Exhaust Gas Catalyst Segmented Palladium Rhodium Regions

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Solution Overview

Problem

Long-term use of exhaust gas control catalysts with iron oxide as an oxygen storage capacity (OSC) material leads to a decrease in catalytic activity and oxygen storage capacity.

Innovation Solution

The catalyst layer is structured with adjacent palladium and rhodium regions, where the palladium region contains palladium, aluminum oxide, ceria-zirconia solid solution, and a composite oxide of lanthanum, iron, and zirconium, and the rhodium region contains rhodium, aluminum oxide, and ceria-zirconia solid solution, with the palladium region's surface area controlling diffusion to inhibit activity and capacity decline.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If iron oxide is used as an OSC material in the catalyst layer, then the oxygen storage capacity is improved, but the catalytic activity and oxygen storage capacity decrease after long-term use

Engineering Contradiction:
Improveoxygen storage capacityVSAvoidcatalytic activity stability
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The catalyst layer is segmented into multiple functional regions: a first region containing iron oxide particles as OSC material, a second region containing catalytic noble metal particles, and a third region containing both iron oxide and noble metal particles. This spatial segmentation prevents direct contact between iron oxide and noble metal in the first region, reducing unwanted interactions while maintaining oxygen storage capacity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Different regions of the catalyst layer have different compositions and functions. The first region provides oxygen storage with iron oxide, the second region provides catalytic activity with noble metals, and the third region provides combined functionality. This local differentiation allows each material to perform its optimal function without detrimental interactions.

Inventive Principle:
Principle #3Local quality

2Quantity of substance

If iron oxide particles are dispersed in the catalyst layer, then the oxygen storage capacity is enhanced, but the catalytic noble metal activity decreases over time

Engineering Contradiction:
Improveoxygen storage capacityVSAvoidcatalytic activity
Core Design Contradiction:
Quantity of substanceVSProductivity

Solution Approach 1:

The catalyst layer is divided into distinct regions where iron oxide particles are concentrated in the first region and catalytic noble metal particles are concentrated in the second region. This segmentation prevents iron oxide from interfering with noble metal catalytic sites while still providing adequate oxygen storage capacity throughout the layer.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The third region acts as an intermediary zone containing both iron oxide particles and catalytic noble metal particles, allowing controlled interaction between the two materials. This intermediate region mediates the balance between oxygen storage and catalytic activity, preventing complete separation while avoiding excessive interaction that would reduce activity.

Inventive Principle:
Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration substantially inhibits the decrease in catalytic activity and oxygen storage capacity over time, maintaining effective exhaust gas control performance.

Implementation Method 1

a palladium region that contains palladium, aluminum oxide, ceria-zirconia solid solution, and a composite oxide of lanthanum, iron, and zirconium

Methodology Applied
Scientific EffectCatalysis: Catalysis

Implementation Method 2

a rhodium region that is arranged adjacent to the palladium region along a plane direction of the first catalyst layer and contains rhodium, aluminum oxide, and ceria-zirconia solid solution

Methodology Applied
Scientific EffectCatalysis: Catalysis

Implementation Method 3

The OSC material stores and releases oxygen to promote an exhaust gas control reaction by the catalytic noble metals

Methodology Applied
Scientific EffectOxygen storage capacity: Absorption (physical)

Implementation Method 4

a composite oxide of lanthanum, iron, and zirconium

Methodology Applied
Scientific EffectOxygen storage capacity: Absorption (physical)

Data Source

PatentUS9937487B2Exhaust gas control catalyst
Publication Date: 2018.04.10 TOYOTA JIDOSHA KK
  • US9937487B2 patent drawing
  • US9937487B2 patent drawing
  • US9937487B2 patent drawing

AI summary

Provided is an exhaust gas control catalyst including: a substrate (21); and a catalyst layer (22) that is arranged on the substrate, in which the catalyst layer (22) includes a palladium region (23) that contains palladium, aluminum oxide, ceria-zirconia solid solution, and a composite oxide of lanthanum, iron, and zirconium, and a rhodium region (24) that is arranged adjacent to the palladium region along a plane direction of the catalyst layer and contains rhodium, aluminum oxide, and ceria-zirconia solid solution.