Exhaust purifying catalyst for use in an internal combustion engine and method of manufacturing same
AssigneesTokyo Roki Co., Ltd., Mazda Motor Corporation
InventorsShigeru Yasaki, Yasutaka Yoshino, Kazunori Ihara
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Abstract
An exhaust gas purifying catalyst for use in an internal combustion engine includes a porous monolithic carrier, a catalyst coating layer formed on a surface of the monolithic carrier and containing a catalytic material capable of purifying exhaust gases, and a palladium-supporting layer formed in the catalyst coating layer at a location close to an exhaust gas inlet end of the monolithic carrier. Palladium is distributed at a high concentration in the palladium-supporting layer.
Claims17
An exhaust gas purifying device for use in an internal combustion engine, said device comprising:
- an exhaust gas manifold;
- a first converter disposed downstream from said exhaust gas manifold and communicating therewith, said first converter accommodating a catalyst for performing pretreatment with respect to exhaust gases;
- and
- a second converter disposed downstream from said first converter and communicating therewith, said second converter accommodating at least one exhaust gas purifying catalyst comprising:
- a porous monolithic carrier having opposite exhaust gas inlet and outlet ends and a longitudinal axis;
- a catalyst coating layer formed on a surface of said monolithic carrier and containing a catalytic material capable of purifying exhaust gases;
- and
- said catalyst coating layer including, at an upstream side thereof relative to a direction of flow of exhaust gases and at a location at said exhaust gas inlet end of said monolithic carrier, a palladium-supporting layer having a thickness of from 2 mm to 7 mm in a direction of said longitudinal axis and having palladium as a catalytic material, said palladium-supporting layer having an upstream end located at said exhaust gas inlet end of said monolithic carrier, said palladium being distributed substantially uniformly in said palladium-supporting layer at a high concentration in an amount of from 0.35 g/l to 1.0 g/l, said catalyst coating layer further including a non-palladium layer adjoining said palladium-supporting layer at said downstream end thereof, said non-palladium layer including at least one catalytic material other than palladium, and the palladium concentration of said catalyst coating layer being greatest in said palladium-supporting layer.
An exhaust gas purifying device for use in an internal combustion engine, said device comprising:
- an exhaust gas manifold;
- a first converter disposed downstream from said exhaust gas manifold and communicating therewith, said first converter accommodating a catalyst for performing pretreatment with respect to exhaust gases;
- and
- a second converter disposed downstream from said first converter and communicating therewith, said second converter accommodating at least one exhaust gas purifying catalyst comprising:
- a porous monolithic carrier having opposite exhaust gas inlet and outlet ends and a longitudinal axis;
- a first catalyst coating layer formed on a surface of said monolithic carrier and containing a catalytic material capable of purifying exhaust gases;
- a second catalyst coating layer formed on a surface of said first catalyst coating layer;
- and
- said second catalyst coating layer including, at an upstream end thereof relative to a direction of flow of exhaust gases and at a location at said exhaust gas inlet end of said monolithic carrier, a palladium-supporting layer having a substantially uniform thickness in a direction of said longitudinal axis of said monolithic carrier and having palladium as a catalytic material, said palladium-supporting layer having an upstream end located at said exhaust gas inlet end of said monolithic carrier, said palladium being distributed substantially uniformly in said palladium-supporting layer at a high concentration in an amount of from 0.35 g/l to 1.0 g/l, said catalyst coating layer further including a non-palladium layer adjoining said palladium-supporting layer at said downstream end thereof, said non-palladium layer including at least one catalytic material other than palladium, and the palladium concentration of said second catalyst coating layer being greatest in said palladium-supporting layer.
Dependencies are inferred from the claim text.