# US 2025/0083102 A1 · Exhaust gas purification catalyst

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- Number: US 2025/0083102 A1
- Document ID: US20250083102A1
- Status: Published application
- Kind: A1
- Application number: 18/793,326
- Filed: 2024-08-02
- Published: 2025-03-13
- Earliest claimed: 2023-09-08
- Assignees: Toyota Jidosha Kabushiki Kaisha; Cataler Corporation
- Inventors: Takahiro Nishio; Takumi Tojo; Nobuyuki Takagi; Sho Hoshino; Naoto Fujita; Yosuke Toda; Shun Sakamoto; Kengo Shimizu
- Web page: https://patentgrep.com/patent/US20250083102A1

## CPC

- B01D 53/945: {characterised by a specific catalyst}
- B01D 53/9472: {in different zones}
- B01J 21/04: Alumina
- B01J 21/066: {Zirconium or hafnium; Oxides or hydroxides thereof}
- B01J 23/44: Palladium
- B01J 23/464: {Rhodium}
- B01J 23/63: with rare earths or actinides
- B01J 27/053: Sulfates
- B01J 35/19: {Catalysts containing parts with different compositions}
- B01J 35/40: characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77)
- B01J 35/45: Nanoparticles
- B01J 35/56: Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths
- B01J 37/0228: {in several steps}
- B01J 37/0244: {Coatings comprising several layers}
- B01D 2255/1021: Platinum
- B01D 2255/1023: Palladium
- B01D 2255/1025: Rhodium
- B01D 2255/2042: Barium
- B01D 2255/9022: Two layers
- B01D 2255/9032: Two zones
- B01D 2255/908: O2-storage component incorporated in the catalyst
- B01D 2255/9155: Wall flow filters
- B01D 2255/9202: Linear dimensions
- B01D 2257/502: Carbon monoxide
- B01D 2257/702: Hydrocarbons
- B01D 2258/01: Engine exhaust gases
- F01N 3/101: {Three-way catalysts}
- F01N 3/2803: {characterised by structure, by material or by manufacturing of catalyst support}
- F01N 2370/02: used in catalytic reactors
- F01N 2510/0684: having more than one coating layer, e.g. multi-layered coatings
- 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)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- 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

An exhaust gas purification catalyst includes a substrate and a catalyst layer on the substrate. The catalyst layer includes lower and upper catalyst layers. The lower catalyst layer includes a powder material containing a powdered carrier, and catalyst metal particles containing Rh on the carrier. The upper catalyst layer includes an upstream catalyst layer in an upstream side in an exhaust gas flow direction, and a downstream catalyst layer in a downstream side in the exhaust gas flow direction. At least the upstream catalyst layer of the upstream and downstream catalyst layers includes a powder material containing a powdered carrier, and catalyst metal particles containing Pd on the carrier. A cumulative 50% particle size D50 in a volume-based particle size distribution of the powder material included in at least the upstream catalyst layer of the upstream and downstream catalyst layers is 6 μm or more and 10 μm or less.

## Claims

### Claim 1

An exhaust gas purification catalyst comprising:
a substrate; and
a catalyst layer disposed on the substrate,
wherein the catalyst layer includes a lower catalyst layer disposed on the substrate, and an upper catalyst layer disposed on the lower catalyst layer,
wherein the lower catalyst layer includes a powder material containing a powdered carrier, and catalyst metal particles containing Rh supported on the carrier,
wherein the upper catalyst layer includes an upstream catalyst layer disposed in an upstream side in an exhaust gas flow direction, and a downstream catalyst layer disposed in a downstream side in the exhaust gas flow direction,
wherein at least the upstream catalyst layer of the upstream catalyst layer and the downstream catalyst layer includes a powder material containing a powdered carrier, and catalyst metal particles containing Pd supported on the carrier, and
wherein a cumulative 50% particle size D50 in a volume-based particle size distribution of the powder material included in at least the upstream catalyst layer of the upstream catalyst layer and the downstream catalyst layer is 6 μm or more and 10 μm or less.

### Claim 2 (depends on 1)

The exhaust gas purification catalyst according to claim 1,
wherein a proportion of a weight of the catalyst metal particles included in the upstream catalyst layer to a weight of the catalyst metal particles included in the upper catalyst layer is 50 weight % or more and 90 weight % or less.

### Claim 3 (depends on 1)

The exhaust gas purification catalyst according to claim 1,
wherein a proportion of a length in an axial direction of the upstream catalyst layer to a length in the axial direction of the substrate is 30% or more and 70% or less.