# US 10,118,156 B2 · Exhaust gas purification device > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,118,156 B2 - Document ID: US10118156B2 - Status: Granted - Kind: B2 - Application number: 15/298,922 - Filed: 2016-10-20 - Published: 2017-04-27 - Granted: 2018-11-06 - Earliest claimed: 2015-10-27 - Assignees: Cataler Corporation; Toyota Jidosha Kabushiki Kaisha - Applicants: Cataler Corporation; Toyota Jidosha Kabushiki Kaisha - Inventors: Keiji Horaguchi; Makoto Tsuji; Hiroto Imai; Yasuyoshi Sasaki; Hiroto Yoshida; Takeshi Nobukawa - Web page: https://patentgrep.com/patent/US10118156B2 ## CPC - B01J 23/58: with alkali- or alkaline earth metals - B01D 53/9422: {for removing nitrogen oxides by NOx storage or reduction by cyclic switching between lean and rich exhaust gases (LNT, NSC, NSR)} - B01J 23/10: of rare earths - B01J 23/63: with rare earths or actinides - B01J 37/0213: {Preparation of the impregnating solution} - B01J 37/0236: {Drying, e.g. preparing a suspension, adding a soluble salt and drying} - B01J 37/08: Heat treatment {(B01J37/0009, B01J37/0018 take precedence)} - F01N 3/28: Construction of catalytic reactors - B01D 2255/1021: Platinum - B01D 2255/1023: Palladium - B01D 2255/1025: Rhodium - B01D 2255/2042: Barium - B01D 2255/2092: Aluminium - B01D 2255/407: Zr-Ce mixed oxides - B01D 2255/9022: Two layers - B01D 2255/91: NOx-storage component incorporated in the catalyst - B01D 2257/404: Nitrogen oxides other than dinitrogen oxide - B01J 35/56: Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths - B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS - B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28) - F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16) ## Abstract Exhaust gas purification device having a catalyst layer including an Rh—Ba-loaded catalyst, and a Pt/Pd—Ba-loaded catalyst. The exhaust gas purification device satisfies at least one of (a) the degree of Rh—Ba dispersion is greater than 0.001 and less than 1.000, (b) the loaded amount of Ba based on the weight of a first carrier particle in the Rh—Ba-loaded catalyst is greater than 0.01% by weight and less than 10.00% by weight, and the loaded amount of Ba based on the weight of a second carrier particle in the Pt/Pd—Ba-loaded catalyst is 10.00% by weight to 20.00% by weight, and (c) the loaded amount of Ba based on the weight of the first carrier particle in Rh—Ba-loaded catalyst is greater than 0.005 times to less than 0.800 times the loaded amount of Ba based on the weight of the second carrier particle in Pt/Pd—Ba-loaded catalyst. ## Claims ### Claim 1 An exhaust gas purification device having on a substrate a catalyst layer comprising: an Rh—Ba-loaded catalyst obtained by loading Rh and Ba on a first carrier particle, and a Pt/Pd—Ba-loaded catalyst obtained by loading Ba and one or more types of precious metals selected from Pt and Pd on a second carrier particle; wherein the exhaust gas purification device satisfies the following condition (a): (a) the degree of Rh—Ba dispersion, as calculated by measuring with an EPMA, in the catalyst layer is greater than 0.001 and less than 1.000. ### Claim 2 (depends on 1) The exhaust gas purification device according to claim 1, which further satisfies the following condition (b): (b) the loaded amount of Ba based on the weight of the first carrier particle in the Rh—Ba-loaded catalyst is greater than 0.01% by weight and less than 10.00% by weight, and the loaded amount of Ba based on the weight of the second carrier particle in the Pt/Pd—Ba-loaded catalyst is 10.00% by weight to 20.00% by weight. ### Claim 3 (depends on 1) The exhaust gas purification device according to claim 1, which further satisfies the condition (c): (c) the loaded amount of Ba based on the weight of the first carrier particle in the Rh—Ba-loaded catalyst is greater than 0.005 times to less than 0.800 times the loaded amount of Ba based on the weight of the second carrier particle in the Pt/Pd—Ba-loaded catalyst. ### Claim 4 (depends on 1) The exhaust gas purification device according to claim 1, wherein at least one of the first carrier particle and the second carrier particle contains alumina. ### Claim 5 (depends on 1) The exhaust gas purification device according to claim 1, wherein the catalyst layer further contains a ceria-zirconia composite oxide. ### Claim 6 (depends on 1) The exhaust gas purification device according to claim 1, wherein the catalyst layer is composed of two or more layers, at least one of those layers contains the Rh—Ba-loaded catalyst and the Pt/Pd—Ba-loaded catalyst, and the other layers contain the Pt/Pd—Ba-loaded catalyst. ### Claim 7 (depends on 1) A method for producing the exhaust gas purification device according to claim 1, comprising: preparing a slurry having a pH of 4 to 8 that contains: an Rh—Ba-loaded catalyst obtained by loading Rh and Ba on a first carrier particle, a Pt/Pd—Ba-loaded catalyst obtained by loading Ba and at least one type of precious metal selected from Pt and Pd on a second carrier particle, a binder, and water; and, impregnating the slurry into a substrate followed by drying and baking to load the slurry components on the substrate. ### Claim 8 (depends on 7) The method according to claim 7, wherein barium acetate is used as a Ba salt in the preparation of the Rh—Ba-loaded catalyst and the Pt/Pd—Ba-loaded catalyst. ### Claim 9 (depends on 7) The method according to claim 7, wherein the binder contains a boehmite sol.