JP5024219B2 - Exhaust gas purification catalyst body and exhaust gas purification device - Google Patents

Exhaust gas purification catalyst body and exhaust gas purification device Download PDF

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JP5024219B2
JP5024219B2 JP2008190613A JP2008190613A JP5024219B2 JP 5024219 B2 JP5024219 B2 JP 5024219B2 JP 2008190613 A JP2008190613 A JP 2008190613A JP 2008190613 A JP2008190613 A JP 2008190613A JP 5024219 B2 JP5024219 B2 JP 5024219B2
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catalyst component
exhaust gas
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carrier
central
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JP2010022996A (en
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邦裕 小島
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Denso Corp
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Description

本発明は、自動車等の内燃機関の排気ガスを浄化する排気ガス浄化用触媒体およびそれを備える排気ガス浄化装置に関するものである。 The present invention relates to an exhaust gas purifying catalyst body for purifying exhaust gas of an internal combustion engine such as an automobile, and an exhaust gas purifying apparatus including the same.

排気ガス浄化用の触媒成分を担体に担持した触媒体において、排気ガス流れ方向からみた担体の中央部とその周縁域である周縁部とのうち、周縁部での触媒成分の担持量を中央部よりも少なくすることで、触媒成分の無駄を省いた経済的な触媒体を提供する技術が特許文献１に開示されている。これは、特許文献１の図２のガス流速分布に示されるように、触媒体を通過する排気ガスの流量は、触媒体の中央部では多く、周縁部では少ないという事実に基づくものである。
特開平１０−２８０９５１号公報 In the catalyst body supporting the exhaust gas purification catalyst component on the carrier, the amount of catalyst component supported on the peripheral portion of the central portion of the carrier viewed from the exhaust gas flow direction and the peripheral portion of the peripheral portion is the central portion. Patent Document 1 discloses a technique for providing an economical catalyst body that reduces waste of catalyst components by reducing the amount of the catalyst component. This is based on the fact that, as shown in the gas flow velocity distribution of FIG. 2 of Patent Document 1, the flow rate of the exhaust gas passing through the catalyst body is large in the central portion and small in the peripheral portion.
JP-A-10-280951

しかし、特許文献１に記載の技術では、排気ガスの流れ方向全域に渡って触媒体の周縁部における触媒成分の担持量を少なくしているので、触媒体の周縁部での浄化性能が低下してしまう恐れがある。   However, in the technique described in Patent Document 1, since the amount of the catalyst component supported on the peripheral portion of the catalyst body is reduced over the entire exhaust gas flow direction, the purification performance at the peripheral portion of the catalyst body is reduced. There is a risk that.

すなわち、特許文献１では、排気ガスの流れ方向全域に渡って、周縁部での触媒成分の担持量を、中央部での担持量の約半分の量としている。このため、エンジン運転状態が低負荷時のように周縁部での排気ガスの流量が少ない場合であれば、周縁部を通過する排気ガスの浄化が可能だが、エンジン運転状態が高負荷時のように、触媒体を通過する排気ガスの流量が全体的に多くなって周縁部での排気ガスの流量が多くなる場合では、周縁部を通過する排気ガスの浄化が不可能となる恐れがある。   That is, in Patent Document 1, the amount of the catalyst component supported at the peripheral portion is about half of the amount supported at the central portion over the entire exhaust gas flow direction. For this reason, if the flow rate of the exhaust gas at the peripheral portion is small, such as when the engine is operating at a low load, the exhaust gas passing through the peripheral portion can be purified. In addition, when the flow rate of exhaust gas passing through the catalyst body increases as a whole and the flow rate of exhaust gas at the peripheral portion increases, purification of the exhaust gas passing through the peripheral portion may not be possible.

本発明は上記点に鑑みて、触媒体の周縁部を流れる排気ガスに対する浄化性能の低下を抑制しつつ、触媒成分の担持量の低減化を図ることを目的とする。   In view of the above points, an object of the present invention is to reduce the amount of catalyst components supported while suppressing a decrease in purification performance with respect to exhaust gas flowing around the periphery of a catalyst body.

上記目的を達成するため、請求項１、２、８に記載の発明では、担体（２）は、一端（２ａ）から貫通孔の延伸方向で所定長さの範囲である一端側部分（４）と、担体（２）のうち一端側部分（４）を除いた範囲である他端側部分（５）とを有し、他端側部分（５）では、貫通孔の延伸方向からみた中央部（５ａ）と中央部（５ａ）の周縁に位置する周縁部（５ｂ）とのうち、中央部（５ａ）のみに触媒成分が担持されており、もしくは、周縁部（５ｂ）は中央部（５ａ）よりも少ない量の触媒成分が担持されており、一端側部分（４）では、貫通孔の延伸方向からみた中央部（４ａ）と中央部（４ａ）の周縁に位置する周縁部（４ｂ）とにおける触媒成分の担持量が、他端側部分（５）の中央部（５ａ）における触媒成分の担持量と同等以上となっている。
そして、請求項１に記載の発明では、一端側部分（４）において、中央部（４ａ）における触媒成分の担持量が周縁部（４ｂ）における触媒成分の担持量よりも多くなっていることを特徴としている。
また、請求項２に記載の発明では、一端部側部分（４）の周縁部（４ｂ）に担持される触媒成分と、他端部側部分（５）の中央部（５ａ）に担持される触媒成分として、それぞれ、異なる貴金属元素が用いられていることを特徴としている。
また、請求項８に記載の発明では、一端側部分は、担体（２）の排気ガス流れの上流側端部（２ａ）から所定長さ（Ｌ１）の範囲である上流部（４）であり、他端側部分は、上流部（４）よりも排気ガス流れの下流側に位置する下流部（５）であることを特徴としている。
また、請求項３に記載の発明では、担体（２）は、一端（２ａ）から貫通孔の延伸方向で所定長さの範囲である一端側部分（４）と、担体（２）のうち一端側部分（４）を除いた範囲である他端側部分（５）とを有し、他端側部分（５）では、貫通孔の延伸方向からみた中央部（５ａ）と中央部（５ａ）の周縁に位置する周縁部（５ｂ）とのうち、中央部（５ａ）のみに触媒成分が担持されており、もしくは、周縁部（５ｂ）は中央部（５ａ）よりも少ない量の触媒成分が担持されており、一端側部分（４）では、貫通孔の延伸方向からみた中央部（４ａ）と中央部（４ａ）の周縁に位置する周縁部（４ｂ）とにおける触媒成分の担持量が、他端側部分（５）の中央部（５ａ）における触媒成分の担持量よりも多くなっていることを特徴としている。 In order to achieve the above object, in the inventions according to claims 1 , 2 , and 8 , the carrier (2) has a predetermined length in the extending direction of the through hole from the one end (2 a). And the other end side portion (5) which is a range excluding the one end side portion (4) of the carrier (2), and the other end side portion (5) has a central portion viewed from the extending direction of the through hole. (5a) and the peripheral part (5b) located at the peripheral edge of the central part (5a), the catalyst component is supported only in the central part (5a), or the peripheral part (5b) is the central part (5a). ) And a peripheral part (4b) positioned at the peripheral part of the central part (4a) and the central part (4a) as viewed from the extending direction of the through hole. The amount of catalyst component supported on the other end side portion (5) is equal to or less than the amount of catalyst component supported on the central portion (5a) It is on .
And in invention of Claim 1, in one end side part (4), it is that the carrying amount of the catalyst component in the center part (4a) is larger than the carrying amount of the catalyst component in a peripheral part (4b). It is a feature.
Moreover, in invention of Claim 2, it is carry | supported by the catalyst component carry | supported by the peripheral part (4b) of the one end part side part (4), and the center part (5a) of the other end part side part (5). As the catalyst component, different noble metal elements are used, respectively.
In the invention according to claim 8, the one end side portion is the upstream portion (4) that is within a predetermined length (L1) from the upstream end portion (2a) of the exhaust gas flow of the carrier (2). The other end portion is a downstream portion (5) located downstream of the upstream portion (4) in the exhaust gas flow.
In the invention according to claim 3, the carrier (2) has one end side portion (4) having a predetermined length in the extending direction of the through hole from one end (2a) and one end of the carrier (2). The other end portion (5) is a range excluding the side portion (4), and the other end portion (5) has a central portion (5a) and a central portion (5a) as viewed from the extending direction of the through hole. The catalyst component is supported only in the central portion (5a) of the peripheral portion (5b) located at the peripheral portion of the peripheral portion, or the peripheral portion (5b) has a smaller amount of catalyst component than the central portion (5a). In the one end side portion (4), the supported amount of the catalyst component in the central portion (4a) viewed from the extending direction of the through hole and the peripheral portion (4b) located at the peripheral edge of the central portion (4a) is It is characterized in that it is larger than the supported amount of catalyst component in the central part (5a) of the other end side part (5). There.

これらによれば、担体の他端側部分においては、中央部のみに触媒成分を担持させて周縁部には触媒成分を担持させないようにし、もしくは、周縁部での触媒成分の担持量を中央部での担持量よりも少なくしているので、担体全域に触媒成分を担持する場合よりも触媒成分の担持量を低減できる。 According to these, the other end portion of the carrier, at the peripheral portion by supporting the catalyst component only in the central portion so as not to support the catalyst component, or, the amount of supported catalyst component in the periphery center Therefore, the amount of the catalyst component supported can be reduced as compared with the case where the catalyst component is supported on the entire support.

その一方で、担体の一端側部分においては、中央部と周縁部の両方に他端側部分の中央部と同等以上の（請求項３に記載の発明では、他端側部分の中央部よりも多い）量の触媒成分を担持させているので、特許文献１に記載の技術のように、排気ガスの流れ方向全域に渡って触媒体の周縁部における触媒成分の担持量を中央部よりも少なくする場合と比較して、触媒体の周縁部を流れる排気ガスに対する浄化性能の低下を抑制できる。 On the other hand, in the one end side portion of the carrier, both the central portion and the peripheral portion are equal to or more than the central portion of the other end side portion (in the invention according to claim 3, than the central portion of the other end side portion). Since a large amount of catalyst component is supported, the amount of catalyst component supported in the peripheral portion of the catalyst body is smaller than that in the central portion over the entire exhaust gas flow direction as in the technique described in Patent Document 1. Compared with the case where it does, the fall of the purification performance with respect to the exhaust gas which flows through the peripheral part of a catalyst body can be suppressed.

また、請求項１ないし３のいずれか１つに記載の発明においては、例えば、請求項４のように、一端側部分（４）は、一端（２ａ）からの所定長さ（Ｌ１）が、担体（２）の貫通孔の延伸方向での全長（Ｌ２）の１／３以上２／３以下の長さであり、一端側部分（４）および他端側部分（５）における中央部（４ａ、５ａ）は、貫通孔の延伸方向に垂直な断面での中心から端部までの距離（Ｒ１）が、担体（２）における貫通孔の延伸方向に垂直な断面での中心から外周端までの距離（Ｒ２）の１／３以上２／３以下の長さである構成を採用できる。 In the invention according to any one of claims 1 to 3, for example, as in claim 4 , the one end side portion (4) has a predetermined length (L1) from one end (2a), The length of the entire length (L2) in the extending direction of the through hole of the carrier (2) is not less than 1/3 and not more than 2/3, and the central portion (4a) in the one end side portion (4) and the other end side portion (5) 5a), the distance (R1) from the center to the end of the cross section perpendicular to the extending direction of the through hole is from the center to the outer peripheral end of the cross section perpendicular to the extending direction of the through hole in the carrier (2). A configuration having a length of 1/3 or more and 2/3 or less of the distance (R2) can be employed.

また、請求項２または３に記載の発明においては、例えば、請求項５のように、一端側部分（４）では、中央部（４ａ）における触媒成分の担持量が周縁部（４ｂ）における触媒成分の担持量よりも多い構成を採用できる。 In the invention described in claim 2 or 3, for example, as in claim 5 , in the one end side portion (4), the amount of the catalyst component supported in the central portion (4a) is the catalyst in the peripheral portion (4b). It is possible to employ a configuration that is larger than the amount of components supported.

また、請求項１または３に記載の発明においては、例えば、請求項６のように、一端部側部分（４）の周縁部（４ｂ）に担持される触媒成分と、他端部側部分（５）の中央部（５ａ）に担持される触媒成分として、それぞれ、異なる貴金属元素が用いられている構成を採用できる。 Moreover, in invention of Claim 1 or 3, for example, like Claim 6 , the catalyst component carry | supported by the peripheral part (4b) of the one end part side part (4), and the other end part side part ( As the catalyst component supported on the central portion (5a) of 5), it is possible to adopt a configuration in which different noble metal elements are used.

また、請求項２または６に記載の発明においては、例えば、請求項７のように、一端部側部分（４）の周縁部（４ｂ）に担持される触媒成分として、Ｐｄ、ＰｔおよびＲｈのうちＰｄのみが用いられ、他端部側部分（５）の中央部（５ａ）に担持される触媒成分として、Ｐｄ、ＰｔおよびＲｈのうち、Ｐｄを除き、ＰｔとＲｈの少なくとも一方が用いられている構成を採用できる。 Further, in the invention described in claim 2 or 6, for example, as in claim 7 , Pd, Pt, and Rh are used as catalyst components supported on the peripheral portion (4b) of the one end portion (4). Among them, only Pd is used, and at least one of Pt and Rh is used as the catalyst component supported on the central portion (5a) of the other end side portion (5) except for Pd, Pt and Rh. Can be adopted.

なお、この欄および特許請求の範囲で記載した各手段の括弧内の符号は、後述する実施形態に記載の具体的手段との対応関係を示すものである。   In addition, the code | symbol in the bracket | parenthesis of each means described in this column and the claim shows the correspondence with the specific means as described in embodiment mentioned later.

（第１実施形態）
本実施形態は、自動車の排気ガス浄化用触媒体に本発明を適用した例である。 (First embodiment)
This embodiment is an example in which the present invention is applied to an exhaust gas purifying catalyst body of an automobile.

図１に本発明の第１実施形態における触媒体の斜視図を示し、図２に図１中の触媒体の中心線を含む触媒体の縦断面図を示す。また、図３（ａ）に図２中のＡ−Ａ’線断面図を示し、図３（ｂ）に図２中のＡ−Ａ’線部分における触媒担持密度分布を示す。また、図４（ａ）に図２中のＢ−Ｂ’線断面図を示し、図４（ｂ）に図２中のＢ−Ｂ’線部分における触媒担持密度分布を示す。   FIG. 1 shows a perspective view of the catalyst body in the first embodiment of the present invention, and FIG. 2 shows a longitudinal sectional view of the catalyst body including the center line of the catalyst body in FIG. FIG. 3A shows a cross-sectional view taken along the line A-A ′ in FIG. 2, and FIG. 3B shows the catalyst loading density distribution along the line A-A ′ in FIG. 2. Further, FIG. 4A shows a cross-sectional view taken along line B-B ′ in FIG. 2, and FIG. 4B shows a catalyst loading density distribution in the B-B ′ line portion in FIG. 2.

図１に示すように、本実施形態の触媒体１は、外形が円柱形状である担体２に排気ガス浄化用の触媒成分が担持されている。   As shown in FIG. 1, in the catalyst body 1 of this embodiment, a catalyst component for purifying exhaust gas is supported on a carrier 2 having an outer shape that is cylindrical.

担体２は、一端から他端、例えば、図１中の左側端部から右側端部に向かって延伸する複数の貫通孔３を有するハニカム構造である。本実施形態では、貫通孔３の延伸方向が担体２の長手方向となっている。図１中の左側端部が担体２の排気ガス流れの上流側端部２ａであり、図１中の右側端部が担体２の排気ガス流れの下流側端部２ｂであり、図中左側から右側に向かって排気ガスが貫通孔３を通過する。貫通孔３を構成する壁面（内面）に触媒成分が担持されている。   The carrier 2 has a honeycomb structure having a plurality of through holes 3 extending from one end to the other end, for example, from the left end portion to the right end portion in FIG. In the present embodiment, the extending direction of the through hole 3 is the longitudinal direction of the carrier 2. The left end in FIG. 1 is the upstream end 2a of the exhaust gas flow of the carrier 2, and the right end in FIG. 1 is the downstream end 2b of the exhaust gas flow of the carrier 2, from the left in the figure. The exhaust gas passes through the through hole 3 toward the right side. A catalyst component is supported on the wall surface (inner surface) constituting the through hole 3.

図２では担体２における斜線領域が触媒成分の担持領域を示している。図２に示すように、担体２における触媒成分の担持領域は、担体２の上流部４と下流部５とで異なっており、担体２の中心線を通る縦断面ではＴ字状となっている。ここで、上流部４は、担体２のうち上流側端部２ａから貫通孔３の延伸方向（担体２の長手方向）での所定長さＬ１の範囲を占める部分である。下流部５は、担体２のうち上流部４を除いた範囲の部分であり、上流部４よりも排気ガス流れの下流側に位置する部分である。   In FIG. 2, the hatched area in the carrier 2 indicates the catalyst component loading area. As shown in FIG. 2, the catalyst component loading region in the carrier 2 is different between the upstream portion 4 and the downstream portion 5 of the carrier 2, and has a T-shape in a longitudinal section passing through the center line of the carrier 2. . Here, the upstream portion 4 is a portion that occupies a range of a predetermined length L1 in the extending direction of the through hole 3 (longitudinal direction of the carrier 2) from the upstream end 2a of the carrier 2. The downstream portion 5 is a portion of the carrier 2 excluding the upstream portion 4, and is a portion located on the downstream side of the exhaust gas flow from the upstream portion 4.

まず、下流部５では、図４（ａ）、（ｂ）に示すように、担体２の横断面において、貫通孔３の延伸方向からみた中央部５ａと、中央部５ａの周縁に位置する周縁部５ｂとのうち、中央部５ａのみに触媒成分が担持されており、周縁部５ｂには触媒成分が担持されていない。   First, in the downstream portion 5, as shown in FIGS. 4A and 4B, in the cross section of the carrier 2, a central portion 5 a viewed from the extending direction of the through-hole 3 and a peripheral edge located at the peripheral edge of the central portion 5 a Of the portion 5b, the catalyst component is supported only on the central portion 5a, and no catalyst component is supported on the peripheral portion 5b.

一方、上流部４では、全領域に触媒成分が担持されているが、図３（ａ）に示すように、中央部４ａと周縁部４ｂとでは触媒成分の担持量が異なっている。具体的には、図３（ｂ）に示すように、中央部４ａでの触媒成分の担持密度は、周縁部４ｂでの触媒成分の担持密度よりも高いｄ２であり、周縁部４ｂでの触媒成分の担持密度は、図３（ｂ）、図４（ｂ）に示されるように、下流部５の中央部５ａにおける触媒成分の担持密度と同じｄ１である。すなわち、中央部４ａと周縁部４ｂとにおける触媒成分の担持量は、下流部５の中央部５ａにおける触媒成分の担持量と同等以上となっている。   On the other hand, in the upstream portion 4, the catalyst component is supported in the entire region, but as shown in FIG. 3A, the supported amount of the catalyst component is different between the central portion 4a and the peripheral portion 4b. Specifically, as shown in FIG. 3B, the support density of the catalyst component at the central portion 4a is d2 higher than the support density of the catalyst component at the peripheral portion 4b, and the catalyst at the peripheral portion 4b. The component loading density is d1 which is the same as the catalyst component loading density in the central portion 5a of the downstream portion 5, as shown in FIGS. 3 (b) and 4 (b). That is, the loading amount of the catalyst component at the central portion 4a and the peripheral edge portion 4b is equal to or greater than the loading amount of the catalyst component at the central portion 5a of the downstream portion 5.

このように、上流部４では、担体２の横断面における全域に渡って触媒成分が担持されている。これにより、触媒体１に流入する排気ガスを担体２の横断面全域で受け止めて、触媒と必ず接触させることができ、触媒体１に流入する排気ガスが浄化されずに大気に放出されることを防止できる。   As described above, in the upstream portion 4, the catalyst component is supported over the entire region in the cross section of the carrier 2. As a result, the exhaust gas flowing into the catalyst body 1 can be received over the entire cross section of the carrier 2 and always brought into contact with the catalyst, and the exhaust gas flowing into the catalyst body 1 is released to the atmosphere without being purified. Can be prevented.

そして、下流部５では、中央部５ａのみに触媒成分が担持されている。これは、通常、触媒体２に排気ガスが流入するとき、担体２の中央部４ａ、５ａを排気ガスの主流が通過するため、排気ガスの主流を取りこぼし無く、十分に浄化させるためである。したがって、担体２の上流側端部２ａから下流側端部２ｂまでの全域に渡って、中央部４ａ、５ａに排気ガスの浄化に必要十分な量の触媒成分が集中して担持されている。   And in the downstream part 5, the catalyst component is carry | supported only at the center part 5a. This is because when the exhaust gas flows into the catalyst body 2, the main flow of the exhaust gas passes through the central portions 4a and 5a of the carrier 2, so that the main flow of the exhaust gas is not missed and is sufficiently purified. Therefore, a sufficient amount of catalyst components necessary for purifying the exhaust gas are concentrated and supported on the central portions 4a and 5a over the entire region from the upstream end 2a to the downstream end 2b of the carrier 2.

一方、下流部５の周縁部５ｂに流れる排気ガス量は中央部５ａよりも少なく、上流部４の周縁部４ｂに担持された触媒によって、触媒体１の周縁部に流入した排気ガスを浄化できるので、下流部５の周縁部５ｂでは触媒成分を担持していない。   On the other hand, the amount of exhaust gas flowing to the peripheral portion 5b of the downstream portion 5 is smaller than that of the central portion 5a, and the exhaust gas flowing into the peripheral portion of the catalyst body 1 can be purified by the catalyst carried on the peripheral portion 4b of the upstream portion 4. Therefore, the catalyst component is not supported on the peripheral edge portion 5b of the downstream portion 5.

なお、上流部４の長さＬ１は、触媒成分の担持量を低減しつつ、上流部４の周縁部４ｂに担持された触媒によって、触媒体１の周縁部に流入した排気ガスを十分に浄化させるという観点より、貫通孔の延伸方向での担体２の全長Ｌ２の１／３以上２／３以下の長さであることが好ましい。   The length L1 of the upstream portion 4 sufficiently purifies the exhaust gas flowing into the peripheral portion of the catalyst body 1 by the catalyst supported on the peripheral portion 4b of the upstream portion 4 while reducing the amount of catalyst component supported. From the viewpoint of making it, it is preferable that the length is 1/3 or more and 2/3 or less of the total length L2 of the carrier 2 in the extending direction of the through hole.

また、中央部４ａ、５ａは、担体２の横断面において、中心から所定距離の範囲の部分であり、担体２の横断面における排気ガスの主流が通過する範囲を考慮して、担体２の横断面での中心から端部までの距離Ｒ１が、担体２の横断面での中心から外周端までの距離Ｌ２の１／３以上２／３以下の長さであることが好ましい。   Further, the central portions 4a and 5a are portions within a predetermined distance from the center in the cross section of the carrier 2, and in consideration of the range through which the main flow of exhaust gas passes in the cross section of the carrier 2, It is preferable that the distance R1 from the center to the end on the surface is not less than 1/3 and not more than 2/3 of the distance L2 from the center to the outer peripheral end in the cross section of the carrier 2.

ここで、所定距離Ｒ１は、図２では一定となっているが、一定でなくても良い。すなわち、図３（ａ）、４（ａ）では、担体２の横断面をみたときの中央部４ａ、５ａと周縁部４ｂ、５ｂとの境界線を円形状としているが、境界線は必ずしも円形状でなくても良く、歪な形状となっても良い。   Here, the predetermined distance R1 is constant in FIG. 2, but may not be constant. That is, in FIGS. 3A and 4A, the boundary line between the central portions 4a and 5a and the peripheral edge portions 4b and 5b when the cross section of the carrier 2 is viewed is circular, but the boundary line is not necessarily circular. It may not be a shape, and may be a distorted shape.

次に、担体２および触媒成分について詳細に説明する。   Next, the carrier 2 and the catalyst component will be described in detail.

図５（ａ）に担体２の貫通孔の壁面付近の拡大図を示し、図５（ｂ）に図５（ａ）中の金属酸化物粒子２０の拡大図を示し、図５（ｃ）に図５（ｂ）中の触媒成分３０の拡大図を示す。   FIG. 5 (a) shows an enlarged view of the vicinity of the wall surface of the through hole of the carrier 2, FIG. 5 (b) shows an enlarged view of the metal oxide particles 20 in FIG. 5 (a), and FIG. 5 (c). The enlarged view of the catalyst component 30 in FIG.5 (b) is shown.

図５（ａ）、（ｂ）に示すように、触媒成分３０は、金属酸化物粒子２０を介して、担体２の貫通孔の壁面上に担持されている。   As shown in FIGS. 5A and 5B, the catalyst component 30 is supported on the wall surface of the through hole of the carrier 2 through the metal oxide particles 20.

担体２は、例えば、コーディエライトで構成されており、それ自体が多数の空孔１１を有している。担体２としては、例えば、一体成形されたモノリス（コーディエライトモノリス）を用いることができる。   The carrier 2 is made of, for example, cordierite and has a large number of holes 11 itself. As the carrier 2, for example, an integrally formed monolith (cordierite monolith) can be used.

金属酸化物粒子２０は、担体２の貫通孔の壁面上に３次元的に集積されている。この金属酸化物粒子２０は、図５（ｂ）に示すように、触媒成分３０よりも大きな粒子間隙よりなる細孔２２と、この細孔２２同士を連通させ、触媒成分３０よりも小さな粒子間隙よりなる連通細孔２３とを有している。そして、この細孔２２内に触媒成分３０が配置されており、触媒成分３０は金属酸化物粒子２０の表面に担持されている。   The metal oxide particles 20 are three-dimensionally accumulated on the wall surface of the through hole of the carrier 2. As shown in FIG. 5 (b), the metal oxide particles 20 have pores 22 each having a larger particle gap than the catalyst component 30, and the pores 22 communicate with each other, and a particle gap smaller than the catalyst component 30. It has the communicating pore 23 which consists of. A catalyst component 30 is disposed in the pores 22, and the catalyst component 30 is supported on the surface of the metal oxide particles 20.

金属酸化物粒子２０としては、ＣｅＯ２、ＺｒＯ２、Ａｌ２Ｏ３、ＴｉＯ２、ＳｉＯ２、ＭｇＯ、Ｙ２Ｏ３、Ｎｉ２Ｏ３、Ｗ２Ｏ３およびこれらの組成物から選ばれる一種または二種以上の化合物のうちのいずれかから構成されるものを採用することができる。 The metal oxide particle 20 is a kind selected from CeO 2 , ZrO 2 , Al 2 O 3 , TiO 2 , SiO 2 , MgO, Y 2 O 3 , Ni 2 O 3 , W 2 O 3 and these compositions. Or what consists of either of 2 or more types of compounds is employable.

触媒成分３０としては、例えば、図５（ｃ）に示すように、助触媒粒子３１の表面の少なくとも一部が被覆層３２によって覆われた粒子を採用できる。助触媒粒子３１は、ＣｅＯ２、ＣｅＯ２／ＺｒＯ２固溶体など希土類元素より選択される酸化物や複合酸化物からなり、被覆層３２は、一種類の貴金属や複数種類の貴金属元素を含む合金または酸化物、複合酸化物等の貴金属成分からなる。助触媒粒子３１の粒径は、例えば、３ｎｍ以上５０ｎｍ以下であり、望ましくは１０ｎｍ以下である。被覆層（貴金属成分）３２の厚さ（粒径）は、例えば、１０ｎｍ以下であり、望ましくは１ｎｍ以下である。なお、触媒成分３０としては、助触媒成分と貴金属成分とが単独で存在する状態のものを採用しても良く、助触媒成分を省略して貴金属成分のみによって構成されたものを採用しても良い。 As the catalyst component 30, for example, as shown in FIG. 5C, particles in which at least a part of the surface of the promoter particles 31 are covered with a coating layer 32 can be adopted. The cocatalyst particles 31 are made of an oxide or composite oxide selected from rare earth elements such as CeO 2 , CeO 2 / ZrO 2 solid solution, and the coating layer 32 is made of an alloy containing one kind of noble metal or plural kinds of noble metal elements. It consists of noble metal components such as oxides and composite oxides. The particle size of the promoter particles 31 is, for example, 3 nm or more and 50 nm or less, and desirably 10 nm or less. The thickness (particle diameter) of the coating layer (noble metal component) 32 is, for example, 10 nm or less, and desirably 1 nm or less. The catalyst component 30 may be one in which the promoter component and the noble metal component are present alone, or may be one composed only of the noble metal component with the promoter component omitted. good.

そして、本実施形態では、触媒体１の各部位で、用いている貴金属元素の種類が異なっている。すなわち、貴金属元素として、上流部４の周縁部４ｂではＰｄのみが用いられ、上流部の中央部４ａではＰｄとＰｔとが用いられ、下流部５の中央部５ａではＰｔのみが用いられている。なお、Ｐｔの代わりに、ＲｈもしくはＰｔとＲｈの両方を用いても良い。   In the present embodiment, the type of noble metal element used is different in each part of the catalyst body 1. That is, as the noble metal element, only Pd is used in the peripheral portion 4b of the upstream portion 4, Pd and Pt are used in the central portion 4a of the upstream portion, and only Pt is used in the central portion 5a of the downstream portion 5. . Note that Rh or both Pt and Rh may be used instead of Pt.

このように、上流部４では、触媒成分の貴金属元素としてＰｄを用いることにより、Ｐｄは他の貴金属元素と比較して触媒反応の着火性に優れるため、低温活性を向上することが可能である。さらには、Ｐｄによる上流部４での昇温効果は、下流部５に担持された触媒成分の昇温にも寄与するので、触媒体全体における低温活性を向上できる。   As described above, in the upstream portion 4, by using Pd as the noble metal element of the catalyst component, Pd is superior in ignitability of the catalytic reaction as compared with other noble metal elements, and therefore, the low temperature activity can be improved. . Furthermore, since the temperature rise effect at the upstream portion 4 by Pd also contributes to the temperature rise of the catalyst component carried on the downstream portion 5, the low temperature activity in the entire catalyst body can be improved.

本実施形態の触媒体１は、貴金属元素としてＰｔ、Ｐｄ、Ｒｈを用い、ＣｅＯ２、ＣｅＯ２／ＺｒＯ２固溶体などの助触媒を用いているので、触媒体全体として、自動車の排気ガスに含まれるＨＣ、ＣＯ、ＮＯｘ等の有害成分を浄化する三元触媒の機能を有している。 Catalyst body 1 of the present embodiment, Pt, Pd, and Rh is used as noble metal element, because of the use of co-catalysts such as CeO 2, CeO 2 / ZrO 2 solid solution, the whole catalyst, contained in the exhaust gas of an automobile It functions as a three-way catalyst that purifies harmful components such as HC, CO, and NOx.

次に、上記した構造の触媒体１の製造方法について説明する。   Next, a method for producing the catalyst body 1 having the above structure will be described.

まず、担体２としてのコーディエライトモノリスを用意し、担体２の全域に金属酸化物粒子を含浸法等によって担持する。担持方法として含浸法を採用する場合、金属酸化物粒子を分散したスラリー溶液に担体２を浸漬した後、乾燥、焼成することで、担体２の上流部４および下流部５の両方に渡って均一に金属酸化物粒子を担持させる。   First, a cordierite monolith as the carrier 2 is prepared, and metal oxide particles are supported on the entire region of the carrier 2 by an impregnation method or the like. When the impregnation method is adopted as the supporting method, the support 2 is immersed in a slurry solution in which metal oxide particles are dispersed, and then dried and fired, so that it is uniform over both the upstream portion 4 and the downstream portion 5 of the support 2. The metal oxide particles are supported on.

その後、上流部４に担持させるための触媒成分が分散された第１の触媒スラリー溶液を用意し、担体２のうち上流側端部２ａから所定長さＬ１までの部分をこのスラリー溶液中に浸漬し、乾燥させる。   Thereafter, a first catalyst slurry solution in which a catalyst component to be supported on the upstream portion 4 is dispersed is prepared, and a portion of the carrier 2 from the upstream end 2a to a predetermined length L1 is immersed in the slurry solution. And dry.

続いて、下流部５の中央部５ａに担持させるための触媒成分が分散された第２の触媒スラリー溶液を用意し、担体２の上流側端部２ａから担体２の中央部４ａ、５ａのみに、このスラリー溶液を流し込む。この方法としては、例えば、担体２の中央部４ａ、５ａに対応する所定の半径Ｒ１を有する円柱状のガイド冶具を担体２の上流側端面に設置し、このガイド治具に沿ってスラリー溶液を流し込む方法を採用することができる。その後、乾燥させ、焼成することで、上記した構造の触媒体１が得られる。   Subsequently, a second catalyst slurry solution in which a catalyst component to be supported on the central portion 5a of the downstream portion 5 is dispersed is prepared, and only the central portions 4a and 5a of the carrier 2 are provided from the upstream end portion 2a of the carrier 2. Pour the slurry solution. As this method, for example, a cylindrical guide jig having a predetermined radius R1 corresponding to the central portions 4a and 5a of the carrier 2 is installed on the upstream end surface of the carrier 2, and the slurry solution is poured along the guide jig. A pouring method can be adopted. Thereafter, the catalyst body 1 having the above-described structure is obtained by drying and firing.

本実施形態では、このように第２の触媒スラリー溶液を担体２の中央部４ａ、５ａに流し込む方法を採用することで、上流部４の中央部４ａに触媒成分を二重に担持させている。これにより、上流部４の中央部４ａに担持される触媒成分の担持密度を、上流部４の周縁部４ｂや下流部５の中央部５ａの担持密度よりも高くでき、触媒体１を通過する排気ガスの主流を効率良く浄化させることができる。   In the present embodiment, by adopting a method in which the second catalyst slurry solution is poured into the central portions 4a and 5a of the carrier 2 in this way, the catalyst component is supported twice on the central portion 4a of the upstream portion 4. . Thereby, the carrying density of the catalyst component carried by the central part 4a of the upstream part 4 can be made higher than the carrying density of the peripheral part 4b of the upstream part 4 and the central part 5a of the downstream part 5, and passes through the catalyst body 1. The main stream of exhaust gas can be purified efficiently.

なお、本実施形態では、触媒成分の担持の順番を、上流部４、下流部５の順としていたが順番を逆にしても良い。また、触媒成分の乾燥、焼成については、上流部４、下流部５で別々に行ったり、同時に行ったりしても良い。   In this embodiment, the loading order of the catalyst components is the order of the upstream part 4 and the downstream part 5, but the order may be reversed. Further, drying and firing of the catalyst component may be performed separately in the upstream portion 4 and the downstream portion 5 or may be performed simultaneously.

以上の説明の通り、本実施形態では、担体２の下流部５においては、中央部５ａのみに触媒成分を担持させて周縁部５ｂには触媒成分を担持させていないので、下流部５の中央部５ａと同量の触媒成分を担体２の全域に担持する場合と比較して、触媒成分の担持量を低減できる。   As described above, in the present embodiment, in the downstream portion 5 of the carrier 2, the catalyst component is supported only on the central portion 5a and the catalyst component is not supported on the peripheral portion 5b. Compared with the case where the same amount of catalyst component as that of the part 5a is supported on the entire area of the carrier 2, the amount of catalyst component supported can be reduced.

その一方で、担体２の上流部４においては、中央部４ａには下流部５の中央部５ａよりも多い量の触媒成分を担持させ、周縁部４ｂには下流部５の中央部５ａと同等の量の触媒成分を担持させている。   On the other hand, in the upstream part 4 of the carrier 2, the central part 4a carries a larger amount of catalyst component than the central part 5a of the downstream part 5, and the peripheral part 4b is equivalent to the central part 5a of the downstream part 5. The amount of catalyst component is supported.

これにより、特許文献１に記載の技術のように、排気ガスの流れ方向全域に渡って触媒体の周縁部における触媒成分の担持量を中央部よりも少なくする場合と比較して、触媒体１の周縁部４ｂ、５ｂを流れる排気ガスに対する浄化性能の低下を抑制できる。   Thus, as in the technique described in Patent Document 1, the catalyst body 1 is compared with the case where the supported amount of the catalyst component in the peripheral edge portion of the catalyst body is smaller than that in the central portion over the entire exhaust gas flow direction. Of the exhaust gas flowing through the peripheral edges 4b and 5b can be suppressed.

すなわち、触媒体を通過する排気ガスの流量は、触媒体の中央部では多く、周縁部では少ない傾向があり、エンジン運転状態が高負荷時のように、触媒体を通過する排気ガスの流量が全体的に多い場合では、この傾向は維持されるものの、周縁部での排気ガスの流量は低負荷時に比べて多くなる。これに対して、本実施形態によれば、担体２の上流部４の周縁部４ｂに、下流部５の中央部５ａと同等の量の触媒成分を担持させているので、このような場合であっても、周縁部を通過しようとする排気ガスを、上流部４の周縁部４ｂで浄化することが可能となる。   That is, the flow rate of the exhaust gas passing through the catalyst body tends to be large at the central portion of the catalyst body and small at the peripheral portion. In the case of a large number as a whole, this tendency is maintained, but the flow rate of the exhaust gas at the peripheral portion is larger than that at the time of low load. On the other hand, according to the present embodiment, the peripheral portion 4b of the upstream portion 4 of the carrier 2 carries the same amount of catalyst component as the central portion 5a of the downstream portion 5, so in such a case Even if it exists, it becomes possible to purify | clean the exhaust gas which is going to pass a peripheral part with the peripheral part 4b of the upstream part 4. FIG.

ところで、触媒成分として複数種類の貴金属元素を用いた触媒体では、触媒体が高温になることで、複数種類の貴金属元素が合金化してしまうという問題が生じる。   By the way, in a catalyst body using a plurality of kinds of noble metal elements as a catalyst component, there arises a problem that the plurality of kinds of noble metal elements are alloyed when the catalyst body becomes high temperature.

これに対して、本実施形態では、触媒成分の貴金属元素として、上流部４の周縁部４ｂでは、Ｐｄ、ＰｔおよびＲｈのうち、Ｐｄのみを用い、下流部５の中央部５ａでは、Ｐｄ、ＰｔおよびＲｈのうちＰｄを除く、ＰｔとＲｈの少なくとも一方を用いており、Ｐｄ、Ｐｔ、Ｒｈの使用領域を分けているので、ＰｄとＰｔの合金化や、ＰｄとＲｈとの合金化を防止することができる。   On the other hand, in the present embodiment, as the noble metal element of the catalyst component, only Pd is used among the Pd, Pt, and Rh in the peripheral portion 4b of the upstream portion 4, and Pd, Of Pt and Rh, at least one of Pt and Rh, excluding Pd, is used, and Pd, Pt, and Rh are used separately. Therefore, alloying of Pd and Pt and alloying of Pd and Rh are performed. Can be prevented.

（第２実施形態）
図６に第２実施形態における触媒体の斜視図を示し、図７に図６中の触媒体の中心線を含む触媒体の縦断面図を示す。また、図８（ａ）に図７中のＣ−Ｃ’線断面図を示し、図８（ｂ）に図７中のＣ−Ｃ’線部分における触媒担持密度分布を示す。また、図９（ａ）に図７中のＤ−Ｄ’線断面図を示し、図９（ｂ）に図７中のＤ−Ｄ’線部分における触媒担持密度分布を示す。 (Second Embodiment)
FIG. 6 shows a perspective view of the catalyst body in the second embodiment, and FIG. 7 shows a longitudinal sectional view of the catalyst body including the center line of the catalyst body in FIG. Further, FIG. 8A shows a cross-sectional view taken along the line CC ′ in FIG. 7, and FIG. 8B shows a catalyst carrying density distribution along the line CC ′ in FIG. Further, FIG. 9A shows a cross-sectional view along the line DD ′ in FIG. 7, and FIG. 9B shows the catalyst carrying density distribution at the line DD ′ in FIG.

第１実施形態では、上流部４は中央部４ａと周縁部４ｂとで触媒成分の担持密度が異なっていたが、本実施形態では、図７、８に示すように、上流部４は全域で触媒成分の担持密度が均一である。なお、図９に示すように、下流部５の構成については第１実施形態と同様である。   In the first embodiment, the upstream portion 4 has different catalyst component loading densities in the central portion 4a and the peripheral portion 4b. However, in the present embodiment, as shown in FIGS. The loading density of the catalyst component is uniform. As shown in FIG. 9, the configuration of the downstream portion 5 is the same as that of the first embodiment.

本実施形態では、触媒成分の貴金属元素として、上流部４の全域では、Ｐｄ、ＰｔおよびＲｈのうち、Ｐｄのみを用い、下流部５の中央部５ａでは、Ｐｄ、ＰｔおよびＲｈのうちＰｄを除く、ＰｔとＲｈの少なくとも一方を用いており、Ｐｄ、Ｐｔ、Ｒｈの使用領域を分けているので、ＰｄとＰｔの合金化や、ＰｄとＲｈとの合金化を防止することができる。   In the present embodiment, as the noble metal element of the catalyst component, only Pd out of Pd, Pt and Rh is used in the entire upstream portion 4, and Pd out of Pd, Pt and Rh is used in the central portion 5a of the downstream portion 5. Since at least one of Pt and Rh is used and Pd, Pt, and Rh are used separately, alloying of Pd and Pt and alloying of Pd and Rh can be prevented.

また、本実施形態の触媒体は、第１実施形態で説明した触媒体の製造方法の一部を以下のように変更することで製造可能である。   Moreover, the catalyst body of this embodiment can be manufactured by changing a part of the manufacturing method of the catalyst body demonstrated in 1st Embodiment as follows.

例えば、第１実施形態では、下流部５の中央部５ａに担持させるための触媒成分が分散された第２の触媒スラリー溶液を用意し、担体２の上流側端部２ａから担体２の中央部４ａ、５ａのみに、このスラリー溶液を流し込んでいた。これに対して、本実施形態では、担体２の下流側端面のうち周縁部５ｂに相当する部位をマスクした状態で、担体２の下流側端部２ｂから上流部４との境界までの部分を第２の触媒スラリー溶液に浸漬する方法に変更する。この方法により、上流部４の全域での触媒成分の担持密度を均一な状態とすることができる。   For example, in the first embodiment, a second catalyst slurry solution in which a catalyst component to be supported on the central portion 5a of the downstream portion 5 is dispersed is prepared, and the central portion of the carrier 2 is formed from the upstream end portion 2a of the carrier 2. This slurry solution was poured into only 4a and 5a. On the other hand, in the present embodiment, a portion from the downstream end 2b of the carrier 2 to the boundary with the upstream portion 4 is masked in a portion corresponding to the peripheral edge 5b of the downstream end surface of the carrier 2. It changes to the method of immersing in a 2nd catalyst slurry solution. By this method, the catalyst component loading density in the entire area of the upstream portion 4 can be made uniform.

（第３実施形態）
図１０に本実施形態における触媒体の中心線を含む触媒体の縦断面図を示す。また、図１１（ａ）に図１０中のＥ−Ｅ’線断面図を示し、図１１（ｂ）に図１０中のＥ−Ｅ’線部分における触媒担持密度分布を示す。 (Third embodiment)
FIG. 10 is a longitudinal sectional view of the catalyst body including the center line of the catalyst body in the present embodiment. Further, FIG. 11A shows a cross-sectional view taken along the line EE ′ in FIG. 10, and FIG. 11B shows the catalyst carrying density distribution in the portion taken along the line EE ′ in FIG.

第１、第２実施形態では、担体２の下流部５の周縁部５ｂに触媒成分を担持させていなかったが、本実施形態では、図１１（ａ）、（ｂ）に示すように、下流部５の中央部５ａでの触媒成分の担持密度がｄ１のとき、下流部５の周縁部５ｂでの触媒成分の担持密度をｄ１よりも低いｄ３としている。なお、上流部４の構成は、第１実施形態もしくは第２実施形態と同様である。   In the first and second embodiments, the catalyst component is not supported on the peripheral edge portion 5b of the downstream portion 5 of the carrier 2, but in this embodiment, as shown in FIGS. When the catalyst component loading density at the central portion 5a of the portion 5 is d1, the catalyst component loading density at the peripheral portion 5b of the downstream portion 5 is d3 lower than d1. In addition, the structure of the upstream part 4 is the same as that of 1st Embodiment or 2nd Embodiment.

また、本実施形態の触媒体１は、第１、第２実施形態で説明した触媒体の製造方法の一部を以下のように変更することで製造可能である。   Moreover, the catalyst body 1 of this embodiment can be manufactured by changing a part of the manufacturing method of the catalyst body demonstrated in 1st, 2nd embodiment as follows.

例えば、第１実施形態で説明した触媒体の製造方法に対して、担体２の全域に対して触媒成分を担持させる工程を追加する。この工程は、上流部４、下流部５に触媒成分を担持させる工程の前、後のどちらに追加しても良い。また、このときの触媒成分の担持密度は、下流部５の周縁部５ｂでの触媒成分の担持密度に設定する。   For example, a process of supporting the catalyst component over the entire region of the carrier 2 is added to the method for manufacturing the catalyst body described in the first embodiment. This step may be added either before or after the step of supporting the catalyst component on the upstream portion 4 and the downstream portion 5. Further, the catalyst component loading density at this time is set to the catalyst component loading density at the peripheral portion 5 b of the downstream portion 5.

他の例としては、第２実施形態で説明した触媒体の製造方法に対して、下流部５の全域に触媒成分を担持させる工程を追加する。この工程は、下流部５の中央部５ａに触媒成分を担持させる工程の前、後のどちらに追加しても良い。また、このときの触媒成分の担持密度は、下流部５の周縁部５ｂでの触媒成分の担持密度に設定する。   As another example, a process of supporting a catalyst component over the entire region of the downstream portion 5 is added to the method for manufacturing the catalyst body described in the second embodiment. This step may be added either before or after the step of supporting the catalyst component on the central portion 5a of the downstream portion 5. Further, the catalyst component loading density at this time is set to the catalyst component loading density at the peripheral portion 5 b of the downstream portion 5.

本実施形態では、下流部５の周縁部５ｂに中央部５ａよりも少ない量の触媒成分を担持させており、すなわち、周縁部５ｂに担持する触媒成分の量を低減させているので、下流部５の中央部５ａと同量の触媒成分を担体２の全域に担持する場合と比較して、触媒成分の担持量を低減できる。   In the present embodiment, the peripheral portion 5b of the downstream portion 5 is loaded with a smaller amount of catalyst component than the central portion 5a, that is, the amount of the catalyst component supported on the peripheral portion 5b is reduced. As compared with the case where the same amount of the catalyst component as the central portion 5a of 5 is supported on the entire area of the carrier 2, the amount of catalyst component supported can be reduced.

（他の実施形態）
（１）上記した各実施形態では、触媒体の製造方法において、金属酸化物粒子と触媒成分とを別々の工程で担体２に担持していたが、金属酸化物粒子と触媒成分との両方を分散させたスラリー溶液を用いることによって、金属酸化物粒子と触媒成分とを同じ工程で担体２に担持させても良い。 (Other embodiments)
(1) In each of the embodiments described above, in the method for producing a catalyst body, the metal oxide particles and the catalyst component are supported on the carrier 2 in separate steps, but both the metal oxide particles and the catalyst component are supported. By using the dispersed slurry solution, the metal oxide particles and the catalyst component may be supported on the carrier 2 in the same step.

（２）上記した各実施形態では、触媒成分の貴金属元素として、上流部４の周縁部４ｂでは、Ｐｄ、ＰｔおよびＲｈのうち、Ｐｄのみを用い、下流部５の中央部５ａでは、Ｐｄ、ＰｔおよびＲｈのうちＰｄを除く、ＰｔとＲｈの少なくとも一方を用いていたが、触媒成分の貴金属元素およびその組み合わせは任意に変更しても良い。貴金属元素としては、例えば、Ｐｔ、Ｒｈ、Ｐｄ、Ａｕ、Ａｇ、Ｒｕ、Ｉｒ、Ｏｓ等が挙げられる。   (2) In each of the above-described embodiments, as the noble metal element of the catalyst component, only Pd is used in the peripheral portion 4b of the upstream portion 4 among Pd, Pt and Rh, and Pd, Although at least one of Pt and Rh excluding Pd is used among Pt and Rh, the noble metal element of the catalyst component and the combination thereof may be arbitrarily changed. Examples of the noble metal element include Pt, Rh, Pd, Au, Ag, Ru, Ir, Os, and the like.

例えば、上流部４の周縁部４ｂに担持される触媒成分としてＰｔとＲｈの一方もしくは両方を用いても良い。また、上流部４の周縁部４ｂに担持される触媒成分と、下流部５の中央部５ａに担持される触媒成分として、同じ種類の貴金属元素を用いたり、異なる種類の貴金属元素を用いたりしても良い。   For example, one or both of Pt and Rh may be used as the catalyst component supported on the peripheral edge 4b of the upstream portion 4. Further, the same kind of noble metal element or different kinds of noble metal elements may be used as the catalyst component carried on the peripheral edge 4b of the upstream portion 4 and the catalyst component carried on the central portion 5a of the downstream portion 5. May be.

ただし、貴金属元素同士の合金化を防止するという観点では、触媒体１の部位毎に貴金属元素の種類を異ならせ、貴金属元素の使用領域を分けることが好ましい。また、触媒体１の部位毎に貴金属元素の種類を異ならせることで、排気ガス浄化の対象とするガス種の選択性を向上させることができる。   However, from the viewpoint of preventing alloying of the noble metal elements, it is preferable to vary the type of the noble metal element for each part of the catalyst body 1 and to separate the use area of the noble metal element. Further, by making the type of the noble metal element different for each part of the catalyst body 1, it is possible to improve the selectivity of the gas species to be subjected to exhaust gas purification.

（３）上記した各実施形態では、ハニカム構造の担体２として、モノリスを用いていたが、複数のハニカム構造体を一体化させた担体を用いても良い。また、担体２の形状を円柱形状以外の他の形状としても良い。   (3) In each of the above-described embodiments, the monolith is used as the honeycomb structure carrier 2, but a carrier in which a plurality of honeycomb structures are integrated may be used. Further, the shape of the carrier 2 may be other than the cylindrical shape.

（４）上記した各実施形態では、上流部４の周縁部４ｂにおける触媒成分の担持量が下流部５の中央部５ａと同じであったが、上流部４の周縁部４ｂにおける触媒成分の担持量を下流部５の中央部５ａよりも多くしても良い。要するに、上流部４では、中央部４ａと周縁部４ｂとにおける触媒成分の担持量が、下流部５の中央部５ａにおける触媒成分の担持量と同等以上となっていれば良い。   (4) In each of the above-described embodiments, the loading amount of the catalyst component in the peripheral portion 4b of the upstream portion 4 is the same as that of the central portion 5a of the downstream portion 5, but the loading of the catalyst component in the peripheral portion 4b of the upstream portion 4 is carried out. The amount may be larger than the central portion 5a of the downstream portion 5. In short, in the upstream portion 4, it is sufficient that the supported amount of the catalyst component in the central portion 4 a and the peripheral portion 4 b is equal to or greater than the supported amount of the catalyst component in the central portion 5 a of the downstream portion 5.

（５）上記した各実施形態では、下流部５において、中央部５ａのみに触媒成分が担持され、もしくは、周縁部５ｂに中央部５ａよりも少ない量の触媒成分が担持されており、上流部４において、中央部４ａと周縁部４ｂとにおける触媒成分の担持量が、下流部５の中央部５ａにおける触媒成分の担持量と同等以上となっていたが、上流部４と下流部５との関係を逆にしても良い。   (5) In each of the above-described embodiments, in the downstream portion 5, the catalyst component is supported only in the central portion 5a, or the catalyst component in a smaller amount than the central portion 5a is supported in the peripheral portion 5b. 4, the supported amount of the catalyst component in the central portion 4 a and the peripheral portion 4 b is equal to or greater than the supported amount of the catalyst component in the central portion 5 a of the downstream portion 5. The relationship may be reversed.

すなわち、上記した各実施形態では、担体２の一端から貫通孔の延伸方向での所定長さの範囲である一端側部分を上流部４とし、担体２のうち一端側部分を除いた範囲である他端側部分を下流部５とした場合を説明したが、一端側部分を下流部５とし、他端側部分を上流部４としても良い。   That is, in each of the above-described embodiments, the one end side portion that is a range of a predetermined length in the extending direction of the through hole from one end of the carrier 2 is the upstream portion 4, and the one end portion of the carrier 2 is excluded. Although the case where the other end portion is the downstream portion 5 has been described, the one end portion may be the downstream portion 5 and the other end portion may be the upstream portion 4.

なお、上流部４の周縁部４ｂに、下流部５の中央部５ａと同等以上の触媒成分を担持させた場合、上流部４の周縁部４ｂでの触媒反応による熱が、下流部５に担持された触媒成分の昇温に寄与することから、下流部５の周縁部５ｂではなく、上流部４の周縁部４ｂに、下流部５の中央部５ａと同等以上の触媒成分を担持させることが好ましい。   In addition, when the catalyst component equal to or higher than the central portion 5a of the downstream portion 5 is supported on the peripheral portion 4b of the upstream portion 4, heat from the catalytic reaction at the peripheral portion 4b of the upstream portion 4 is supported on the downstream portion 5. Therefore, the catalyst component equal to or higher than that of the central portion 5a of the downstream portion 5 is supported not on the peripheral portion 5b of the downstream portion 5 but on the peripheral portion 4b of the upstream portion 4. preferable.

（６）上記した各実施形態では、自動車の排気ガスを浄化する触媒体を例として説明したが、自動車以外の内燃機関の排気ガスを浄化する触媒体に対しても本発明は適用可能である。   (6) In each of the above embodiments, the catalyst body that purifies the exhaust gas of the automobile has been described as an example. However, the present invention can also be applied to a catalyst body that purifies the exhaust gas of an internal combustion engine other than the automobile. .

（７）上記した各実施形態は、実施可能な範囲で任意に組み合わせが可能である。   (7) Each embodiment mentioned above can be arbitrarily combined in the range which can be implemented.

本発明の第１実施形態における触媒体の斜視図である。It is a perspective view of the catalyst body in a 1st embodiment of the present invention. 図１中の触媒体の縦断面図である。It is a longitudinal cross-sectional view of the catalyst body in FIG. （ａ）は図２中のＡ−Ａ’線断面図であり、（ｂ）は図２中のＡ−Ａ’線部分における触媒担持密度分布を示す図である。FIG. 3A is a cross-sectional view taken along the line A-A ′ in FIG. 2, and FIG. 3B is a view showing a catalyst carrying density distribution at the line A-A ′ in FIG. 2. （ａ）は図２中のＢ−Ｂ’線断面図であり、（ｂ）は図２中のＢ−Ｂ’線部分における触媒担持密度分布を示す図である。FIG. 3A is a cross-sectional view taken along the line B-B ′ in FIG. 2, and FIG. 3B is a view showing a catalyst loading density distribution at the line B-B ′ in FIG. 2. （ａ）は担体２の貫通孔の壁面付近の拡大図であり、（ｂ）は（ａ）中の金属酸化物粒子２０の拡大図であり、（ｃ）は（ｂ）中の触媒成分３０の拡大図である。(A) is an enlarged view of the vicinity of the wall surface of the through hole of the carrier 2, (b) is an enlarged view of the metal oxide particles 20 in (a), and (c) is a catalyst component 30 in (b). FIG. 第２実施形態における触媒体の斜視図である。It is a perspective view of the catalyst body in 2nd Embodiment. 図６中の触媒体の縦断面図である。It is a longitudinal cross-sectional view of the catalyst body in FIG. （ａ）は図７中のＣ−Ｃ’線断面図であり、（ｂ）は図７中のＣ−Ｃ’線部分における触媒担持密度分布を示す図である。FIG. 8A is a cross-sectional view taken along the line C-C ′ in FIG. 7, and FIG. 8B is a view showing a catalyst carrying density distribution at the C-C ′ line portion in FIG. 7. （ａ）は図７中のＤ−Ｄ’線断面図であり、（ｂ）は図７中のＤ−Ｄ’線部分における触媒担持密度分布を示す図である。FIG. 8A is a cross-sectional view taken along the line D-D ′ in FIG. 7, and FIG. 8B is a view showing the catalyst carrying density distribution at the D-D ′ line portion in FIG. 7. 第３実施形態における触媒体の縦断面図である。It is a longitudinal cross-sectional view of the catalyst body in 3rd Embodiment. （ａ）は図１０中のＥ−Ｅ’線断面図であり、（ｂ）は図１０中のＥ−Ｅ’線部分における触媒担持密度分布を示す図である。FIG. 11A is a cross-sectional view taken along line E-E ′ in FIG. 10, and FIG. 11B is a view showing a catalyst carrying density distribution at a portion taken along line E-E ′ in FIG. 10.

符号の説明Explanation of symbols

１ 触媒体
２ 担体
３ 貫通孔
４ 上流部
４ａ 上流部の中央部
４ｂ 上流部の周縁部
５ 下流部
５ａ 下流部の中央部
５ｂ 下流部の周縁部 DESCRIPTION OF SYMBOLS 1 Catalyst body 2 Support | carrier 3 Through-hole 4 Upstream part 4a Central part of upstream part 4b Peripheral part of upstream part 5 Downstream part 5a Central part of downstream part 5b Peripheral part of downstream part

Claims (8)

一端（２ａ）から他端（２ｂ）に向かって延伸する複数の貫通孔（３）を有するハニカム構造の担体（２）と、
前記貫通孔（３）の内面に担持された排気ガス浄化用の触媒成分とを有する排気ガス浄化用触媒体において、
前記担体（２）は、前記一端（２ａ）から前記貫通孔の延伸方向で所定長さの範囲である一端側部分（４）と、前記担体（２）のうち前記一端側部分（４）を除いた範囲である他端側部分（５）とを有し、
前記他端側部分（５）では、前記貫通孔の延伸方向からみた中央部（５ａ）と前記中央部（５ａ）の周縁に位置する周縁部（５ｂ）とのうち、前記中央部（５ａ）のみに前記触媒成分が担持されており、もしくは、前記周縁部（５ｂ）は前記中央部（５ａ）よりも少ない量の前記触媒成分が担持されており、
前記一端側部分（４）では、前記貫通孔の延伸方向からみた中央部（４ａ）と前記中央部（４ａ）の周縁に位置する周縁部（４ｂ）とにおける前記触媒成分の担持量が、前記他端側部分（５）の前記中央部（５ａ）における前記触媒成分の担持量と同等以上となっており、
前記一端側部分（４）では、前記中央部（４ａ）における前記触媒成分の担持量が前記周縁部（４ｂ）における前記触媒成分の担持量よりも多くなっていることを特徴とする排気ガス浄化用触媒体。 A honeycomb structure carrier (2) having a plurality of through holes (3) extending from one end (2a) to the other end (2b);
An exhaust gas purifying catalyst body having an exhaust gas purifying catalyst component carried on the inner surface of the through hole (3);
The carrier (2) includes one end side portion (4) having a predetermined length in the extending direction of the through hole from the one end (2a), and the one end side portion (4) of the carrier (2). Having the other end side part (5) which is the excluded range,
In the other end side part (5), the central part (5a) is selected from the central part (5a) viewed from the extending direction of the through hole and the peripheral part (5b) located at the peripheral edge of the central part (5a). Only the catalyst component is supported, or the peripheral portion (5b) is loaded with a smaller amount of the catalyst component than the central portion (5a),
In the one end side portion (4), the supported amount of the catalyst component at the central portion (4a) viewed from the extending direction of the through hole and the peripheral portion (4b) located at the peripheral edge of the central portion (4a) is It is equal to or greater than the loading amount of the catalyst component in the central portion (5a) of the other end side portion (5) ,
In the one end side portion (4), the amount of the catalyst component supported in the central portion (4a) is larger than the amount of the catalyst component supported in the peripheral portion (4b). Catalyst body. 一端（２ａ）から他端（２ｂ）に向かって延伸する複数の貫通孔（３）を有するハニカム構造の担体（２）と、
前記貫通孔（３）の内面に担持された排気ガス浄化用の触媒成分とを有する排気ガス浄化用触媒体において、
前記担体（２）は、前記一端（２ａ）から前記貫通孔の延伸方向で所定長さの範囲である一端側部分（４）と、前記担体（２）のうち前記一端側部分（４）を除いた範囲である他端側部分（５）とを有し、
前記他端側部分（５）では、前記貫通孔の延伸方向からみた中央部（５ａ）と前記中央部（５ａ）の周縁に位置する周縁部（５ｂ）とのうち、前記中央部（５ａ）のみに前記触媒成分が担持されており、もしくは、前記周縁部（５ｂ）は前記中央部（５ａ）よりも少ない量の前記触媒成分が担持されており、
前記一端側部分（４）では、前記貫通孔の延伸方向からみた中央部（４ａ）と前記中央部（４ａ）の周縁に位置する周縁部（４ｂ）とにおける前記触媒成分の担持量が、前記他端側部分（５）の前記中央部（５ａ）における前記触媒成分の担持量と同等以上となっており、
前記一端部側部分（４）の前記周縁部（４ｂ）に担持される前記触媒成分と、前記他端部側部分（５）の前記中央部（５ａ）に担持される前記触媒成分として、それぞれ、異なる貴金属元素が用いられていることを特徴とする排気ガス浄化用触媒体。 A honeycomb structure carrier (2) having a plurality of through holes (3) extending from one end (2a) to the other end (2b);
An exhaust gas purifying catalyst body having an exhaust gas purifying catalyst component carried on the inner surface of the through hole (3);
The carrier (2) includes one end side portion (4) having a predetermined length in the extending direction of the through hole from the one end (2a), and the one end side portion (4) of the carrier (2). Having the other end side part (5) which is the excluded range,
In the other end side part (5), the central part (5a) is selected from the central part (5a) viewed from the extending direction of the through hole and the peripheral part (5b) located at the peripheral edge of the central part (5a). Only the catalyst component is supported, or the peripheral portion (5b) is loaded with a smaller amount of the catalyst component than the central portion (5a),
In the one end side portion (4), the supported amount of the catalyst component at the central portion (4a) viewed from the extending direction of the through hole and the peripheral portion (4b) located at the peripheral edge of the central portion (4a) is It is equal to or greater than the loading amount of the catalyst component in the central portion (5a) of the other end side portion (5) ,
The catalyst component carried on the peripheral edge (4b) of the one end portion (4) and the catalyst component carried on the central portion (5a) of the other end portion (5), A catalyst body for purifying exhaust gas , wherein different noble metal elements are used . 一端（２ａ）から他端（２ｂ）に向かって延伸する複数の貫通孔（３）を有するハニカム構造の担体（２）と、
前記貫通孔（３）の内面に担持された排気ガス浄化用の触媒成分とを有する排気ガス浄化用触媒体において、
前記担体（２）は、前記一端（２ａ）から前記貫通孔の延伸方向で所定長さの範囲である一端側部分（４）と、前記担体（２）のうち前記一端側部分（４）を除いた範囲である他端側部分（５）とを有し、
前記他端側部分（５）では、前記貫通孔の延伸方向からみた中央部（５ａ）と前記中央部（５ａ）の周縁に位置する周縁部（５ｂ）とのうち、前記中央部（５ａ）のみに前記触媒成分が担持されており、もしくは、前記周縁部（５ｂ）は前記中央部（５ａ）よりも少ない量の前記触媒成分が担持されており、
前記一端側部分（４）では、前記貫通孔の延伸方向からみた中央部（４ａ）と前記中央部（４ａ）の周縁に位置する周縁部（４ｂ）とにおける前記触媒成分の担持量が、前記他端側部分（５）の前記中央部（５ａ）における前記触媒成分の担持量よりも多くなっていることを特徴とする排気ガス浄化用触媒体。 A honeycomb structure carrier (2) having a plurality of through holes (3) extending from one end (2a) to the other end (2b);
An exhaust gas purifying catalyst body having an exhaust gas purifying catalyst component carried on the inner surface of the through hole (3);
The carrier (2) includes one end side portion (4) having a predetermined length in the extending direction of the through hole from the one end (2a), and the one end side portion (4) of the carrier (2). Having the other end side part (5) which is the excluded range,
In the other end side part (5), the central part (5a) is selected from the central part (5a) viewed from the extending direction of the through hole and the peripheral part (5b) located at the peripheral edge of the central part (5a). Only the catalyst component is supported, or the peripheral portion (5b) is loaded with a smaller amount of the catalyst component than the central portion (5a),
In the one end side portion (4), the supported amount of the catalyst component at the central portion (4a) viewed from the extending direction of the through hole and the peripheral portion (4b) located at the peripheral edge of the central portion (4a) is An exhaust gas purifying catalyst body characterized in that it is larger than the amount of the catalyst component supported in the central portion (5a) of the other end side portion (5). 前記一端側部分（４）は、前記一端（２ａ）からの前記所定長さ（Ｌ１）が、前記担体（２）の前記貫通孔の延伸方向での全長（Ｌ２）の１／３以上２／３以下の長さであり、
前記一端側部分（４）および前記他端側部分（５）における前記中央部（４ａ、５ａ）は、前記貫通孔の延伸方向に垂直な断面での中心から端部までの距離（Ｒ１）が、前記担体（２）における前記貫通孔の延伸方向に垂直な断面での中心から外周端までの距離（Ｒ２）の１／３以上２／３以下の長さであることを特徴とする請求項１ないし３のいずれか１つに記載の排気ガス浄化用触媒体。 The one end side portion (4) has a predetermined length (L1) from the one end (2a) of 1/3 or more of the total length (L2) in the extending direction of the through hole of the carrier (2). A length of 3 or less,
The central portion (4a, 5a) in the one end side portion (4) and the other end side portion (5) has a distance (R1) from the center to the end portion in a cross section perpendicular to the extending direction of the through hole. The length of the carrier (2) is not less than 1/3 and not more than 2/3 of the distance (R2) from the center to the outer peripheral end in a cross section perpendicular to the extending direction of the through hole. The exhaust gas purifying catalyst body according to any one of 1 to 3 . 前記一端側部分（４）では、前記中央部（４ａ）における前記触媒成分の担持量が前記周縁部（４ｂ）における前記触媒成分の担持量よりも多くなっていることを特徴とする請求項２または３に記載の排気ガス浄化用触媒体。 Wherein the end portion (4), according to claim, characterized in that the supported amount of the catalyst component in the central portion (4a) is larger than that supported amount of the catalyst component in the peripheral portion (4b) 2 Or the exhaust gas purifying catalyst body according to 3. 前記一端部側部分（４）の前記周縁部（４ｂ）に担持される前記触媒成分と、前記他端部側部分（５）の前記中央部（５ａ）に担持される前記触媒成分として、それぞれ、異なる貴金属元素が用いられていることを特徴とする請求項１または３に記載の排気ガス浄化用触媒体。 The catalyst component carried on the peripheral edge (4b) of the one end portion (4) and the catalyst component carried on the central portion (5a) of the other end portion (5), the exhaust gas purifying catalyst body according to claim 1 or 3, characterized in that different noble metal element is used. 前記一端部側部分（４）の前記周縁部（４ｂ）に担持される前記触媒成分として、Ｐｄ、ＰｔおよびＲｈのうちＰｄのみが用いられ、
前記他端部側部分（５）の前記中央部（５ａ）に担持される前記触媒成分として、Ｐｄ、ＰｔおよびＲｈのうち、Ｐｄを除き、ＰｔとＲｈの少なくとも一方が用いられていることを特徴とする請求項２または６に記載の排気ガス浄化用触媒体。 As the catalyst component supported on the peripheral edge (4b) of the one end portion (4), only Pd is used among Pd, Pt and Rh.
As the catalyst component supported on the central portion (5a) of the other end portion (5), at least one of Pt and Rh is used out of Pd, Pt and Rh except for Pd. The exhaust gas purifying catalyst body according to claim 2 or 6 , characterized in that: 一端（２ａ）から他端（２ｂ）に向かって延伸する複数の貫通孔（３）を有するハニカム構造の担体（２）と、前記貫通孔（３）の内面に担持された排気ガス浄化用の触媒成分とを有する排気ガス浄化用触媒体を備え、内燃機関の排気ガスが前記排気ガス浄化用触媒体を通過することにより、内燃機関の排気ガスを浄化する排気ガス浄化装置において、
前記担体（２）は、前記一端（２ａ）から前記貫通孔の延伸方向で所定長さの範囲である一端側部分（４）と、前記担体（２）のうち前記一端側部分（４）を除いた範囲である他端側部分（５）とを有し、
前記他端側部分（５）では、前記貫通孔の延伸方向からみた中央部（５ａ）と前記中央部（５ａ）の周縁に位置する周縁部（５ｂ）とのうち、前記中央部（５ａ）のみに前記触媒成分が担持されており、もしくは、前記周縁部（５ｂ）は前記中央部（５ａ）よりも少ない量の前記触媒成分が担持されており、
前記一端側部分（４）では、前記貫通孔の延伸方向からみた中央部（４ａ）と前記中央部（４ａ）の周縁に位置する周縁部（４ｂ）とにおける前記触媒成分の担持量が、前記他端側部分（５）の前記中央部（５ａ）における前記触媒成分の担持量と同等以上となっており、
前記一端側部分は、前記担体（２）の排気ガス流れの上流側端部（２ａ）から前記所定長さ（Ｌ１）の範囲である上流部（４）であり、
前記他端側部分は、前記上流部（４）よりも排気ガス流れの下流側に位置する下流部（５）であることを特徴とする排気ガス浄化装置。 A honeycomb-structured carrier (2) having a plurality of through holes (3) extending from one end (2a) to the other end (2b), and an exhaust gas purification carrier carried on the inner surface of the through hole (3) In an exhaust gas purifying apparatus for purifying exhaust gas of an internal combustion engine by including an exhaust gas purification catalyst body having a catalyst component and passing exhaust gas of the internal combustion engine through the exhaust gas purification catalyst body ,
The carrier (2) includes one end side portion (4) having a predetermined length in the extending direction of the through hole from the one end (2a), and the one end side portion (4) of the carrier (2). Having the other end side part (5) which is the excluded range,
In the other end side part (5), the central part (5a) is selected from the central part (5a) viewed from the extending direction of the through hole and the peripheral part (5b) located at the peripheral edge of the central part (5a). Only the catalyst component is supported, or the peripheral portion (5b) is loaded with a smaller amount of the catalyst component than the central portion (5a),
In the one end side portion (4), the supported amount of the catalyst component at the central portion (4a) viewed from the extending direction of the through hole and the peripheral portion (4b) located at the peripheral edge of the central portion (4a) is It is equal to or greater than the loading amount of the catalyst component in the central portion (5a) of the other end side portion (5) ,
The one end side portion is an upstream portion (4) that is in a range from the upstream end portion (2a) of the exhaust gas flow of the carrier (2) to the predetermined length (L1),
The other end portion, a downstream portion (5) der Rukoto exhaust gas purification device according to claim located downstream of the exhaust gas flow than said upstream portion (4).
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