# US 8,465,703 B2 · Filter catalyst and method of analyzing a catalytic layer thereof

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- Number: US 8,465,703 B2
- Document ID: US8465703B2
- Status: Granted
- Kind: B2
- Application number: 10/568,429
- Filed: 2005-02-10
- Published: 2007-01-04
- Granted: 2013-06-18
- Earliest claimed: 2004-02-10
- Assignees: Cataler Corporation; Toyota Jidosha Kabushiki Kaisha
- Applicants: Makoto Tsuji; Daisuke Oki; Juji Suzuki
- Inventors: Makoto Tsuji; Daisuke Oki; Juji Suzuki
- Web page: https://patentgrep.com/patent/US8465703B2

## CPC

- B01D 53/9454: {characterised by a specific device}
- B01J 23/42: Platinum
- B01J 37/0215: {Coating}
- B01J 37/0242: {Coating followed by impregnation}
- B01J 21/063: {Titanium; Oxides or hydroxides thereof}
- B01J 35/30: characterised by their physical properties
- B01J 35/56: Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths
- B01J 2235/30: Scanning electron microscopy; Transmission electron microscopy
- Y02T 10/12: Improving ICE efficiencies
- 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
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

To provide a filter catalyst in which the closure of ventilation holes by a catalytic layer is inhibited. A filter catalyst of the present is characterized in that, in a filter catalyst comprising: a catalyst-support substrate; and a catalytic layer; an SEM photograph on a cross section of the filter catalyst is turned into electronic data so that, in a processed image in which image processing is performed to the SEM photograph, a ratio of a number of pixels forming an outer periphery of the catalytic layer to a number of pixels forming the catalytic layer is 0.5 or more. An analyzing method of the present invention finds a ratio a number of pixels forming an outer periphery of the catalytic layer to a number of pixels forming the catalytic layer by performing image processing to a cross section of the filter catalyst. The filter catalyst of the present invention has an effect of being capable of inhibiting the rise of pressure loss when sufficient particulates deposit. Moreover, the analyzing method of the present invention can analyze the uniformity of the catalytic layer of the filter catalyst.

## Claims

### Claim 1

A filter catalyst comprising: a catalyst-support substrate comprising a heat-resistant porous structure having chained pores; and a catalytic layer for burning particulates, the catalytic layer formed on a surface of the catalyst-support substrate; the filter catalyst being characterized in that an SEM photograph on a cross section of the filter catalyst is turned into electronic data so that, in an image being turned into electronic data, a ratio of a number of pixels forming an outer periphery of the catalytic layer to a number of pixels forming the catalytic layer is 0.5 or more; wherein: forming the catalytic layer comprises removing excess oxide slurry by repeating a pressure fluctuation at both ends of the catalyst-support substrate; and particles forming the oxide slurry having a diameter of 1 μm or less are present in an amount of 70% or more by weight of an entire amount of particles forming the oxide slurry.

### Claim 2

A method of analyzing a catalytic layer of a filter catalyst comprising: comprising turning an SEM photograph on a cross section of the filter catalyst into electronic data so that, in an image being turned into electronic data, a coated state is analyzed from a ratio of a number of pixels forming an outer periphery of the catalytic layer to a number of pixels forming the catalytic layer; wherein the filter catalyst comprises: a catalyst-support substrate comprising a heat-resistant porous structure having chained pores; and a catalytic layer for burning particulates, the catalytic layer formed on a surface of the catalyst-support substrate, wherein: forming the catalytic layer comprises removing excess oxide slurry by repeating a pressure fluctuation at both ends of the catalyst-support substrate, and particles forming the oxide slurry having a diameter of 1 μm or less are present in an amount of 70% or more by weight of an entire amount of particles forming the oxide slurry.

### Claim 3 (depends on 1)

The filter catalyst set forth in claim 1, wherein the catalytic layer is formed in a loading amount of 150 g/1-liter to 200 g/1-liter apparent volume of the catalyst-support substrate.

### Claim 4 (depends on 1)

The filter catalyst set forth in claim 1, wherein the diameter of the particles forming the slurry is 1 μm or less.

### Claim 5

A method of analyzing a catalytic layer of a filter catalyst comprising turning an SEM photograph on a cross section of the filter catalyst into electronic data so that, in an image being turned into electronic data, a coated state is analyzed from a ratio of a number of pixels forming an outer periphery of the catalytic layer to a number of pixels forming the catalytic layer;
wherein the filter catalyst comprises:
a catalyst-support substrate of comprising a heat-resistant porous structure having chained pores; and
a catalytic layer for burning particulates, the catalytic layer formed on a surface of the catalyst-support substrate, wherein:
forming the catalytic layer comprises removing excess slurry by repeating a pressure fluctuation at both ends of the catalyst-support substrate, and
particles forming the slurry having a diameter of 1 μm or less are present in an amount of 70% or more by weight of an entire amount of particles forming the slurry.

### Claim 6 (depends on 5)

The method of analyzing a catalytic layer of a filter catalyst set forth in claim 5, wherein said image being turned into the electronic data is an image with 1-to-3-μm/pixel magnification.

### Claim 7 (depends on 5)

The method of analyzing a catalytic layer of a filter catalyst set forth in claim 5, wherein the catalytic layer is formed in a loading amount of 150 g/1-liter to 200 g/1-liter apparent volume of the catalyst-support substrate.

### Claim 8

A filter catalyst comprising: a catalyst-support substrate comprising a heat-resistant porous structure having chained pores; and a catalytic layer for burning particulates, the catalytic layer formed on a surface of the catalyst-support substrate; wherein: a ratio of an outer peripheral length of the catalytic layer in the cross section of the filter catalyst to a cross-sectional area of the catalytic layer is 0.5 or more; forming the catalytic layer comprises removing excess oxide slurry by repeating a pressure fluctuation at both ends of the catalyst-support substrate, substrate; and particles forming the oxide slurry having a diameter of 1 μm or less are present in an amount of 70% or more by weight of an entire amount of particles forming the oxide slurry.