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Patent US5332554A successfully refreshed from Google Patents.
US5332554A
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US
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Exhaust purifying catalyst for use in an internal combustion engine and method of manufacturing same
Assignee: Mazda Motor Corp
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Filing: 1992-10-14
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Granted: 1994-07-26
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Expires: 2012-10-14
Abstract
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.
Inventors
- 👤 Shigeru Yasaki
- 👤 Yasutaka Yoshino
- 👤 Kazunori Ihara
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 18:30
CPC Classifications
B; B01; B01D; B01D53/00; B01D53/34; B01D53/92; B01D53/94; B01D53/9445; B01D53/945; F; F01; F01N; F01N13/00; F01N13/009; F01N13/0097; F01N3/00; F01N3/08; F01N3/10; F01N3/24; F01N3/28; F01N3/2803; F01N3/2825; F01N3/2828; F01N2330/00; F01N2330/06; F01N2510/00; F01N2510/06; Y; Y02; Y02A; Y02A50/00; Y02A50/20; Y02T; Y02T10/00; Y02T10/10; Y02T10/12
Claims Analysis
Total Claims: 19
Claim 1
Independent Claim
257 words
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.
Claim 2
Dependent Claim
257 words
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.
Claim 3
Dependent Claim
18 words
A device as claimed in claim 1, wherein said non-palladium layer includes platinum and rhodium as catalyst components.
Claim 4
Dependent Claim
14 words
A device as claimed in claim 1, wherein said non-palladium layer contains no palladium.
Claim 5
Dependent Claim
26 words
A device as claimed in claim 1, wherein said non-palladium layer contains palladium at a concentration lower than said concentration of palladium in said palladium-supporting layer.
Claim 6
Dependent Claim
45 words
A device as claimed in claim 1, wherein said catalyst coating layer includes a first layer of alumina containing platinum and rhodium and a second layer of cerium oxide formed on said first layer, and wherein said palladium-supporting layer is formed in said second layer.
Claim 7
Dependent Claim
37 words
A device as claimed in claim 1, wherein said amount of palladium in said palladium-supporting layer is from 0.5 g/l to 1.0 g/l, and said thickness of said palladium-supporting layer is from 2 mm to 5 mm.
Claim 8
Dependent Claim
30 words
A device as claimed in claim 1, wherein said palladium-supporting layer is located in an upstreammost end of said catalyst coating layer, relative to the flow of exhaust gas therethrough.
Claim 9
Dependent Claim
24 words
A device as claimed in claim 1, wherein said at least one catalytic material is selected from a group consisting of platinum and rhodium.
Claim 10
Dependent Claim
22 words
A device as claimed in claim 1, wherein said thickness of said palladium-supporting layer is substantially uniform transversely of said longitudinal axis.
Claim 11
Dependent Claim
274 words
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.
Claim 12
Dependent Claim
274 words
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.
Claim 13
Dependent Claim
18 words
A device as claimed in claim 10, wherein said non-palladium layer includes platinum and rhodium as catalyst components.
Claim 14
Dependent Claim
14 words
A device as claimed in claim 10, wherein said non-palladium layer contains no palladium.
Claim 15
Dependent Claim
26 words
A device as claimed in claim 10, wherein said non-palladium layer contains palladium at a concentration lower than said concentration of palladium in said palladium-supporting layer.
Claim 16
Dependent Claim
21 words
A device as claimed in claim 10, wherein said thickness of said palladium-supporting layer is from 2 mm to 7 mm.
Claim 17
Dependent Claim
37 words
A device as claimed in claim 14, wherein said amount of palladium in said palladium-supporting layer is from 0.5 g/l to 1.0 g/l, and said thickness of said palladium-supporting layer is from 2 mm to 5 mm.
Claim 18
Dependent Claim
30 words
A device as claimed in claim 10, wherein said palladium-supporting layer is located in an upstreammost end of said catalyst coating layer, relative to the flow of exhaust gas therethrough.
Claim 19
Dependent Claim
24 words
A device as claimed in claim 10, wherein said at least one catalytic material is selected from a group consisting of platinum and rhodium.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1997-07-25 | 1998-01-24 | 1998-07-26 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-07-25 | 2002-01-24 | 2002-07-26 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-07-25 | 2006-01-24 | 2006-07-26 | $7700.00 | Window Closed / Lapsed |