# US 10,245,579 B2 · Exhaust gas purification catalyst and production method thereof

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- Number: US 10,245,579 B2
- Document ID: US10245579B2
- Status: Granted
- Kind: B2
- Application number: 15/118,213
- Filed: 2014-02-18
- Published: 2017-06-29
- Granted: 2019-04-02
- Earliest claimed: 2014-02-18
- Assignees: Nissan Motor Co., Ltd.
- Applicants: Nissan Motor Co., Ltd.
- Inventors: Misaki Fujimoto; Yasunari Hanaki
- Web page: https://patentgrep.com/patent/US10245579B2

## CPC

- B01J 23/83: with rare earths or actinides
- B01D 53/94: by catalytic processes
- B01D 53/944: {Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts (three-way-catalysts [TWC] B01D53/9445)}
- B01D 53/945: {characterised by a specific catalyst}
- B01J 23/002: {Mixed oxides other than spinels, e.g. perovskite}
- B01J 23/10: of rare earths
- B01J 35/635: {0.5-1.0 ml/g}
- B01J 35/638: {more than 1.0 ml/g}
- B01J 35/643: {less than 2 nm}
- B01J 35/647: {2-50 nm}
- B01J 35/651: {50-500 nm}
- B01J 37/04: Mixing {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 37/08: Heat treatment {(B01J37/0009, B01J37/0018 take precedence)}
- F01N 3/103: {Oxidation catalysts for HC and CO only}
- F01N 3/2828: {Ceramic multi-channel monoliths, e.g. honeycombs}
- B01D 2255/204: Alkaline earth metals
- B01D 2255/2063: Lanthanum
- B01D 2255/2068: Neodymium
- B01D 2255/20738: Iron
- B01D 2255/407: Zr-Ce mixed oxides
- B01D 2255/908: O2-storage component incorporated in the catalyst
- B01D 2255/92: Dimensions
- B01D 2255/9202: Linear dimensions
- B01J 2523/00: Constitutive chemical elements of heterogeneous catalysts
- F01N 2570/12: Hydrocarbons
- Y02T 10/12: Improving ICE efficiencies
- 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)
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

An exhaust gas purification catalyst contains an oxide 1 and an oxide 2. The catalyst has pores P1-260 with a pore size of from 1 nm to 260 nm, that can be measured by the nitrogen absorption method, and the total sum ΣPV1-260 of the pore volume PV1-260 of the pores is equal to or greater than 0.79 cm3/g. The oxide 1 is an oxide with an oxygen release capability. The oxide 2 is represented by LaxM1-xM′O3-δ (2), where M is at least one element selected from the group consisting of Ba, Sr and Ca, M′ is at least one element selected from the group consisting of Fe, Co, Ni and Mn, δ is the amount of oxygen deficiency, x satisfies 0≤x≤1, and δ satisfies 0≤δ≤1.

## Claims

### Claim 1

An exhaust gas purification catalyst containing an oxide 1 that is an oxide of an oxygen storage material with an oxygen release/storage function and an oxide 2 that is represented by the following formula (2):
LaxM1-xM′O3-δtm (2)
where M is at least one element selected from the group consisting of Ba, Sr and Ca, M′ is at least one element selected from the group consisting of Fe, Co, Ni and Mn, δ is the amount of oxygen deficiency, x satisfies 0≤x≤1, and δ satisfies 0≤δ≤1,
wherein the exhaust gas purification catalyst has pores P1-260 with a pore size of from 1 nm to 260 nm, that can be measured by a nitrogen absorption method, and
a total sum ΣPV1-260 of a pore volume PV1-260 of the pores is equal to or greater than 0.79 cm3/g.

### Claim 2 (depends on 1)

The exhaust gas purification catalyst according to claim 1,
wherein the exhaust gas purification catalyst is obtained by making the oxide 1 support the oxide 2, and
an increase ratio ΔδPV100-260 of a total sum of a pore volume of pores with a pore size of from 100 nm to 260 nm by the supporting process satisfies ΔΣPV100-260 1, where the increase ratio ΔΣPV100-260 of the total sum the pore volume is represented by the following equation (1),
ΔΣPV100-260=(Total Sum δPV100-260 of Pore Volume of the Exhaust Gas Purification Catalyst after the Supporting Process) /0.11 (1).

### Claim 3 (depends on 1)

The exhaust gas purification catalyst according to claim 1, wherein the oxide 1 contains cerium (Ce) and/or zirconium (Zr).

### Claim 4 (depends on 2)

The exhaust gas purification catalyst according to claim 2, wherein the oxide 1 contains cerium (Ce) and/or zirconium (Zr).

### Claim 5 (depends on 1)

The exhaust gas purification catalyst according to claim 1, wherein the oxide 1 is a complex oxide that contains cerium (Ce) and/or zirconium (Zr).

### Claim 6 (depends on 2)

The exhaust gas purification catalyst according to claim 2, wherein the oxide 1 is a complex oxide that contains cerium (Ce) and/or zirconium (Zr).

### Claim 7 (depends on 1)

A method of producing the exhaust gas purification catalyst of claim 1, comprising the steps of:
mixing a precursor of the oxide 2 with the oxide 1 before calcining the oxide 1, drying and then calcining a resultant mixture.

### Claim 8 (depends on 7)

The method of producing the exhaust gas purification catalyst according to claim 7, wherein the precursor of the oxide 2 is a carboxylate of lanthanum (La) and at least one element selected from the group consisting of barium (Ba), strontium (Sr), calcium (Ca), iron (Fe), cobalt (Co), nickel (Ni) and manganese (Mn).