaki
  • Publication number: 20140235431
    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: Application
    Filed: April 23, 2014
    Publication date: August 21, 2014
    Applicant: CATALER CORPORATION
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Yuji Yabuzaki
  • Patent number: 8741799
    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: November 28, 2011
    Date of Patent: June 3, 2014
    Assignee: Cataler Corporation
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Yuji Yabuzaki
  • Patent number: 8580706
    Abstract: An exhaust gas-purifying catalyst according to the present invention includes a substrate, a first catalytic layer facing the substrate and includes at least one precious metal selected from the group consisting of palladium and platinum, and alumina doped with an alkaline-earth metal element, and a second catalytic layer facing the substrate with the first catalytic layer interposed therebetween or intervening between the substrate and the first catalytic layer, the second catalytic layer includes rhodium and alumina doped with the alkaline-earth metal element.
    Type: Grant
    Filed: November 22, 2011
    Date of Patent: November 12, 2013
    Assignee: Cataler Corporation
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Yuji Yabuzaki
  • Patent number: 8546296
    Abstract: An exhaust gas-purifying catalyst includes a substrate, and a catalytic layer supported by the substrate. The catalytic layer includes a support made of alumina, an oxygen storage material, an alkaline earth metal and/or a compound of alkaline-earth metal selectively supported by a surface of the support and dispersed on the surface of the support, and a precious metal supported by the surface of the support. A ratio of a number of moles of the alkaline-earth metal in the catalytic layer with respect to a volumetric capacity of the exhaust gas-purifying catalyst falls within a range of 0.0004 mol/L to 0.35 mol/L.
    Type: Grant
    Filed: December 15, 2011
    Date of Patent: October 1, 2013
    Assignee: Cataler Corporation
    Inventors: Yuji Yabuzaki, Akimasa Hirai, Kenichi Taki, Tomohito Mizukami, Satoshi Matsueda
  • Patent number: 8318632
    Abstract: An exhaust gas purification catalyst includes a substrate, and a first catalyst layer formed on the substrate, the first catalyst layer containing palladium and/or platinum and alumina doped with an alkaline-earth metal element. The exhaust gas purification catalyst has a correlation coefficient ?Al,AE given by the following formula of 0.75 or more: ? Al , AE = C Al , AE ? Al ? ? AE .
    Type: Grant
    Filed: June 17, 2011
    Date of Patent: November 27, 2012
    Assignee: Cataler Corporation
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Keiichi Narita, Yuji Yabuzaki, Daisuke Ochiai
  • Publication number: 20120094827
    Abstract: The exhaust gas-purifying catalyst includes a first oxide particle with an oxygen storage capacity, one or more second oxide particles partially or entirely covering a surface of the first oxide particle and having an oxygen storage capacity lower than that of the first oxide particle, an average particle diameter Dav of the one or more second oxide particles being smaller than that of the first oxide particle, and precious metal particles supported on at least one of the second oxide particle.
    Type: Application
    Filed: October 14, 2011
    Publication date: April 19, 2012
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Yuji Yabuzaki, Sho Hoshino
  • Publication number: 20120088655
    Abstract: An exhaust gas-purifying catalyst includes a substrate, and a catalytic layer supported by the substrate. The catalytic layer includes a support made of alumina, an oxygen storage material, an alkaline earth metal and/or a compound of alkaline-earth metal selectively supported by a surface of the support and dispersed on the surface of the support, and a precious metal supported by the surface of the support. A ratio of a number of moles of the alkaline-earth metal in the catalytic layer with respect to a volumetric capacity of the exhaust gas-purifying catalyst falls within a range of 0.0004 mol/L to 0.35 mol/L.
    Type: Application
    Filed: December 15, 2011
    Publication date: April 12, 2012
    Inventors: Yuji Yabuzaki, Akimasa Hirai, Kenichi Taki, Tomohito Mizukami, Satoshi Matsueda
  • Publication number: 20120071318
    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: Application
    Filed: November 28, 2011
    Publication date: March 22, 2012
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Yuji Yabuzaki
  • Publication number: 20120065058
    Abstract: An exhaust gas-purifying catalyst according to the present invention includes a substrate, a first catalytic layer facing the substrate and includes at least one precious metal selected from the group consisting of palladium and platinum, and alumina doped with an alkaline-earth metal element, and a second catalytic layer facing the substrate with the first catalytic layer interposed therebetween or intervening between the substrate and the first catalytic layer, the second catalytic layer includes rhodium and alumina doped with the alkaline-earth metal element.
    Type: Application
    Filed: November 22, 2011
    Publication date: March 15, 2012
    Inventors: Satoshi Matsueda, Akimasa Hirai, Kenichi Taki, Yuji Yabuzaki
  • Patent number: 8133837
    Abstract: Decreasing HC emission is made possible. An exhaust gas-purifying catalyst includes a substrate, a hydrocarbon-adsorbing layer covering the substrate, and a catalytic layer covering the hydrocarbon-adsorbing layer. The catalytic layer includes a layered structure of a first catalytic layer including a precious metal and a carrier supporting it, and a second catalytic layer including the same precious metal as the precious metal of the first catalytic layer and a carrier supporting it and having a concentration of the precious metal higher than that in the first catalytic layer.
    Type: Grant
    Filed: March 11, 2009
    Date of Patent: March 13, 2012
    Assignee: Cataler Corporation
    Inventors: Yuji Yabuzaki, Akimasa Hirai, Kenichi Taki