JPWO2020031975A1 - Catalyst coated gasoline particulate filter and its manufacturing method - Google Patents

Abstract

Provided are a catalyst-coated gasoline particulate filter having a dramatically improved PN collection rate as compared with a conventional GPF catalyst, a method for producing the same, and the like. A catalyst-coated gasoline particulate filter provided with a catalyst layer that purifies the exhaust gas emitted from a gasoline engine, the introduction side cell 11 in which the end portion 11a on the exhaust gas introduction side is open, and the end portion 12a on the exhaust gas emission side. The discharge side cell 12 opened by the wall flow type base material 10 defined by the porous partition wall 13, and a plurality of porous dense portions 31a in which the pores of the partition wall 13 are filled with inorganic fine particles. A porous dense collection layer 31 formed over the stretching direction of the partition wall 13 of the wall flow type base material 10, 0.4 to 0.4 to the total length L of the wall flow type base material 10 in a cross-sectional view. A catalyst-coated gasoline particulate filter 100 comprising at least the porous dense collection layer 31 having a length La of 0.9 L.

Description

The present invention relates to a catalyst-coated gasoline particulate filter in which a catalyst layer is provided on a wall-flow type base material, and a method for producing the same.

Exhaust gas emitted from an internal combustion engine contains particulate matter (PM: Particulate Matter) containing carbon as a main component and ash composed of a non-combustible component, and is known to cause air pollution. Diesel engines, which emit particulate matter relatively more easily than gasoline engines, have traditionally been strictly regulated in particulate matter emissions. However, in recent years, it has been confirmed that particulate matter equal to or higher than that of diesel engines is emitted into the exhaust gas of direct-injection gasoline engines and the like, and the momentum for tightening the exhaust gas regulations of gasoline engines is increasing. For example, in Switzerland, regulations on PN (Particulate Number, PM particle number) have been introduced, and in EURO 6 and California, there is a movement to start PN regulations.

In order to reduce the particulate matter contained in the exhaust gas, conventionally, in a diesel engine, a diesel particulate filter (hereinafter, may be referred to as "DPF") that deposits and collects the particulate matter is used as an exhaust gas passage. It was often installed in. Therefore, in a gasoline engine as well, it is considered to be provided in the exhaust gas passage with a gasoline particulate filter (hereinafter, may be referred to as "GPF") for accumulating and collecting particulate matter. ..

Furthermore, in recent years, from the viewpoint of saving space for mounting a gasoline engine, emission control of particulate matter and removal of harmful components such as carbon monoxide (CO), hydrocarbons (HC) and nitrogen oxides (NOx) have been achieved. A catalyst slurry such as a three-way catalyst is applied to a particulate filter, and a catalyst layer is provided by firing the catalyst slurry (hereinafter referred to as "GPF catalyst"). It may be referred to.) Is being considered.

However, if a catalyst layer is provided in the GPF where the pressure loss tends to increase due to the accumulation of particulate matter, the flow path of the exhaust gas becomes narrower and the pressure loss tends to increase further, which causes a decrease in engine output. There is. In order to solve such a problem, for example, in Patent Documents 1 to 3, it is necessary to devise the type of catalyst layer and the position where they are provided for the purpose of suppressing an increase in pressure loss and improving exhaust gas purification performance. Proposed. Further, in Patent Document 4, for the purpose of suppressing an increase in pressure loss, it is possible to adjust the average particle size of the powder in the slurry for forming the catalyst coat layer and the amount of the catalyst coated on the substrate. Proposed.

WO2016 / 060048 WO2016 / 060049 WO2016 / 06050 Japanese Unexamined Patent Publication No. 2017-14602

However, according to the studies by the present inventors, these conventional GPF catalysts are limited to suppressing the increase in pressure loss and optimizing the improvement of the exhaust gas purification performance. That is, the conventional GPF catalyst has an insufficient PN collection rate as the basic performance of GPF, and it is required to develop a GPF catalyst based on a new design guideline that can respond to the planned tightening of PN regulations worldwide in the future. Has been done.

The present invention has been made in view of the above problems. That is, an object of the present invention is to provide a catalyst-coated gasoline particulate filter and a method for producing the same, in which the PN collection rate is dramatically improved as compared with the conventional GPF catalyst. Another object of the present invention is to provide a new catalyst structure capable of dramatically increasing the PN collection rate and at the same time achieving the same level of pressure loss and exhaust gas purification performance as the conventional one. It is in.

It should be noted that the present invention is not limited to the purpose described here, and it is an action and effect derived by each configuration shown in the embodiment for carrying out the invention described later, and it is also possible to exert an action and effect that cannot be obtained by the conventional technique. It can be positioned as another purpose.

The present inventors have diligently studied to solve the above problems. As a result, they have found that the above problems can be solved by zone-coating a porous dense collection layer capable of collecting extremely minute PM in the stretching direction of the partition wall of the wall flow type base material, and complete the present invention. It came to.

That is, the present invention provides various specific aspects shown below.
(1) A catalyst-coated gasoline particulate filter provided with a catalyst layer that purifies the exhaust gas emitted from a gasoline engine. The introduction side cell with an open end on the exhaust gas introduction side and the end on the exhaust gas emission side. The exhaust side cell opened by the wall flow type base material is composed of a wall flow type base material defined by a porous partition wall and a plurality of porous dense portions in which the pores of the partition wall are filled with inorganic fine particles. It is a porous dense collecting layer formed over the stretching direction of the partition wall of the base material, and has a length La of 0.4 to 0.9 L with respect to the total length L of the wall flow type base material in a cross-sectional view. A catalyst-coated gasoline particulate filter having at least the porous dense collection layer.

(2) The catalyst-coated gasoline particulate filter according to (1) above, wherein the porous dense collection layer has a thickness Da of 0.1 to 0.9 D with respect to a thickness D of the partition wall in a cross-sectional view. ..

(3) The porous dense collection layer is unevenly distributed on the cell wall surface side of the introduction side cell or the cell wall surface side of the discharge side cell in the thickness direction in the cross-sectional view of the partition wall. The catalyst-coated gasoline particulate filter according to 2).
(4) The catalyst coating according to any one of (1) to (3) above, which contains a total of 0.1 g / L or more and 10 g / L or less of platinum group elements per volume of the wall flow type base material. Industrial gasoline catalyst filter.

(5) The catalyst-coated gasoline particulate filter according to any one of (1) to (4) above, wherein the porous dense portion is provided on the pore surface of the partition wall.
(6) The above (1) to (5), wherein the first catalyst layer containing a platinum group element is provided on the pore surface of the partition wall, and the porous dense portion is provided on the first catalyst layer. The catalyst-coated gasoline particulate filter according to any one of the above.
(7) The catalyst coating according to (6) above, wherein the first catalyst layer contains at least the first base material particles and the first composite catalyst particles having a platinum group element supported on the first base material particles. Industrial gasoline particulate filter.
(8) The catalyst-coated gasoline particulate filter according to any one of (1) to (7) above, wherein the porous dense collection layer contains a platinum group element.
(9) The catalyst-coated gasoline patty according to (8) above, wherein the porous dense collection layer contains at least the inorganic fine particles and the second composite catalyst particles having a platinum group element supported on the inorganic fine particles. Curated filter.

(10) A method for manufacturing a catalyst-coated gasoline particulate filter provided with a catalyst layer for purifying exhaust gas emitted from a gasoline engine, in which an introduction-side cell having an open end on the exhaust gas introduction side and an exhaust gas emission side. In the step of preparing a wall flow type base material defined by a porous partition wall, the discharge side cell having an open end portion is inorganic from the exhaust gas introduction side or the exhaust gas discharge side end portion of the wall flow type base material. A precursor composition of a porous dense collection layer containing fine particles is supplied, and 0.4 with respect to the total length L of the wall flow type base material in a cross-sectional view over the extending direction of the partition wall of the wall flow type base material. The step of applying the precursor composition into the pores of the partition wall by a length of about 0.9 L, and the heat treatment of the obtained coated wall flow type substrate are performed, and the precursor composition is heat-treated into the pores of the partition wall. A method for producing a catalyst-coated gasoline particulate filter, which comprises at least a step of forming a plurality of porous dense portions filled with inorganic fine particles to form the porous dense collection layer.

(11) Before the step of applying the precursor composition, the first catalyst composition containing a platinum group element is supplied from the end of the wall flow type base material on the exhaust gas introduction side or the exhaust gas discharge side. A step of applying the first catalyst composition to a plurality of locations in the pores of the partition wall to form a first catalyst layer along the stretching direction of the partition wall of the wall flow type base material is further provided, and the precursor is further provided. In the step of applying the body composition, the precursor composition is impregnated and coated on the first catalyst layer in the pores of the wall flow type base material which has been coated with the first catalyst layer. A method for manufacturing a catalyst-coated gasoline particulate filter according to 10).

(12) The precursor composition is a catalyst composition containing at least the inorganic fine particles, the second composite catalyst particles having a platinum group element supported on the inorganic fine particles, and water. 11) The method for manufacturing a catalyst-coated gasoline particulate filter according to 11).
(13) The method for producing a catalyst-coated gasoline particulate filter according to any one of (10) to (12) above, wherein the precursor composition contains a water-soluble polymer compound.
(14) The method for producing a catalyst-coated gasoline particulate filter according to any one of (10) to (13) above, wherein the precursor composition contains a pore-forming material.

According to the present invention, it is possible to realize a catalyst-coated gasoline particulate filter and a method for producing the same, in which the PN collection rate is dramatically improved as compared with the conventional GPF catalyst. This catalyst-coated gasoline particulate filter is not only a particulate filter with a particularly excellent PN collection rate, but also a three-way catalyst (TWC: Three Way Catalyst) that reduces NOx, CO, HC, etc. in the exhaust gas. ), It can be replaced with a three-way catalyst installed in a catalyst converter directly under the engine or a catalyst converter directly under the tandem arrangement, which saves space, reduces canning costs, reduces costs, etc. Can be planned.

It is a schematic schematic cross-sectional view which shows one Embodiment of a catalyst coating gasoline particulate filter 100. It is sectional drawing (II)-(II) of FIG. It is sectional drawing (III)-(III) of FIG. It is a flowchart which shows an example of the manufacturing method of the catalyst coating gasoline particulate filter 100. The step S11 of the manufacturing method of the catalyst coating gasoline particulate filter 100 is shown. The step S12 of the manufacturing method of the catalyst coating gasoline particulate filter 100 is shown. The step S12 of the manufacturing method of the catalyst coating gasoline particulate filter 100 is shown. The step S21 of the manufacturing method of the catalyst coating gasoline particulate filter 100 is shown. The step S31 of the manufacturing method of the catalyst coating gasoline particulate filter 100 is shown. FIG. 5 is a schematic schematic cross-sectional view showing another embodiment of the catalyst-coated gasoline particulate filter 100. FIG. 10 is a cross-sectional view taken along the line (XI)-(XI) of FIG. FIG. 10 is a cross-sectional view taken along the line (XII)-(XII) of FIG. FIG. 5 is a schematic schematic cross-sectional view showing another embodiment of a catalyst-coated gasoline particulate filter 100. FIG. 13 is a cross-sectional view taken along the line (XIV)-(XIV) of FIG. FIG. 13 is a cross-sectional view taken along the line (XV)-(XV) of FIG. FIG. 5 is a schematic schematic cross-sectional view showing still another embodiment of the catalyst-coated gasoline particulate filter 100. FIG. 16 is a cross-sectional view taken along the line (XVII)-(XVII) of FIG. 16 is a cross-sectional view taken along the line (XVIII)-(XVIII) of FIG.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following embodiments are examples (representative examples) of embodiments of the present invention, and the present invention is not limited thereto. That is, the present invention can be arbitrarily modified and implemented without departing from the gist thereof. In addition, in this specification, the positional relationship such as up, down, left and right shall be based on the positional relationship shown in the drawings unless otherwise specified. Moreover, the dimensional ratio of the drawing is not limited to the ratio shown in the drawing. In addition, in this specification, when a numerical value or a physical property value is put before and after using "~", it is used as including the value before and after that. For example, the notation of the numerical range of "1 to 100" includes both the upper limit value "100" and the lower limit value "1". The same applies to the notation of other numerical ranges. Further, in the present specification, the "D50 particle size" refers to the particle size when the integrated value from the small particle size reaches 50% of the total in the cumulative distribution of the particle size based on the volume, and refers to the so-called median size. Meaning, "D90 particle size" means the particle size when the integrated value from the small particle size reaches 90% of the total in the cumulative distribution of the particle size based on the volume, and these are laser diffraction type. It means a value measured by a particle size distribution measuring device (for example, a laser diffraction type particle size distribution measuring device SALD-3100 manufactured by Shimadzu Corporation).

[First Embodiment]
<Catalyst coated gasoline particulate filter>
FIG. 1 is a schematic cross-sectional view showing a schematic configuration of a catalyst-coated gasoline particulate filter 100 (hereinafter, may be referred to as “GPF catalyst”) according to an embodiment of the present invention. The catalyst-coated gasoline particulate filter 100 of the present embodiment includes at least a wall flow type base material 10 and a porous dense collection layer 31 zone-coated on a part of the wall flow type base material 10. The black arrows in FIG. 1 indicate the introduction direction and the discharge direction of the exhaust gas. Hereinafter, the overall configuration of the catalyst-coated gasoline particulate filter 100 will be described in detail.

As shown in FIG. 1, in the wall flow type base material 10, the introduction side cell 11 in which the end portion 11a on the exhaust gas introduction side is opened and the discharge side cell 12 in which the end portion 12a on the exhaust gas discharge side is opened are porous. It is composed of a plurality of structures (catalyst carriers) arranged side by side via the partition wall 13. In the wall flow type base material 10, the opening of one end 11a and the opening of the other end 12a in the cell stretching direction are alternately sealed by the sealing wall 51, whereby the partition wall 13 is sealed. Adjacent introduction-side cells 11 and discharge-side cells 12 are alternately formed. Then, in the present embodiment, the exhaust gas introduced from the end portion 11a side of the introduction side cell 11 passes through the introduction side cell 11, the partition wall 13, and the discharge side cell 12 in this order, and from the end portion 12a side of the discharge side cell 12. It is discharged to the outside of the system.

A first catalyst layer 21 containing a platinum group element is provided on the partition wall 13 of the wall flow type base material 10 by a wash coat (hereinafter, the wall flow type base material 10 after coating the first catalyst layer 21). May be referred to as "wall flow type base material 41 after catalyst coating"). As shown in FIGS. 2 and 3, the first catalyst layer 21 is provided on the pore surface of the partition wall 13 of the wall flow type base material 10. Therefore, the wall-flow type base material 41 after catalyst coating functions as an exhaust gas purification catalyst that purifies the exhaust gas discharged from the gasoline engine in the first catalyst layer 21, and also functions as an exhaust gas purification catalyst, and is a particulate matter (PM: Particulate) contained in the exhaust gas. It functions as a GPF (Gasoline Particulate Filter) that collects and separates (removes) Matter) on the surface of the partition wall 13 and in the pores.

In the catalyst-coated gasoline particulate filter 100 of the present embodiment, in the cross-sectional view shown in FIG. 1, a porous dense collection layer having a predetermined length La over the stretching direction of the partition wall 13 of the wall flow type base material 10. 31 is provided by a wash coat. The porous dense collection layer 31 is provided on the first catalyst layer 21 formed in the pores of the partition wall 13 of the wall flow type base material 41 after the catalyst coating (see FIG. 3). The porous dense collection layer 31 is for collecting PM contained in the exhaust gas with high efficiency. In the present embodiment, as shown in FIG. 3, the porous dense collection layer 31 is inside the pores of the partition wall 13 of the wall flow type base material 10 (inside the pores of the partition wall 13 of the wall flow type base material 41 after catalyst coating). It is composed of a plurality of porous dense portions 31a in which inorganic fine particles are densely packed. By filling the pores of the partition wall 13 with inorganic fine particles at a high density in this way, a porous dense portion 31a having voids (pores) having an extremely small pore diameter as compared with the pores of the partition wall 13 is formed. .. Due to the presence of the porous dense portion 31a, even a minute PM that was difficult to collect in the past can be collected, so that the PN collection rate is dramatically improved.

As shown in FIG. 3, the porous dense collection layer 31 is conceptualized as a set of porous dense portions 31a formed in the pores of the partition wall 13 of the wall flow type base material 10. .. As shown in the schematic cross-sectional view of FIG. 1, the porous dense collection layer 31 is macroscopically represented as a region in which a plurality of porous dense portions 31a exist.

As shown in FIG. 1, the porous dense collection layer 31 is La zone coated with a predetermined length in the stretching direction of the partition wall 13 of the wall flow type base material 10. The length La is 0.4 to 0.9 L with respect to the total length L of the wall flow type base material 10 in a cross-sectional view. By zone-coating with such a length La, the PN collection rate can be dramatically improved, and the balance between pressure loss and exhaust gas purification performance can be maintained. Further, from the viewpoint of maintaining a high balance between the PN collection rate, the pressure loss, the exhaust gas purification performance, etc., the length La of the porous dense collection layer 31 is relative to the total length L in the cross-sectional view of the wall flow type base material 10. The amount is preferably 0.45 to 0.85 L, more preferably 0.5 to 0.8 L. In this embodiment, as shown in FIG. 1, the porous dense collection layer 31 is zone-coated with a length of La = 0.8L.

On the other hand, the thickness Da of the porous dense collection layer 31 can be appropriately set according to the desired performance and is not particularly limited. From the viewpoint of maintaining a high balance between the PN collection rate, the pressure loss, the exhaust gas purification performance, etc., the thickness Da of the porous dense collection layer 31 is 0.1 to 0 with respect to the thickness D in the cross-sectional view of the partition wall 13. 9.9D is preferable, more preferably 0.1 to 0.7D, still more preferably 0.2 to 0.5D.

The location where the porous dense collection layer 31 is formed is not particularly limited in the thickness direction of the partition wall 13 in the cross-sectional view, but from the viewpoint of ease of production of the porous dense collection layer 31 (porous dense portion 31a). , It is preferable that the introduction side cell 11 is unevenly distributed on the cell wall surface side, or the discharge side cell 12 is unevenly distributed on the cell wall surface side. The uneven distribution of the porous dense collection layer 31 can be confirmed by, for example, a scanning electron microscope on the cross section of the partition wall 13 of the catalyst-coated gasoline particulate filter 100.

Further, in the present embodiment, in addition to the first catalyst layer 21, a second catalyst layer 32 is further provided by a wash coat (see FIG. 1). In the second catalyst layer 32, in the wall flow type base material 41 after the catalyst coating, the porous dense collection layer 31 is provided in the region on the end portion 11a side of the uncoated exhaust gas introduction side. Specifically, in the uncoated region of the porous dense collection layer 31, the second catalyst layer 21 is provided on the pore surface of the partition wall 13 of the wall flow type base material 41 after the catalyst coating. A catalyst layer 32 is provided. The second catalyst layer 32 contains base material particles of inorganic fine particles and a third composite catalyst particle having a platinum group element supported on the base material particles. The second catalyst layer 32 is for reinforcing the exhaust gas purification performance of the first catalyst layer 21, and is an arbitrary catalyst layer. Further, if necessary, a third catalyst layer or a fourth catalyst layer can be provided.

The second catalyst layer 32 is provided with a predetermined length Lb from the end portion 11a side on the exhaust gas introduction side toward the stretching direction of the partition wall 13 of the wall flow type base material 10. The length Lb can be appropriately set according to the desired performance and is not particularly limited, but is preferably 0.1 to 0.6 L with respect to the total length L of the wall flow type base material 10 in a cross-sectional view, and is 0.15 to 0. It is preferably .55 L, more preferably 0.2 to 0.5 L.

The thickness of the second catalyst layer 32 can be appropriately set according to the desired performance and is not particularly limited. In the present embodiment, the second catalyst layer 32 is provided in the region corresponding to the thickness D of the partition wall 13, but the thickness of the second catalyst layer 32 may be less than the thickness D of the partition wall 13. At this time, the second catalyst layer 32 may be unevenly distributed on the cell wall surface side of the introduction side cell 11 or the cell wall surface side of the discharge side cell 12 in the thickness direction of the partition wall 13 in the cross-sectional view. The uneven distribution of the second catalyst layer 32 can be confirmed, for example, by a scanning electron microscope on the cross section of the partition wall 13 of the catalyst-coated gasoline particulate filter 100.

In the catalyst-coated gasoline particulate filter 100 having such a structure, the exhaust gas discharged from the gasoline engine flows into the introduction side cell 11 from the end portion 11a (opening) on the exhaust gas introduction side, and the pores of the partition wall 13 are formed. It passes through the inside, flows into the adjacent discharge side cell 12, and flows out of the system from the end portion 12a (opening) on the exhaust gas discharge side. In this process, the exhaust gas comes into contact with the first catalyst layer 21 (and the second catalyst layer) formed in the pores of the partition wall 13, thereby carbon monoxide (CO) and hydrocarbons (HC) contained in the exhaust gas. Is oxidized to water (H ₂ O), carbon dioxide (CO ₂ ), etc., nitrogen oxides (NOx) are _{reduced to nitrogen (N 2} ), and harmful components are purified (detoxified).

On the other hand, the particulate matter (PM) contained in the exhaust gas is deposited on the partition wall 13 in the introduction side cell 11 and / or in the pores of the partition wall 13. In the present embodiment, since the porous dense collection layer 31 composed of a plurality of porous dense portions 31a in which the pores of the partition wall 13 of the wall flow type base material 10 are densely filled with inorganic fine particles is provided. The particle size is smaller than that of the conventional PM collection by only the pores of the partition 13 or the PM collection by only the first catalyst layer 21 provided on the surface of the pores of the conventional partition 13. Since PM can be collected with high efficiency, the PN collection rate is dramatically increased. The deposited particulate matter is removed according to a conventional method, for example, by the catalytic function of the catalyst layer 21 or by burning at a predetermined temperature (for example, about 500 to 700 ° C.).

Here, from the viewpoint of collecting PM having a small particle size with high efficiency and increasing the PN collection rate, the porous dense collection layer 31 (porous dense portion 31a) has many fine voids and coarse voids. It is desirable to have microporousness. The porosity of the porous dense collection layer 31 (porous dense portion 31a) is determined by the pore diameter by the mercury intrusion method (for example, the mode diameter (the pore diameter having the largest appearance ratio in the frequency distribution of the pore diameter (maximum value of the distribution)). )) And can be detected by measuring the pore volume. From the viewpoint of achieving a higher PN collection rate, the porous dense collection layer 31 preferably has microporous properties in which the pore volume by the mercury intrusion method satisfies the following relationship.
Pore diameter 0.1 μm or more, less than 1 μm: 0.010 cm ³ / g or more Pore diameter 1 μm or more, less than 5 μm: 0.020 cm ³ / g or more Pore diameter 5 μm or more, less than 10 μm: 0.050 cm ³ / g or more Pore diameter 10 μm Above: 0.500 cm less than ^{3 / g}

Here, in the present specification, the microporousness of the porous dense collection layer 31 is measured by collecting a measurement sample of a predetermined size from the partition wall 13 on which the porous dense collection layer 31 is formed, and using the following examples. It means a value calculated by the mercury press-fitting method under the described conditions.

In the present embodiment, from the viewpoint of collecting PM having a small particle size with high efficiency and increasing the PN collection rate, the porosity has a large porosity with a pore volume of 0.1 μm or more and less than 5 μm. The densely packed layer 31 is particularly preferably used. Pore volume of less than or pore diameter 0.1 [mu] m 5 [mu] m is more preferably at least 0.06 cm ³ / g, more preferably 0.07 cm ³ / g or more, 0.08 cm ³ / g or more is particularly preferable. The upper limit of such pore volume is not particularly limited, but usually is a measure is 5.00 cm ³ / g or less, preferably 3.00 cm ³ / g or less, more preferably 2.00 cm ³ / g or less be. The porous dense collecting layer 31 having such microporous uses fine inorganic fine particles capable of forming voids having a pore diameter of 0.1 μm or more and less than 5 μm when forming the porous dense portion 31a. It can be realized by applying various known methods such as using a minute pore-forming material capable of forming a void having a pore diameter of 0.1 μm or more and less than 5 μm when forming the dense portion 31a.

At this time, To be more specific, the pore volume of less than the pore diameter 0.1 [mu] m 1 [mu] m is more preferably at least 0.015cm ³ / g, 0.02cm ³ / more preferably more than g, 0.25 cm ³ / g or more Is particularly preferable, and 0.30 cm ³ / g or more is most preferable. The upper limit of such pore volume is not particularly limited, but usually is a measure is 5.00 cm ³ / g or less, preferably 3.00 cm ³ / g or less, more preferably 2.00 cm ³ / g or less be. The porous dense collecting layer 31 having such microporous uses fine inorganic fine particles capable of forming voids having a pore diameter of 0.1 μm or more and less than 1 μm when forming the porous dense portion 31a. It can be realized by applying various known methods such as using a minute pore-forming material capable of forming a void having a pore diameter of 0.1 μm or more and less than 1 μm when forming the dense portion 31a.

Further, the pore volume of less than or pore diameter 1 [mu] m 5 [mu] m is more preferably more than 0.025 cm ³ / g, more preferably 0.03 cm ³ / g or more, particularly preferably 0.034cm ³ / g or more, 0.36 cm ³ / G or more is most preferable. The upper limit of such pore volume is not particularly limited, but usually is a measure is 5.00 cm ³ / g or less, preferably 3.00 cm ³ / g or less, more preferably 2.00 cm ³ / g or less be. The porous dense collecting layer 31 having such microporous uses fine inorganic fine particles capable of forming voids having a pore diameter of 1 μm or more and less than 5 μm when forming the porous dense portion 31a. It can be realized by applying various known methods such as using a minute pore-forming material capable of forming voids having a pore diameter of 1 μm or more and less than 5 μm when forming 31a.

Further, from the viewpoint of collecting PM having a small particle size with high efficiency and increasing the PN collection rate, the pore volume having a pore diameter of 5 μm or more and less than 10 μm ^{is more preferably 0.055 cm 3} / g or more, and 0.06 cm ³ / G or more is more preferable, 0.07 cm ³ / g or more is particularly preferable, and 0.08 cm ³ / g or more is most preferable. The upper limit of such pore volume is not particularly limited, but usually is a measure is 7.00cm ³ / g or less, preferably 5.00 cm ³ / g or less, more preferably 3.00 cm ³ / g or less be. The porous dense collecting layer 31 having such microporous uses fine inorganic fine particles capable of forming voids having a pore diameter of 5 μm or more and less than 10 μm when forming the porous dense portion 31a. It can be realized by applying various known methods such as using a minute pore-forming material capable of forming voids having a pore diameter of 5 μm or more and less than 10 μm when forming 31a.

On the other hand, from the viewpoint of reducing the existence ratio of the coarse void enhances the PN collection rate, or more pore volume pore diameter 10μm is more preferably less than 0.400cm ³ / g, more preferably less than 0.300cm ³ / g , 0.250 cm ^{less than 3} / g is particularly preferable, and ^{less than 0.200 cm 3} / g is most particularly preferable. The porous dense collection layer 31 having such microporous is highly filled with fine inorganic fine particles in the pores so that voids having a pore diameter of 10 μm or more are not formed when the porous dense portion 31a is formed. It can be realized by applying various known methods such as using a pore-forming material having a small presence ratio of coarse powder of 15 μm or more so that voids having a pore diameter of 10 μm or more are not formed when forming the porous dense portion 31a. can.

The pore volume (total volume of the pore diameter of 0.1 μm or more) of the porous dense collection layer 31 varies depending on the size of the wall flow type base material 10 to be used and is not particularly limited, but is usually 0.2 to 2. 0.8 cm ³ / g, more preferably from 0.25~0.7cm ³ / g, more preferably from 0.3~0.6cm ³ / g, particularly preferably 0.3 to 0. It is 55 cm ³ / g.

Hereinafter, each component will be described in more detail (base material).
In the wall flow type base material 10, the introduction side cell 11 in which the end portion 11a on the exhaust gas introduction side is opened and the discharge side cell 12 in which the end portion 12a on the exhaust gas discharge side is opened adjacent to the introduction side cell 11 are porous. It is a structure partitioned by a quality partition wall 13. As such a structure, various materials and shapes used in conventional applications of this type can be used. For example, the material of the wall flow type base material 10 is exposed to high-temperature (for example, 400 ° C. or higher) exhaust gas generated when an internal combustion engine is operated under a high load condition, or particulate matter is burned and removed at a high temperature. It is preferably made of a heat-resistant material so that it can be used in various cases. Examples of the heat-resistant material include ceramics such as cordierite, silicon carbide, silicon nitride, mulite, aluminum titanate, and silicon carbide (SiC); alloys such as stainless steel. Further, the shape of the wall flow type base material 10 can be appropriately adjusted from the viewpoint of exhaust gas purification performance, suppression of pressure loss increase, and the like. For example, the outer shape of the wall flow type base material 10 can be a cylindrical shape, an elliptical cylinder shape, a polygonal cylinder shape, or the like. The capacity (total volume of cells) of the wall flow type base material 10 is usually preferably 0.1 to 5 L, more preferably 0.5 to 3 L, although it varies depending on the space to be incorporated. Further, the total length of the wall flow type base material 10 in the stretching direction (total length of the partition wall 13 in the stretching direction) also differs depending on the space or the like of the incorporation destination, but is usually preferably 10 to 500 mm, more preferably 50 to 300 mm. be.

The introduction side cell 11 and the discharge side cell 12 are regularly arranged along the axial direction of the tubular shape, and as described above, the adjacent cells are one open end in the extension direction and the other open end. And are sealed alternately. The introduction-side cell 11 and the discharge-side cell 12 can be set to an appropriate shape and size in consideration of the flow rate and components of the supplied exhaust gas. For example, the mouth shape of the introduction side cell 11 and the discharge side cell 12 can be a triangle; a rectangle such as a square, a parallelogram, a rectangle, and a trapezoid; another polygon such as a hexagon and an octagon; a circle. .. Further, it may have a High Ash Capacity (HAC) structure in which the cross-sectional area of the introduction side cell 11 and the cross-sectional area of the discharge side cell 12 are different from each other. The number of introduction-side cells 11 and discharge-side cells 12 can be appropriately set so as to promote the generation of turbulent flow of exhaust gas and suppress clogging due to fine particles or the like contained in the exhaust gas, and is particularly limited. However, usually 200 cpsi to 400 cpsi is preferable.

The partition wall 13 that partitions adjacent cells is not particularly limited as long as it has a porous structure through which exhaust gas can pass, and the configuration thereof includes exhaust gas purification performance, suppression of increase in pressure loss, and mechanical strength of the base material. It can be adjusted as appropriate from the viewpoint of improving the above. For example, when the slurry composition of the first catalyst layer 21 described later is applied and dried to form the first catalyst layer 21 in the partition wall 13, the pore diameter (for example, the mode diameter (the appearance ratio in the frequency distribution of the pore diameter) When the pore diameter (maximum value of distribution))) or the pore volume is large, the pores are generally less likely to be blocked by the first catalyst layer 21, and the pressure loss of the obtained exhaust gas purification catalyst increases. Although it tends to be difficult, the ability to collect particulate matter tends to decrease, and the mechanical strength of the base material also tends to decrease. On the other hand, when the pore diameter and the pore volume are small, the pressure loss is generally likely to increase, but the ability to collect particulate matter is improved and the mechanical strength of the base material is also improved. There is a tendency.

From this point of view, the pore diameter (mode diameter) of the partition wall 13 of the wall flow type base material 10 before forming the first catalyst layer 21 is preferably 8 to 25 μm, more preferably 10 to 22 μm. , More preferably 13 to 20 μm. The thickness D of the partition wall 13 of the wall flow type base material 10 before forming the first catalyst layer 21 is preferably 6 to 12 mil, more preferably 6 to 10 mil. Further, the pore volume of the partition wall 13 of the wall flow type base material 10 before forming the first catalyst layer 21 is preferably 0.2 to 1.5 cm ³ / g by the mercury intrusion method, and more preferably 0. It is 25 to 0.9 cm ³ / g, more preferably 0.3 to 0.8 cm ³ / g. The porosity of the partition wall 13 at that time is preferably 20 to 80%, more preferably 40 to 70%, and even more preferably 60 to 70%. When the pore volume or porosity is equal to or higher than the lower limit, the increase in pressure loss tends to be further suppressed. Further, when the pore volume or the porosity is not more than the upper limit, the strength of the base material tends to be further improved. The pore diameter (mode diameter), pore volume, and porosity mean values calculated by the mercury intrusion method under the conditions described in the following examples.

(First catalyst layer)
Next, the first catalyst layer 21 will be described. The first catalyst layer 21 is formed at least at a plurality of locations in the pores of the partition wall 13, and in the present embodiment, the first catalyst layer 21 has a total length L and a thickness D over the entire region in a cross-sectional view of the wall flow type base material 10. The catalyst layer 21 is formed (see FIGS. 1 to 3). The location where the first catalyst layer 21 is formed may be appropriately set according to the desired performance, and the first catalyst layer 21 does not necessarily have to be formed over the entire region in a cross-sectional view of the wall flow type base material 10. , The first catalyst layer 21 may be formed only partially.

The first catalyst layer 21 of the present embodiment contains at least the first base material particles and the first composite catalyst particles having a platinum group element supported on the first base material particles. By constructing the first catalyst layer 21 using such a platinum group element-supporting catalyst, it is possible to realize high exhaust gas purification performance, for example, high light-off performance while suppressing an increase in pressure loss.

Here, examples of the platinum group element include platinum (Pt), palladium (Pd), rhodium (Rh), ruthenium (Ru), iridium (Ir), and osmium (Os). Of these, palladium (Pd) and platinum (Pt) are preferable from the viewpoint of oxidizing activity, and rhodium (Rh) is preferable from the viewpoint of reducing activity. As the platinum group elements, one type may be used alone, or two or more types may be used in any combination and ratio. Examples of the combination of platinum group elements are not particularly limited, but a combination of two or more platinum group elements having excellent oxidative activity, a combination of two or more platinum group elements having excellent reducing activity, and a platinum group element having excellent oxidative activity. And a combination of platinum group elements having excellent reducing activity. Among these, as one aspect of the synergistic effect, a combination of a platinum group element having an excellent oxidizing activity and a platinum group element having an excellent reducing activity is preferable. Specifically, a combination of Pd and Rh, a combination of Pt and Rh, and a combination of Pd, Pt and Rh are preferable. With such a combination, the exhaust gas purification performance, particularly the light-off performance, tends to be further improved.

The fact that the first catalyst layer 21 contains a platinum group element can be confirmed by a scanning electron microscope or the like on the cross section of the partition wall 13 of the catalyst-coated gasoline particulate filter 100. Specifically, it can be confirmed by performing energy dispersive X-ray analysis in the field of view of a scanning electron microscope.

Further, as the first base material particles carrying a platinum group element, an inorganic compound conventionally used in this type of exhaust gas purification catalyst can be considered. For example, oxygen storage materials (OSC materials) such as cerium oxide (Ceria: CeO ₂ ) and ceria-zirconia composite oxides (CZ composite oxides), aluminum oxide (alumina: Al ₂ O ₃ ), zirconium oxide (zirconia: ZrO). ₂ ), metal oxides such as silicon oxide (silica: SiO ₂ ), titanium oxide (titania: TiO ₂ ), composite oxides containing these oxides as main components, perovskite-type oxides, zeolites, etc. can be mentioned. , The type is not particularly limited. Further, these may be a composite oxide or a solid solution to which a rare earth element such as lantern or yttrium, a transition metal element, or an alkaline earth metal element is added. As these base metal particles, one type can be used alone, or two or more types can be used in any combination and ratio. Here, the oxygen occlusion material (OSC material) is when the air-fuel ratio of the exhaust gas is lean (that is, the atmosphere on the oxygen excess side), the oxygen in the exhaust gas is occlusioned, and when the air-fuel ratio of the exhaust gas is rich (that is, the air-fuel ratio of the exhaust gas is rich). That is, the atmosphere on the excess fuel side) is the one that releases the stored oxygen. The first base material particles function as carrier particles that support the catalytically active particles in a highly dispersed manner.

The D90 particle size of the first base material particles in the first catalyst layer 21 can be appropriately set according to the desired performance and is not particularly limited, but is preferably 1 to 7 μm from the viewpoint of exhaust gas purification performance and suppression of pressure loss increase. , More preferably 1 to 6 μm, still more preferably 1 to 5 μm.

The content ratio of platinum group elements in the first catalyst layer 21 (wall flow type group) from the viewpoint of improving the exhaust gas purification performance and suppressing the progress of grain growth (sintering) of platinum group elements on the first base material particles. The mass of the platinum group element per 1 L of the material) is usually preferably 0.1 to 10 g / L, more preferably 0.2 to 8 g / L, and further preferably 0.3 to 6 g / L.

(Porosity dense collection layer)
Next, the porous dense collection layer 31 will be described. As described above, in the present embodiment, a plurality of porous dense portions 31a constituting the porous dense collection layer 31 are formed on the first catalyst layer 21 formed on the pore surface of the partition wall 13. The porous dense portion 31a is formed by highly filling the pores of the partition wall 13 after coating the first catalyst layer 21 with inorganic fine particles.

As the inorganic fine particles constituting the porous dense portion 31a, an inorganic compound conventionally used in this type of exhaust gas purification catalyst can be considered. For example, oxygen storage materials (OSC materials) such as cerium oxide (Ceria: CeO ₂ ) and ceria-zirconia composite oxides (CZ composite oxides), aluminum oxide (alumina: Al ₂ O ₃ ), zirconium oxide (zirconia: ZrO). ₂ ), oxides such as silicon oxide (silica: SiO ₂ ) and titanium oxide (titania: TiO ₂ ) and composite oxides containing these oxides as main components can be mentioned, but the types thereof are not particularly limited. Further, these may be a composite oxide or a solid solution to which a rare earth element such as lantern or yttrium, a transition metal element, or an alkaline earth metal element is added. As these inorganic fine particles, one type can be used alone, or two or more types can be used in any combination and ratio. Here, the oxygen occlusion material (OSC material) is when the air-fuel ratio of the exhaust gas is lean (that is, the atmosphere on the oxygen excess side), the oxygen in the exhaust gas is occlusioned, and when the air-fuel ratio of the exhaust gas is rich (that is, the air-fuel ratio of the exhaust gas is rich). That is, the atmosphere on the excess fuel side) is the one that releases the stored oxygen.

The D90 particle size of the inorganic fine particles constituting the porous dense portion 31a can be appropriately set according to the desired performance and is not particularly limited, but is 1 to 7 μm from the viewpoint of achieving the above-mentioned microporousness with good reproducibility and convenience. Is preferable, more preferably 1 to 6 μm, still more preferably 1 to 5 μm.

The porous dense collection layer 31 may contain a platinum group element, if necessary. For example, as the above-mentioned inorganic fine particles, the inorganic fine particles and the second composite catalyst particles having a platinum group element supported on the surface of the inorganic fine particles can be used. By using the second composite catalyst particles in which the platinum group element is supported on the surface as the above-mentioned inorganic fine particles, the porous dense collection layer 31 can also have a catalytic function, thereby purifying the exhaust gas. Performance can be enhanced. In this case, the above-mentioned inorganic fine particles also function as carrier particles that support the catalytically active particles in a highly dispersed manner. Here, examples of the platinum group element include platinum (Pt), palladium (Pd), rhodium (Rh), ruthenium (Ru), iridium (Ir), and osmium (Os). Of these, palladium (Pd) and platinum (Pt) are preferable from the viewpoint of oxidizing activity, and rhodium (Rh) is preferable from the viewpoint of reducing activity. As the platinum group elements, one type may be used alone, or two or more types may be used in any combination and ratio. Examples of the combination of platinum group elements are not particularly limited, but a combination of two or more platinum group elements having excellent oxidative activity, a combination of two or more platinum group elements having excellent reducing activity, and a platinum group element having excellent oxidative activity. And a combination of platinum group elements having excellent reducing activity. Among these, as one aspect of the synergistic effect, a combination of a platinum group element having an excellent oxidizing activity and a platinum group element having an excellent reducing activity is preferable. Specifically, a combination of Pd and Rh, a combination of Pt and Rh, and a combination of Pd, Pt and Rh are preferable. With such a combination, the exhaust gas purification performance, particularly the light-off performance, tends to be further improved.

It can be confirmed by a scanning electron microscope or the like of the cross section of the partition wall 13 of the catalyst-coated gasoline particulate filter 100 that the porous dense collection layer 31 contains a platinum group element. Specifically, it can be confirmed by performing energy dispersive X-ray analysis in the field of view of a scanning electron microscope.

From the viewpoint of improving the exhaust gas purification performance and suppressing the progress of grain growth (sintering) of platinum group elements on inorganic fine particles, the content ratio of platinum group elements in the porous dense collection layer 31 (wall flow type base material). The mass of the platinum group element per 1 L) is usually preferably 0.5 to 10 g / L, more preferably 1 to 8 g / L, and further preferably 1 to 6 g / L.

Here, the pore diameter (mode diameter) of the partition wall 13 on which the porous dense collection layer 31 is formed is preferably 10 to 23 μm, more preferably 12 to 20 μm, and even more preferably 12 to 20 μm by the above-mentioned mercury press-fitting method. It is 14 to 18 μm. The porosity of the partition wall 13 on which the porous dense collection layer 31 is formed is preferably 20 to 80%, more preferably 30 to 70%, and preferably 35 to 60% by the above-mentioned mercury press-fitting method. Is.

(Second catalyst layer)
Next, the second catalyst layer 32 will be described. As described above, the second catalyst layer 32 is an arbitrary component in which the porous dense collection layer 31 is provided in the region on the end portion 11a side of the uncoated exhaust gas introduction side, and the first catalyst layer 21. This is to reinforce the exhaust gas purification performance of.

The second catalyst layer 32 of the present embodiment contains the base material particles of inorganic fine particles and the third composite catalyst particles having a platinum group element supported on the base material particles. The inorganic fine particles used here function as carrier particles that support platinum group elements in a highly dispersed manner. By forming the second catalyst layer 32 using such a platinum group element-supported catalyst (third composite catalyst particles), high exhaust gas purification performance, for example, high light-off performance is realized while suppressing an increase in pressure loss. can do. The third composite catalyst particles of the second catalyst layer 32 may be the same as or different from the first composite catalyst particles of the first catalyst layer 21 and the second composite catalyst particles of the porous dense portion 31a. When the preferred production method described later is applied, the third composite catalyst particles of the second catalyst layer 32 are the same as the second composite catalyst particles of the porous dense portion 31a, thereby forming the second catalyst layer 32. The manufacturing process of the porous dense collecting layer 31 (porous dense portion 31a) can be simplified, and the productivity can be improved.

Here, examples of the platinum group element include platinum (Pt), palladium (Pd), rhodium (Rh), ruthenium (Ru), iridium (Ir), and osmium (Os). Of these, palladium (Pd) and platinum (Pt) are preferable from the viewpoint of oxidizing activity, and rhodium (Rh) is preferable from the viewpoint of reducing activity. As the platinum group elements, one type may be used alone, or two or more types may be used in any combination and ratio. Examples of the combination of platinum group elements are not particularly limited, but a combination of two or more platinum group elements having excellent oxidative activity, a combination of two or more platinum group elements having excellent reducing activity, and a platinum group element having excellent oxidative activity. And a combination of platinum group elements having excellent reducing activity. Among these, as one aspect of the synergistic effect, a combination of a platinum group element having an excellent oxidizing activity and a platinum group element having an excellent reducing activity is preferable. Specifically, a combination of Pd and Rh, a combination of Pt and Rh, and a combination of Pd, Pt and Rh are preferable. With such a combination, the exhaust gas purification performance, particularly the light-off performance, tends to be further improved.

The fact that the second catalyst layer 32 contains a platinum group element can be confirmed by a scanning electron microscope or the like of the cross section of the partition wall 13 of the catalyst-coated gasoline particulate filter 100. Specifically, it can be confirmed by performing energy dispersive X-ray analysis in the field of view of a scanning electron microscope.

Further, as the inorganic fine particles as the base material particles carrying the platinum group element, an inorganic compound conventionally used in this type of exhaust gas purification catalyst can be considered. For example, oxygen storage materials (OSC materials) such as cerium oxide (Ceria: CeO ₂ ) and ceria-zirconia composite oxides (CZ composite oxides), aluminum oxide (alumina: Al ₂ O ₃ ), zirconium oxide (zirconia: ZrO). ₂ ), oxides such as silicon oxide (silica: SiO ₂ ) and titanium oxide (titania: TiO ₂ ) and composite oxides containing these oxides as main components can be mentioned, but the types thereof are not particularly limited. Further, these may be a composite oxide or a solid solution to which a rare earth element such as lantern or yttrium, a transition metal element, or an alkaline earth metal element is added. As these inorganic fine particles, one type can be used alone, or two or more types can be used in any combination and ratio. Here, the oxygen occlusion material (OSC material) is when the air-fuel ratio of the exhaust gas is lean (that is, the atmosphere on the oxygen excess side), the oxygen in the exhaust gas is occlusioned, and when the air-fuel ratio of the exhaust gas is rich (that is, the air-fuel ratio of the exhaust gas is rich). That is, the atmosphere on the excess fuel side) is the one that releases the stored oxygen.

The D90 particle size of the inorganic fine particles in the second catalyst layer 32 can be appropriately set according to the desired performance and is not particularly limited, but is preferably 1 to 7 μm, more preferably, from the viewpoint of exhaust gas purification performance and suppression of pressure loss increase. Is 1 to 6 μm, more preferably 1 to 5 μm.

The content ratio of platinum group elements in the second catalyst layer 32 (wall flow type group) from the viewpoint of improving the exhaust gas purification performance and suppressing the progress of grain growth (sintering) of platinum group elements on the first base material particles. The mass of the platinum group element per 1 L of the material) is usually preferably 0.5 to 10 g / L, more preferably 1 to 8 g / L, and further preferably 1 to 6 g / L.

Here, the porosity of the partition wall 13 on which only the first catalyst layer 21 is formed and the porosity of the partition wall 13 on which the first catalyst layer 21 and the second catalyst layer 32 are formed are the above-mentioned porous dense collection. It is preferable that the layer 31 (porous and dense portion 31a) does not have microporous properties, that is, the pore volume by the mercury intrusion method does not satisfy the above relationship (relationship in the numerical range described as preferable). As described above, the porosity of the partition wall 13 on which only the first catalyst layer 21 or the first catalyst layer 21 and the second catalyst layer 32 are formed, and the microporousness of the partition wall 13 on which the porous dense collection layer 31 is formed. By differentiating the above and separating the functions of each, it is possible to achieve both suppression of pressure loss increase, high exhaust gas purification performance, and dramatically improved PN collection rate.

For example, in the partition wall 13 in which only the first catalyst layer 21 is formed, and in the partition wall 13 in which the first catalyst layer 21 and the second catalyst layer 32 are formed, the pore volumes by the mercury intrusion method are as follows (A) to ( It is preferable to have a porosity that satisfies at least one of D).
(A) Pore diameter 0.1 μm or more and less than 1 μm: 0.010 ^{cm less than 3} / g (B) Pore diameter 1 μm or more and less than 5 μm: 0.020 cm less than ³ / g (C) Pore diameter 5 μm or more and less than 10 μm: 0 .050cm ³ / under g (D) pore diameter 10μm or more: no greater than 0.500 cm ³ / g or more

The total content ratio of platinum group elements (mass of platinum group elements per 1 L of wall flow type base material) contained in the first catalyst layer 21, the second catalyst layer 32, and the porous dense collection layer 31 is the desired exhaust gas. It may be appropriately adjusted in consideration of purification performance, cost and the like, but is usually preferably 1 to 10 g / L, more preferably 1 to 8 g / L, and further preferably 1 to 6 g / L.

(Other ingredients)
In addition to the above-mentioned components, the first catalyst layer 21, the porous dense collection layer 31, and the second catalyst layer 32 may further contain various binders known in the art and known in the art. The type of binder is not particularly limited, and examples thereof include various sol such as boehmite, alumina sol, titania sol, silica sol, and zirconia sol. Further, soluble salts such as aluminum nitrate, aluminum acetate, titanium nitrate, titanium acetate, zirconium nitrate and zirconium acetate can also be used as the binder. In addition, acids such as acetic acid, nitric acid, hydrochloric acid, and sulfuric acid can also be used as the binder. The amount of the binder used is not particularly limited, but is preferably 0.01 to 15% by mass in total, more preferably 0.05 to 10% by mass in total, and each in total with respect to the total amount of each layer. 0.1 to 8% by mass is more preferable.

Further, the first catalyst layer 21, the porous dense collection layer 31, and the second catalyst layer 32 may further contain a Ba-containing compound in addition to the above-mentioned components. By blending a Ba-containing compound, improvement in heat resistance and activation of catalytic performance can be expected. Examples of the Ba-containing compound include, but are not limited to, sulfates, carbonates, composite oxides, oxides and the like. More specifically, BaO, Ba (CH ₃ COO) ₂ , BaO ₂ , BaSO ₄ , BaCO ₃ , BaZrO ₃ , BaAl ₂ O _{4, and the} like can be mentioned, and among these, BaSO ₄ is preferable. The amount of the binder Ba-containing compound used is not particularly limited, but is preferably 1 to 20% by mass in total, more preferably 3 to 15% by mass in total, and 5 in total, respectively, with respect to the total amount of each layer. ~ 13% by mass is more preferable.

Further, the first catalyst layer 21, the porous dense collection layer 31, and the second catalyst layer 32 may contain a catalyst, a co-catalyst, and various additives known in the art in addition to the above-mentioned components. Examples of various additives include dispersion stabilizers such as nonionic surfactants and anionic surfactants; pH adjusters; viscosity regulators, and the like, but the present invention is not particularly limited thereto.

<Manufacturing method>
In the catalyst-coated gasoline particulate filter 100 of the present embodiment, the first catalyst layer 21 and the porous dense collection layer 31 and, if necessary, the first catalyst layer 21 and the porous dense collection layer 31 are placed on the above-mentioned wall flow type base material 10 according to a conventional method. It can be manufactured by providing the two catalyst layers 32. For example, the surface of the wall flow type base material 10 is sequentially coated (supported) with these precursor compositions (for example, a slurry composition), and if necessary, a drying treatment or a heat treatment is performed to carry out the present embodiment. A catalyst coated gasoline slurry filter 100 can be obtained. As a method for applying the precursor composition to the wall flow type base material 10, the wash coat method is preferably used as described above, but it may be carried out according to a conventional method and is not particularly limited. Various known coating methods, zone coating methods and the like can be applied. Then, after the precursor composition is applied, it can be dried or fired according to a conventional method.

Hereinafter, an example of a suitable manufacturing method for the catalyst-coated gasoline particulate filter 100 of the present embodiment will be described. In the present manufacturing method, as shown in FIG. 4, the introduction side cell 11 in which the end portion 11a on the exhaust gas introduction side is opened and the discharge side cell 12 in which the end portion 12a on the exhaust gas discharge side is opened are formed by the porous partition wall 13. The step (S11) of preparing the defined wall flow type base material 10 and the porous dense collection layer containing inorganic fine particles from the ends 11a and 12a of the wall flow type base material 10 on the exhaust gas introduction side or the exhaust gas discharge side. The precursor composition Sl of 31 is supplied, and the length is 0.4 to 0.9 L with respect to the total length L in the cross-sectional view of the wall flow type base material 10 over the stretching direction of the partition wall 13 of the wall flow type base material 10. The step (S21) of applying the precursor composition Sl only to La into the pores of the partition wall 13 and the heat treatment of the obtained coated wall flow type base material 10 are performed, and the pores of the partition wall 13 are filled with inorganic fine particles. It is characterized by having at least a step (S31) of forming the plurality of porous densely packed portions 31a to form the porous densely packed layer 31.

Here, preferably, as the wall flow type base material 10, the above-mentioned wall flow type base material 41 after catalyst coating (wall flow type base material 10 after coating the first catalyst layer 21) is used. As a result, the catalyst-coated gasoline particulate filter 100 in which the first catalyst layer 21 and the porous dense collection layer 31 are formed in this order can be obtained. In order to obtain the wall flow type base material 41 after the catalyst coating, after the step of preparing the wall flow type base material 10 (S11), the precursor composition Sl is applied into the pores of the partition wall 13 (S21). The first composite having the first base material particles and the platinum group elements supported on the first base material particles from the ends 11a, 12a of the wall flow type base material 10 on the exhaust gas introduction side or the exhaust gas discharge side. The slurry composition Sla of the first catalyst layer 21 containing at least the catalyst particles is supplied, and the slurry composition Sla of the first catalyst layer is coated in the pores of the partition wall 13, and if necessary, drying treatment or heat treatment is performed. , The step (S12) of forming the first catalyst layer 21 may be performed. As described above, the precursor of the porous dense collection layer 31 is placed on the first catalyst layer 21 in the pores of the wall flow type base material 41 (the wall flow type base material 10 coated with the first catalyst layer 21) after the catalyst coating. By impregnating and coating the body composition Sl, it is possible to obtain a catalyst-coated gasoline particulate filter 100 in which the first catalyst layer 21 and the porous dense collection layer 31 are laminated and formed in this order.

Further, in the step (S21) of applying the precursor composition Sl of the porous dense collection layer 31, the slurry composition Slb containing a platinum group element is used as the precursor composition Sl, so that the porous composition has a catalytic function. The sex-dense collection layer 31 can be formed. Here, as the precursor composition Sl, the second composite catalyst particles having platinum group elements supported on the inorganic fine particles and the inorganic fine particles, water, and, if necessary, a water-soluble polymer and / or pore formation described later. By using the slurry composition Slb containing at least the material, the porous dense collecting layer 31 having the above-mentioned preferable microporous can be easily obtained with good reproducibility.

Further, after coating the slurry composition Slb (precursor composition Sl), the wall flow type group is applied from the end side (in this example, the end portion 12a on the exhaust gas discharge side) impregnated with the slurry composition Slb. By introducing a gas into the cell of the material 10 and air-blowing the excess precursor composition Sl, the precursor composition Sl is uniformly coated in the pores of the partition wall 13 (the surface of the first catalyst layer 21). Can be made (S22).

At this time, when a slurry composition Slb containing at least inorganic fine particles and a platinum group element is used as the precursor composition Sl, the precursor composition Sl is a part of the coated precursor composition Sl. Blow coating can also be applied to an uncoated region (in this example, a region having a length Lb on the end portion 11a side on the exhaust gas introduction side). The precursor composition Sl (slurry composition Slb) applied to the region of the length Lb on the end portion 11a side on the exhaust gas introduction side is subjected to a drying treatment or a heat treatment as necessary to obtain a porous dense collection layer. It can function as a catalyst layer different from 31 (in this example, a second catalyst layer 32 containing inorganic fine particles and a platinum group element).

Then, the wall-flow type base material 10 after coating is dried and heat-treated as necessary to form the wall-flow type base material 10 strips, the first catalyst layer 21, the porous dense collection layer 31, and the like. And the catalyst-coated gasoline particulate filter 100 on which the second catalyst layer 32 is formed can be obtained (S31).

Hereinafter, each step will be described in detail.
(Preparation step S11 of wall flow type base material)
As shown in FIG. 5, in this preparation step S11, the wall flow type base material 10 described in the catalyst-coated gasoline particulate filter 100 is prepared as the base material.

(Forming step S12 of the first catalyst layer)
As shown in FIGS. 6 and 7, in the first catalyst layer 21 forming step S12, the first catalyst containing a platinum group element is formed from the ends 11a and 12a of the wall flow type base material 10 on the exhaust gas introduction side or the exhaust gas discharge side. The slurry composition Sla of the layer 21 is supplied, and the slurry composition Sla of the first catalyst layer is applied to a plurality of locations in the pores of the partition wall 13 over the stretching direction of the partition wall 13 of the wall flow type base material 10, and is required. The first catalyst layer 21 is formed by performing a drying treatment or a heat treatment according to the above. The coating method of the slurry composition Sla may be carried out according to a conventional method, and is not particularly limited, and a wash coat method or the like is preferably used. At this time, the end portion of the wall flow type base material 10 can be immersed in the slurry composition Sla, and an air blow treatment or a suction treatment can be performed as necessary. Then, the wall flow type base material 10 after coating the slurry composition Sla is subjected to a drying treatment or a heat treatment as necessary to form the first catalyst layer 21. The drying conditions at this time are not particularly limited as long as the dispersion medium can be removed from the slurry composition Sla. For example, the drying temperature is not particularly limited, but is preferably 100 to 225 ° C, more preferably 100 to 200 ° C, and even more preferably 125 to 175 ° C. The drying time is not particularly limited, but is preferably 0.5 to 2 hours, preferably 0.5 to 1.5 hours. The heat treatment conditions are preferably 400 to 650 ° C, more preferably 450 to 600 ° C, and even more preferably 500 to 600 ° C. Further, the firing time is not particularly limited, but is preferably 0.5 to 2 hours, preferably 0.5 to 1.5 hours.

(Slurry Composition Sla)
The slurry composition Sla for forming the first catalyst layer 21 will be described. This slurry composition Sla is a slurry-like mixture containing a platinum group element. A preferred example thereof is a slurry-like mixture containing at least the first base material particles, the first composite catalyst particles having a platinum group element supported on the first base material particles, and a dispersion medium such as water. ..

Examples of the platinum group element contained in the slurry composition Sla include those similar to those exemplified for the platinum group element contained in the first catalyst layer 21. In addition, examples of the first base material particles contained in the slurry composition Sla include those similar to those exemplified for the first base material particles contained in the first catalyst layer 21. As for these platinum group elements and the first base material particles, one type can be used alone, or two or more types can be used in any combination and ratio. From the viewpoint of exhaust gas purification performance, the specific surface area of the first base material particles contained in the slurry composition Sla is preferably 10 to 500 m ² / g, more preferably 30 to 200 m ² / g.

The D90 particle size of the first composite catalyst particles contained in the slurry composition Sla can be appropriately set according to the desired performance and is not particularly limited, but is preferably 1 to 7 μm from the viewpoint of exhaust gas purification performance and suppression of pressure loss increase. , More preferably 1 to 6 μm, still more preferably 1 to 5 μm. When the D90 particle size is 1 μm or more, the crushing time when the first composite catalyst particles are crushed by the milling device can be shortened, and the work efficiency tends to be further improved. Further, when the D90 particle size is 7 μm or less, it is suppressed that the coarse particles block the pores in the partition wall 13, and the increase in pressure loss tends to be suppressed. The solid content of the slurry composition Sla can be appropriately set according to the desired performance and is not particularly limited, but is preferably 1 to 50% by mass from the viewpoint of coatability into the pores of the partition wall 13. , More preferably 10 to 40% by mass, and even more preferably 15 to 30% by mass. With such a solid content, the slurry composition Sla tends to be easily applied to the pore surface in the partition wall 13.

In addition to the above-mentioned components, the slurry composition Sla contains various known binders known in the art, Ba-containing compounds, catalysts and co-catalysts known in the industry, various additives, and the like. May be good. These types and amounts used are as described in the section of the catalyst-coated gasoline particulate filter 100, and duplicate description here will be omitted.

(Coating step S21 of the precursor composition Sl of the porous dense collection layer 31)
As shown in FIG. 8, in the coating step S21 of the precursor composition Sl, the wall flow type base material 10 (wall flow type base material 41 after catalyst coating (wall flow type base material after coating the first catalyst layer 21). The precursor composition Sl of the porous dense collection layer 31 containing the inorganic fine particles is supplied from the ends 11a and 12a on the exhaust gas introduction side or the exhaust gas discharge side of the material 10)), and the partition wall 13 of the wall flow type base material 10 is supplied. In the stretching direction, the precursor composition Sl is applied into the pores of the partition wall 13 by a length La of 0.4 to 0.9 L with respect to the total length L of the wall flow type base material 10 in a cross-sectional view. At this time, when the wall flow type base material 10 after forming the first catalyst layer 21 is used, the precursor composition Sl is applied on the first catalyst layer 21 on the pore surface of the partition wall 13. The coating method of the precursor composition Sl may be carried out according to a conventional method, and is not particularly limited, and a wash coat method or the like is preferably used. At this time, the end portion of the wall flow type base material 10 can be immersed in the precursor composition Sl, and an air blow treatment or a suction treatment can be performed as necessary. Further, the length La when the precursor composition Sl is applied to the partition wall 13 is as described in the section of the length La of the porous dense collection layer 31, and can be appropriately set.

(Precursor Composition Sl)
The precursor composition Sl for forming the porous dense collection layer 31 will be described. This precursor composition Sl is a slurry-like mixture containing at least inorganic fine particles and a dispersion medium such as water. As described above, the porous dense collection layer 31 may contain a platinum group element if necessary. In this case, the precursor composition Sl includes the inorganic fine particles and the platinum group supported on the inorganic fine particles. A slurry composition Slb containing at least a second composite catalyst particle having an element and a dispersion medium such as water is preferably used.

Examples of the platinum group element that can be contained in the precursor composition Sl include those similar to those exemplified for the platinum group element contained in the porous dense collection layer 31. In addition, examples of the inorganic fine particles contained in the precursor composition Sl include those similar to those exemplified for the inorganic fine particles that can be contained in the porous dense collection layer 31. As for these platinum group elements and inorganic fine particles, one type can be used alone, or two or more types can be used in any combination and ratio. From the viewpoint of exhaust gas purification performance, the specific surface area of the inorganic fine particles contained in the precursor composition Sl is preferably 10 to 500 m ² / g, more preferably 30 to 200 m ² / g.

The D90 particle size of the second composite catalyst particles that can be contained in the precursor composition Sl can be appropriately set according to the desired performance and is not particularly limited, but is 1 to 7 μm from the viewpoint of exhaust gas purification performance and suppression of pressure loss increase. Is preferable, more preferably 1 to 6 μm, still more preferably 1 to 5 μm. When the D90 particle size is 1 μm or more, the crushing time when the second composite catalyst particles are crushed by the milling device can be shortened, and the work efficiency tends to be further improved. Further, when the D90 particle size is 7 μm or less, it is suppressed that the coarse particles block the pores in the partition wall 13, and the increase in pressure loss tends to be suppressed. The solid content of the precursor composition Sl (slurry composition Slb) can be appropriately set according to the desired performance and is not particularly limited, but is preferably from the viewpoint of coatability into the pores of the partition wall 13. It is 1 to 50% by mass, more preferably 10 to 40% by mass, and even more preferably 15 to 30% by mass. By setting such a solid content, the coatability of the precursor composition Sl (slurry composition Slb) tends to be improved.

Here, the precursor composition Sl preferably further contains a water-soluble polymer compound. Since the water-soluble polymer compound functions as a thickener that reduces the permeability (penetration) into the wall-flow type base material 10, the inside of the wall-flow type base material 10 can be blended with the water-soluble polymer compound. Permeation of the precursor composition Sl into the skin is suppressed, and the above-mentioned microporous dense collecting layer 31 (porous dense portion 31a) tends to be easily obtained.

The type of the water-soluble polymer compound is not particularly limited as long as it is a polymer material capable of thickening the precursor composition Sl, which is an aqueous dispersion. Specific examples thereof include, but are not limited to, celluloses, synthetic polymers, natural polymers, polysaccharides and derivatives thereof. Specifically, celluloses and their derivatives (eg, methyl cellulose, ethyl cellulose, isopropyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose, hydroxypropyl cellulose, hydroxymethyl cellulose phthalate, hydroxypropyl methyl cellulose acetate succinate, carboxymethyl ethyl cellulose, sodium carboxymethyl cellulose, Cellulose phthalate acetate, hypromerose succinate, etc.), synthetic polymers (eg, (meth) acrylic acid, itaconic acid, maleic acid, styrene sulfonic acid, acrylamide 2-methylpropane sulfonic acid, 2-hydroxypropyl-β-cyclo Dextrin, polyvinyl alcohol, (meth) acrylamide, dimethylacrylamide, diethylacrylamide, isopropylacrylamide, hydroxyethylacrylamide, polyvinylpyrrolidone, vinylformamide, vinylacetamide, polyethylene oxide, polyacrylic acid, polyarginic acid, carboxyvinyl polymer, polyethylene glycol, polypropylene Glycol, polyoxyethine polyoxypropylene glycol, polyvinylcaptolactam / polyvinylacetate / polyethylene glycol graft copolymer, and salts thereof, etc.), natural polymers and sugars (eg, gum arabic, guar gum, xanthan gum, locust bean gum, carrageenan) , Sodium alginate, polyethylene glycol alginate, agar, gelatin, etc.), but are not particularly limited thereto. These can be used alone or in any combination and ratio of two or more.

The content ratio of the water-soluble polymer compound in the precursor composition Sl can be appropriately set according to the desired performance, and is not particularly limited. In terms of solid content with respect to the total amount of the precursor composition Sl, it is usually preferably 0.05 to 1.0% by mass, more preferably 0.1 to 0.7% by mass, and further preferably 0.15 to 0.5. It is mass%.

Further, from the viewpoint of easily obtaining the porous dense collecting layer 31 (porous dense portion 31a) having the above-mentioned microporous property with good reproducibility, the precursor composition Sl further comprises a pore-forming material (pore-forming material). It is preferable to contain it. The pore-forming material disappears due to combustion, thermal decomposition, etc. when the precursor composition Sl is heat-treated after coating, thereby forming pores (voids). By blending such a pore-forming material, it becomes easy to adjust the pore diameter and the pore volume of the obtained porous dense collection layer 31 (porous dense portion 31a).

The type of the pore-forming material is not particularly limited as long as it disappears by combustion or thermal decomposition by heat treatment and can form pores (voids). As the pore-forming material, for example, hollow resin particles, foamed resin, water-absorbent resin, starches, silica gel and the like are known, and those known in the art can be appropriately selected and used. Specifically, emulsification of celluloses such as starch, phenol resin, carbon fiber, carbon powder, polyvinyl alcohol, carboxymethyl cellulose and methyl cellulose, other polysaccharides, polyolefin polymers such as polyethylene and polypropylene, polymethyl methacrylate and polystyrene. Examples thereof include acrylic or styrene-based polymers obtained by polymerization or suspension polymerization, but the present invention is not particularly limited thereto.

The particle size of the pore-forming material can be appropriately set according to the desired performance and is not particularly limited, but the above-mentioned porous dense collecting layer 31 (porous dense portion 31a) having microporous can be easily obtained with good reproducibility. From the viewpoint, the D50 particle size is preferably 0.5 to 10 μm, more preferably 1 to 9 μm, and even more preferably 2 to 8 μm.

The content ratio of the pore-forming material in the precursor composition Sl can be appropriately set according to the desired performance, and is not particularly limited. In terms of solid content with respect to the total amount of the precursor composition Sl, it is usually preferably 10 to 70% by mass, more preferably 20 to 60% by mass, and further preferably 30 to 50% by mass.

In addition to the above-mentioned components, the precursor composition Sl contains various binders known in the art, Ba-containing compounds, catalysts and co-catalysts known in the industry, various additives, and the like. You may. These types and amounts used are as described in the section of the catalyst-coated gasoline particulate filter 100, and duplicate description here will be omitted.

(Blow step S22)
As shown in FIG. 9, in this blow step S22, after applying the precursor composition Sl by a length La of 0.4 to 0.9 L with respect to the total length L of the wall flow type base material 10 in a cross-sectional view. A gas is introduced into the cell of the wall flow type base material 10 from the end side impregnated with the precursor composition Sl (in this example, the end 12a on the exhaust gas discharge side), and the precursor composition Sl is air blown. Thereby, the precursor composition Sl can be dried. At this time, when the slurry composition Slb containing the inorganic fine particles and the platinum group element is used as the precursor composition Sl, the blow pressure is set high so that the precursor composition Sl is not present. Blow coating can be performed by blowing off to the coating region (in this example, the region having a length Lb on the end portion 11a side on the exhaust gas introduction side). That is, in this blowing step S22, a catalyst layer different from the porous dense collection layer 31 (in this example, the second catalyst layer 32 containing inorganic fine particles and platinum group elements) is applied to the region of length Lb. It is possible to do. The slurry composition Slb applied to the region of the length Lb on the end portion 11a side on the exhaust gas introduction side is subjected to a drying treatment or a heat treatment as necessary to provide a catalyst different from that of the porous dense collection layer 31. It functions as a layer (in this example, a second catalyst layer 32 containing inorganic fine particles and a platinum group element).

(Step of Forming Porous Dense Collection Layer 31 S31)
Then, the coated wall flow type base material 10 is dried if necessary, and then heat-treated to form the porous dense collection layer 31. At this time, when the slurry composition Slb is applied to the region of length Lb, the second catalyst layer 32 is also formed at the same time. The drying conditions at this time are not particularly limited as long as the dispersion medium can be removed from the precursor composition Sl (slurry composition Slb). For example, the drying temperature is not particularly limited, but is preferably 100 to 225 ° C, more preferably 100 to 200 ° C, and even more preferably 125 to 175 ° C. The drying time is not particularly limited, but is preferably 0.5 to 2 hours, preferably 0.5 to 1.5 hours. The heat treatment conditions are preferably 400 to 650 ° C, more preferably 450 to 600 ° C, and even more preferably 500 to 600 ° C. The firing time is not particularly limited, but is preferably 0.5 to 2 hours, preferably 0.5 to 1.5 hours.

[Second Embodiment]
FIG. 10 is a schematic cross-sectional view showing a schematic configuration of a catalyst-coated gasoline particulate filter 200 (hereinafter, may be referred to as “GPF catalyst”) according to an embodiment of the present invention.

As shown in FIGS. 10 to 12, in the catalyst-coated gasoline particulate filter 200 of the present embodiment, the formation of the second catalyst layer 32 is omitted, and the pore surface of the partition wall 13 of the wall flow type base material 10 is porous. It has the same configuration as the first embodiment described above, except that the dense collection layer 31 (porous dense portion 31a) is provided. Even with such a configuration, the same effects as those of the above-described first embodiment can be obtained.

[Third Embodiment]
FIG. 13 is a schematic cross-sectional view showing a schematic configuration of a catalyst-coated gasoline particulate filter 300 (hereinafter, may be referred to as “GPF catalyst”) according to an embodiment of the present invention.

As shown in FIGS. 13 to 15, in the catalyst-coated gasoline particulate filter 300 of the present embodiment, the porous dense collection layer 31 has a length La = 0.5 L from the end portion 11a side of the introduction side cell 11. The second catalyst layer 32 is zone-coated so as to be unevenly distributed on the cell wall surface side of the introduction side cell 11, and the second catalyst layer 32 is provided with a length Lb = 0.5L from the end portion 12a side of the discharge side cell 12. It has the same configuration as that of the first embodiment described above, except that the above-described first embodiment is used. Even with such a configuration, the same effects as those of the above-described first embodiment can be obtained.

[Fourth Embodiment]
FIG. 16 is a schematic cross-sectional view showing a schematic configuration of a catalyst-coated gasoline particulate filter 400 (hereinafter, may be referred to as “GPF catalyst”) according to an embodiment of the present invention.

As shown in FIGS. 16 to 18, in the catalyst-coated gasoline particulate filter 400 of the present embodiment, the formation of the second catalyst layer 32 is omitted, and the pore surface of the partition wall 13 of the wall flow type base material 10 is porous. It has the same configuration as the above-described third embodiment except that the dense collection layer 31 (porous dense portion 31a) is provided. Even with such a configuration, the same effect as that of the third embodiment described above can be obtained.

[Use]
The catalyst-coated gasoline particulate filters 100, 200, 300, 400 of each of the above embodiments can purify carbon monoxide (CO), hydrocarbons (HC), nitrogen oxides (NOx), and the like, and further. , Particulate matter (PM) is collected with high efficiency, and the PN collection rate is dramatically increased. Therefore, it is useful in an exhaust gas purification application of an internal combustion engine that burns an air-fuel mixture containing oxygen and fuel gas to discharge exhaust gas, particularly a gasoline engine, and is particularly useful in an exhaust gas purification application of a direct injection gasoline engine. Further, the catalyst-coated gasoline particulate filters 100, 200, 300, and 400 of each of the above embodiments can be effectively used as a TWC for an engine direct-type catalytic converter, a tandem-arranged direct-type catalytic converter, and the like.

The features of the present invention will be described in more detail with reference to Examples and Comparative Examples, but the present invention is not limited thereto. That is, the materials, amounts used, ratios, treatment contents, treatment procedures, etc. shown in the following examples can be appropriately changed as long as they do not deviate from the gist of the present invention. Further, the values of various production conditions and evaluation results in the following examples have meanings as a preferable upper limit value or a preferable lower limit value in the embodiment of the present invention, and the preferable range is the above-mentioned upper limit value or lower limit value. And may be in the range specified by the combination of the values of the following examples or the values of the examples.

(Example 1)
First, alumina powder having a D50 particle size of 28 μm and a BET specific surface area of 141 m ² / g was impregnated with a palladium nitrate aqueous solution, and then calcined at 500 ° C. for 1 hour to obtain Pd-supported alumina powder (Pd content: 4. 3% by mass) was obtained. Further, a zirconia-lanthanate-modified alumina powder having a D50 particle size of 29 μm and a BET specific surface area of 145 m ² / g was impregnated with an aqueous solution of rhodium nitrate, and then calcined at 500 ° C. for 1 hour to modify Rh-supported zirconia-lantern. Alumina powder (Rh content: 0.7% by mass) was obtained.

1 kg of Pd-supported alumina powder and 1 kg of Rh-supported zirconia-lanthanum-modified alumina powder, 1 kg ^{of ceria zirconia composite oxide powder having a D50 particle size of 10 μm and a BET specific surface area of 71 m 2} / g, and a 46 mass% lanthanate nitrate aqueous solution. 195 g and ion-exchanged water were mixed, and the obtained mixture was put into a ball mill and milled until the D90 particle size of the catalyst powder became 3.0 μm to obtain a dispersion. A water-soluble polymer compound (thickener) was added to the obtained dispersion to obtain a catalyst slurry for the porous dense collection layer of Example 1.

Next, a wall-flow type honeycomb base material made of Cordellite (number of cells / mill thickness: 300 cpsi / 8 mil, diameter: 118.4 mm, total length: 127 mm, porosity: 65%) was prepared. The end of the base material on the exhaust gas discharge side is immersed in the above-mentioned catalyst slurry for the porous dense collection layer, and vacuum suction is performed from the opposite end side to make the length La (from the end on the exhaust gas discharge side). The catalyst slurry for the porous dense collection layer was impregnated and held by 0.5 L). Next, the gas is allowed to flow into the base material from the end face side on the exhaust gas discharge side, the excess catalyst slurry for the porous dense collection layer is blown off, and the length Lb (0.5 L) is blown from the end face on the exhaust gas introduction side. ), The catalyst slurry for the porous dense collection layer (catalyst slurry for the second catalyst layer) was blow-coated to coat the second catalyst layer.

Then, the base material coated with the catalyst slurry is dried at 150 ° C. and fired at 550 ° C. in an atmospheric atmosphere, whereby the above-mentioned porous dense collection layer and the second catalyst layer are zoned into the wall flow type base material. A coated catalyst-coated gasoline particulate filter of Example 1 having the same structure as that of FIGS. 1 to 3 (provided that the thickness Da = 0.28D, the length La = 0.5L, and the length Lb = 0. 5 L, catalyst slurry coating amount 60 g / L) was prepared.

(Example 2)
The same procedure as in Example 1 was carried out except that the length of impregnating the catalyst slurry was changed to length La = 0.8 L and length Lb = 0.2 L, and the above-mentioned porous dense collection layer and the second catalyst were carried out. The catalyst-coated gasoline particulate filter of Example 2 having the same structure as that of FIGS. 1 to 3 in which the layer is zone-coated on a wall-flow type substrate (provided that the thickness is Da = 0.29D and the length is La = 0). .8 L, length Lb = 0.2 L, catalyst slurry coating amount 60 g / L) was prepared.

(Comparative Example 1)
The same procedure as in Example 1 was carried out except that the blending of the thickener was omitted, to obtain a catalyst slurry for the first catalyst layer of Comparative Example 1. Same as in Example 1 except that the catalyst slurry for the first catalyst layer of Comparative Example 1 is used instead of the catalyst slurry for the porous dense collection layer of Example 1 and the entire base material is impregnated with the catalyst slurry. The first catalyst layer was coated over the entire length L of the wall-flow type base material, and the wall-flow type base material after the catalyst coating of Comparative Example 1 having the same structure as that of FIG. 6 was prepared (catalyst slurry coating). Amount 60 g / L).

[Measurement of soot collection performance]
The exhaust gas purification catalyst produced in Examples and Comparative Examples is attached to a vehicle equipped with a 1.5L direct injection turbo engine, and is used when running in WLTC mode using a solid particle number measuring device (manufactured by AVL, trade name: APC 489). The soot emission quantity (PNtest) was measured. Here, the soot collection rate is calculated by the following formula as the reduction rate from the soot amount (PNblank) measured when the above test is performed without the exhaust gas purification catalyst mounted, and the value is used for PN capture. It was the collection rate.
Soot collection rate (%) = {(PNblank-PNtest) / PNblank} x 100 (%)

As a result, the PN collection rate of Comparative Example 1 was 57.6%, while the PN collection rate of Examples 1 and 2 was 65.1% and 82.8%. From this, it was confirmed that the PN collection rate was significantly increased by the formation of the porous dense collection layer. The results are shown in Table 1.

(Example 3)
First, alumina powder having a D50 particle size of 28 μm and a BET specific surface area of 141 m ² / g was impregnated with a palladium nitrate aqueous solution, and then calcined at 500 ° C. for 1 hour to obtain Pd-supported alumina powder (Pd content: 4. 3% by mass) was obtained. Further, a zirconia-lanthanate-modified alumina powder having a D50 particle size of 29 μm and a BET specific surface area of 145 m ² / g was impregnated with an aqueous solution of rhodium nitrate, and then calcined at 500 ° C. for 1 hour to modify Rh-supported zirconia-lantern. Alumina powder (Rh content: 0.7% by mass) was obtained.

1 kg of Pd-supported alumina powder and 1 kg of Rh-supported zirconia-lanthanum-modified alumina powder, 1 kg ^{of ceria zirconia composite oxide powder having a D50 particle size of 10 μm and a BET specific surface area of 71 m 2} / g, and a 46 mass% lanthanate nitrate aqueous solution. 195 g and ion-exchanged water are mixed, the obtained mixture is put into a ball mill, milled until the D90 particle size of the catalyst powder becomes 3.0 μm, and the catalyst slurry for the first catalyst layer of Example 3 is obtained. Got Further, a water-soluble polymer compound (thickener) was blended with the catalyst slurry for the first catalyst layer of Example 3 to obtain a catalyst slurry for the porous dense collection layer of Example 3.

Next, a wall-flow type honeycomb base material made of Cordellite (number of cells / mill thickness: 300 cpsi / 8 mil, diameter: 118.4 mm, total length: 127 mm, porosity: 65%) was prepared. The end of the base material on the exhaust gas discharge side is immersed in the catalyst slurry for the first catalyst layer of Example 3 above to impregnate and hold the catalyst slurry, and then the gas is introduced into the base material from the end face side on the exhaust gas discharge side. The excess catalyst slurry for the first catalyst layer was blown off and dried at 150 ° C., so that the first catalyst layer was coated over the entire length L of the wall flow type substrate, which is equivalent to FIG. After the catalyst coating of Example 3 having the structure of Example 3, a wall flow type base material was prepared (catalyst slurry coating amount 40 g / L).

After that, after the catalyst coating of Example 3, the end portion of the wall flow type base material on the exhaust gas discharge side is immersed in the catalyst slurry for the porous dense collection layer of Example 3 described above, and the end portion on the opposite side is further immersed. The catalyst slurry for the porous dense collection layer was impregnated and held by the length La (0.8 L) from the end on the exhaust gas discharge side. Next, the gas is allowed to flow into the base material from the end face side on the exhaust gas discharge side, the excess catalyst slurry for the porous dense collection layer is blown off, and the length Lb (0.2 L) is blown from the end face on the exhaust gas introduction side. ), The catalyst slurry for the porous dense collection layer (catalyst slurry for the second catalyst layer) was blow-coated to coat the second catalyst layer.

After that, the base material coated with various catalyst slurries is dried at 150 ° C. and calcined at 550 ° C. in an air atmosphere, whereby the above-mentioned porous dense collection layer and the second catalyst layer are the catalysts of Example 3. The catalyst-coated gasoline particulate filter of Example 3 having the same structure as that of FIGS. 1 to 3 and zone-coated on the first catalyst layer of the wall-flow type substrate after coating (provided that the thickness Da = 0. 35D, length La = 0.6L, length Lb = 0.2L, catalyst slurry coating amount 20g / L) was produced.

(Example 4)
The same procedure as in Example 3 was carried out except that the blending amount of the thickener was changed to 1/3 times and 30% by mass of crosslinked acrylic resin beads having a D50 particle size of 1 μm were blended as the pore-forming material. A catalyst slurry for the porous dense collection layer of Example 4 was obtained. The same procedure as in Example 3 was carried out except that the catalyst slurry for the porous dense collection layer of Example 4 was used instead of the catalyst slurry for the porous dense collection layer of Example 3, and the first catalyst layer was a wall. The catalyst-coated gasoline particulate filter of Example 3 having the same structure as that of FIGS. 1 to 3 coated over the entire length L of the flow-type substrate (provided that the thickness Da = 0.40D and the length La = 0. 8 L, length Lb = 0.2 L, catalyst slurry coating amount 20 g / L) was prepared.

(Example 5)
The same procedure as in Example 4 was carried out except that the blending amount of the pore-forming material was changed to 30% by mass to obtain a catalyst slurry for the porous dense collection layer of Example 5. The same procedure as in Example 4 was carried out except that the catalyst slurry for the porous dense collection layer of Example 5 was used instead of the catalyst slurry for the porous dense collection layer of Example 4, and the first catalyst layer was a wall. The catalyst-coated gasoline particulate filter of Example 5 having the same structure as that of FIGS. 1 to 3 coated over the entire length L of the flow-type substrate (provided that the thickness Da = 0.43D and the length La = 0. 8 L, length Lb = 0.2 L, catalyst slurry coating amount 20 g / L) was prepared.

(Example 6)
The same procedure as in Example 4 was carried out except that the pore-forming material was changed to crosslinked acrylic resin beads having a D50 particle size of 5 μm to obtain a catalyst slurry for the porous dense collection layer of Example 6. The same procedure as in Example 4 was carried out except that the catalyst slurry for the porous dense collection layer of Example 6 was used instead of the catalyst slurry for the porous dense collection layer of Example 4, and the first catalyst layer was a wall. The catalyst-coated gasoline particulate filter of Example 6 having the same structure as that of FIGS. 1 to 3 coated over the entire length L of the flow-type substrate (provided that the thickness Da = 0.44D and the length La = 0. 8 L, length Lb = 0.2 L, catalyst slurry coating amount 20 g / L) was prepared.

(Reference example)
As a reference example, a wall flow type honeycomb base material manufactured by Cordellite (number of cells / mill thickness: 300 cpsi / 8 mil, diameter: 118.4 mm, total length: 127 mm, porosity: 65%) was used as it was.

(Comparative Example 2)
The end of the wall flow type honeycomb base material made of Cordellite described above on the exhaust gas discharge side is immersed in the catalyst slurry for the first catalyst layer of Example 3 above to impregnate and hold the catalyst slurry, and then the exhaust gas discharge side. By allowing gas to flow into the base material from the end face side of the above, blowing off the excess catalyst slurry for the first catalyst layer, and drying at 150 ° C., the first catalyst layer becomes the total length L of the wall flow type base material. A wall-flow type substrate after catalyst coating of Comparative Example 2 having a structure equivalent to that of FIG. 6 was prepared (catalyst slurry coating amount 60 g / L).

[Measurement of PN collection rate]
The above-mentioned measurement conditions were used using the catalyst-coated gasoline particulate filter prepared in Examples 3 to 6, the wall-flow type base material after catalyst coating prepared in Comparative Example 2, and the wall-flow type base material of Reference Example 1. The PN collection rate was measured in. The measurement results are shown in Table 2.

As shown in Table 2, the PN collection rate of the wall-flow type base material after catalyst coating in Comparative Example 2 was 61.3%, and the wall-flow type base material after catalyst coating in which the catalyst layer was not coated was used. From the comparison with a certain reference example, it can be seen that the PN collection rate is reduced by the coating of the first catalyst layer. On the other hand, the catalyst-coated gasoline particulate filters of Examples 3 to 6 in which the porous dense collection layer was formed on the wall-flow type base material after the catalyst coating of Comparative Example 2 were compared with those of Reference Example and Comparative Example 2. Then, it was confirmed that the PN collection rate was dramatically improved. From these facts, it was confirmed that the PN collection performance was remarkably improved by providing the porous dense collection layer on the outermost surface side.

[Measurement of stomatal distribution by mercury intrusion method]
Next, the effect of the microporousness of the porous dense collection layer was examined. Here, a sample for measurement is obtained from the catalyst-coated gasoline particulate filter prepared in Examples 3 to 6, the wall-flow type base material after catalyst coating prepared in Comparative Example 2, and the wall-flow type base material of Reference Example 1. (1 cm ³ ) were collected respectively. The measurement was performed under the following conditions.
After the measurement sample was dried, the pore distribution was measured by the mercury intrusion method using a mercury porosimeter (manufactured by Thermo Fisher Scientific, trade names: PASCAL 140 and PAS CAL 440). At this time, the low pressure region (0 to 400 Kpa) was measured by PASCAL 140, and the high pressure region (0.1 Mpa to 400 Mpa) was measured by PASCAL 440. From the obtained pore distribution, the pore diameter (mode diameter) and the pore volume were calculated. Here, from the viewpoint of the reliability of the measured values, the pore volume and the porosity were calculated for the pores having a pore diameter (mode diameter) of 0.1 μm or more.
In addition, as the values of the pore diameter and the pore volume, in Reference Example 1, the partition wall of the wall flow type base material is targeted, and the average of the values obtained in each of the exhaust gas introduction side portion, the exhaust gas discharge side portion, and the intermediate portion is used. Adopted the value. Further, in Comparative Example 2, the partition wall coated with the first catalyst layer was targeted, and the average value of the values obtained in each of the exhaust gas introduction side portion, the exhaust gas discharge side portion, and the intermediate portion was adopted. Further, in Examples 3 to 6, the partition wall coated with the porous dense collection layer and the first catalyst layer is targeted, and the exhaust gas discharge side portion with respect to the length La direction of the porous dense collection layer. The average value of the values obtained in each of the other end side portion and the intermediate portion was adopted. The measurement results are shown in Table 3.

As is clear from Table 3, in the catalyst-coated gasoline particulate filters of Examples 3 to 6 in which the porous dense collection layer was formed, the pore diameter was 15 μm or more coarse in comparison with Reference Example and Comparative Example 2. It was confirmed that the abundance ratio of the fine pores was significantly reduced and the total abundance ratio of the micropores having a pore diameter of less than 10 μm was increased. From this, in order to increase the PN collection rate, coarse pores having a pore diameter of 15 μm or more are filled with inorganic fine particles to form a porous dense collection layer (porous dense portion), and the abundance ratio of micropores. It was confirmed that it is effective to increase the number of particles.

[Measurement of pressure loss]
The catalyst-coated gasoline particulate filters produced in Examples 3 to 6 were installed in pressure loss measuring devices (manufactured by Tsukubarika Seiki Co., Ltd.), and air at room temperature was allowed to flow into the installed exhaust gas purification catalysts. The value obtained by measuring the differential pressure between the introduction side and the discharge side of the air when the amount of air outflow from the exhaust gas purification catalyst is 4 m ^{3 / min is used as the pressure loss of the catalyst-coated gasoline particulate filter.} did. The results are shown in Table 4.

As shown in Table 4, it was confirmed that all of Examples 3 to 6 showed a high PN collection rate. Further, the catalyst-coated gasoline particulate filter of Examples 4 to 6 further using the pore-forming material has a further reduced pressure loss as compared with the catalyst-coated gasoline particulate filter of Example 3 which does not. It was confirmed that. For this reason, pressure loss can be reduced and collection is difficult in the past by forming minute voids (pores) in the porous dense collection layer (porous dense portion) in combination with a pore-forming material. It is presumed that it became possible to collect minute PMs and the PN collection rate was increased. Furthermore, from the comparison between Example 4 and Example 5, it was confirmed that when a large amount of the pore-forming material was blended, the PN collection rate became higher and the pressure loss became lower. Further, from the comparison between Examples 4 and 6, the pore diameter of the minute voids (pores) formed can be adjusted according to the D50 particle diameter of the pore-forming material, whereby the PN collection rate can be adjusted. It was confirmed that the pressure loss can be further increased and the pressure loss can be decreased.

The catalyst-coated gasoline particulate filter of the present invention and its manufacturing method can be widely and effectively used in a three-way catalyst application for reducing NOx, CO, HC, etc. in exhaust gas emitted from a gasoline engine. In particular, since the PN collection rate is dramatically improved as compared with the conventional GPF catalyst, it can be used particularly effectively in the GPF catalyst application corresponding to the future tightening of PN regulations worldwide. ..

100 ・ ・ ・ Catalyst coated gasoline particulate filter 10 ・ ・ ・ Wall flow type base material 11 ・ ・ ・ Introduction side cell 11a ・ ・ ・ End 12 ・ ・ ・ Discharge side cell 12a ・ ・ ・ End 13 ・ ・ ・Partition 21 ・ ・ ・ 1st catalyst layer 32 ・ ・ ・ 2nd catalyst layer 31 ・ ・ ・ Porous dense collecting layer 31a ・ ・ ・ Porous dense part 41 ・ ・ ・ Wall flow type base material after catalyst coating 51 ・・ ・ Sealing wall 200 ・ ・ ・ Catalyst coated gasoline particulate filter 300 ・ ・ ・ Catalyst coated gasoline particulate filter 400 ・ ・ ・ Catalyst coated gasoline particulate filter L ・ ・ ・ Overall length La ・ ・ ・ Length Lb・ ・ ・ Length D ・ ・ ・ Thickness Da ・ ・ ・ Thickness Sl ・ ・ ・ Precursor composition Sla ・ ・ ・ Slurry composition Slb ・ ・ ・ Slurry composition

Claims (14)

A catalyst-coated gasoline particulate filter provided with a catalyst layer that purifies the exhaust gas emitted from a gasoline engine.
A wall-flow type base material in which an introduction-side cell having an open end on the exhaust gas introduction side and an exhaust-side cell having an open end on the exhaust gas discharge side are defined by a porous partition wall, and
A porous dense collection layer composed of a plurality of porous dense portions in which the pores of the partition wall are filled with inorganic fine particles and formed over the stretching direction of the partition wall of the wall flow type base material. The porous dense collection layer having a length La of 0.4 to 0.9 L with respect to the total length L in a cross-sectional view of the mold base material is provided at least.
Catalyst coated gasoline particulate filter. The catalyst-coated gasoline particulate filter according to claim 1, wherein the porous dense collection layer has a thickness Da of 0.1 to 0.9 D with respect to a thickness D of the partition wall in a cross-sectional view. The catalyst according to claim 1 or 2, wherein the porous dense collection layer is unevenly distributed on the cell wall surface side of the introduction side cell or the cell wall surface side of the discharge side cell in the thickness direction of the partition wall in a cross-sectional view. Coated gasoline particulate filter. The catalyst-coated gasoline particulate filter according to any one of claims 1 to 3, which contains a total of 0.1 g / L or more and 10 g / L or less of platinum group elements per volume of the wall flow type base material. The catalyst-coated gasoline particulate filter according to any one of claims 1 to 4, wherein the porous dense portion is provided on the pore surface of the partition wall. A first catalyst layer containing a platinum group element is provided on the pore surface of the partition wall.
The catalyst-coated gasoline particulate filter according to any one of claims 1 to 5, wherein the porous dense portion is provided on the first catalyst layer. The catalyst-coated gasoline particulate according to claim 6, wherein the first catalyst layer contains at least the first base material particles and the first composite catalyst particles having a platinum group element supported on the first base material particles. filter. The catalyst-coated gasoline particulate filter according to any one of claims 1 to 7, wherein the porous dense collection layer contains a platinum group element. The catalyst-coated gasoline particulate filter according to claim 8, wherein the porous dense collection layer contains at least the inorganic fine particles and the second composite catalyst particles having a platinum group element supported on the inorganic fine particles. A method for manufacturing a catalyst-coated gasoline particulate filter provided with a catalyst layer that purifies the exhaust gas emitted from a gasoline engine.
A process of preparing a wall-flow type base material in which an introduction-side cell having an open end on the exhaust gas introduction side and a discharge-side cell having an open end on the exhaust gas discharge side are defined by a porous partition wall.
The precursor composition of the porous dense collection layer containing inorganic fine particles is supplied from the end of the wall flow type base material on the exhaust gas introduction side or the exhaust gas discharge side, and the extension direction of the partition wall of the wall flow type base material. The precursor composition of the porous dense collection layer is coated in the pores of the partition wall by a length La of 0.4 to 0.9 L with respect to the total length L of the wall flow type base material in a cross-sectional view. The process of construction, and
A step of heat-treating the obtained coated wall-flow type base material to form a plurality of porous dense portions filled with the inorganic fine particles in the pores of the partition wall to form the porous dense collection layer. A method for manufacturing a catalyst-coated gasoline particulate filter having at least. Before the step of applying the precursor composition, the slurry composition of the first catalyst layer containing a platinum group element is supplied from the end of the wall flow type base material on the exhaust gas introduction side or the exhaust gas discharge side. Further, there is a step of applying the slurry composition of the first catalyst layer to a plurality of locations in the pores of the partition wall in the stretching direction of the partition wall of the wall flow type base material to form the first catalyst layer. death,
In the step of applying the precursor composition of the porous dense collection layer, the precursor is placed on the first catalyst layer in the pores of the wall flow type substrate coated with the first catalyst layer. The method for producing a catalyst-coated gasoline particulate filter according to claim 10, wherein the body composition is impregnated and coated. The catalyst according to claim 10 or 11, wherein the precursor composition is a catalyst composition containing at least the inorganic fine particles, the second composite catalyst particles having a platinum group element supported on the inorganic fine particles, and water. A method for manufacturing a coated gasoline particulate filter. The method for producing a catalyst-coated gasoline particulate filter according to any one of claims 10 to 12, wherein the precursor composition contains a water-soluble polymer compound. The method for producing a catalyst-coated gasoline particulate filter according to any one of claims 10 to 13, wherein the precursor composition contains a pore-forming material.

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