JP2003225575A - Filter type catalyst for purifying exhaust gas from diesel engine - Google Patents
Filter type catalyst for purifying exhaust gas from diesel engineInfo
- Publication number
- JP2003225575A JP2003225575A JP2002029457A JP2002029457A JP2003225575A JP 2003225575 A JP2003225575 A JP 2003225575A JP 2002029457 A JP2002029457 A JP 2002029457A JP 2002029457 A JP2002029457 A JP 2002029457A JP 2003225575 A JP2003225575 A JP 2003225575A
- Authority
- JP
- Japan
- Prior art keywords
- filter
- exhaust gas
- catalyst
- partition wall
- diesel exhaust
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000003054 catalyst Substances 0.000 title claims abstract description 180
- 238000005192 partition Methods 0.000 claims description 103
- 239000002245 particle Substances 0.000 claims description 65
- 238000000576 coating method Methods 0.000 claims description 42
- 230000002093 peripheral effect Effects 0.000 claims description 42
- 239000011248 coating agent Substances 0.000 claims description 39
- 239000011232 storage material Substances 0.000 claims description 13
- 238000011144 upstream manufacturing Methods 0.000 claims description 13
- 229910000510 noble metal Inorganic materials 0.000 claims description 11
- 239000000919 ceramic Substances 0.000 claims description 9
- 230000035945 sensitivity Effects 0.000 abstract description 18
- 230000008018 melting Effects 0.000 abstract description 9
- 238000002844 melting Methods 0.000 abstract description 9
- 230000008929 regeneration Effects 0.000 abstract description 6
- 238000011069 regeneration method Methods 0.000 abstract description 6
- 239000010410 layer Substances 0.000 description 61
- 239000011148 porous material Substances 0.000 description 42
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 37
- 239000000843 powder Substances 0.000 description 33
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Substances [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 27
- 230000000052 comparative effect Effects 0.000 description 24
- 239000002002 slurry Substances 0.000 description 21
- 238000000034 method Methods 0.000 description 19
- 229910052697 platinum Inorganic materials 0.000 description 17
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 16
- 229910052700 potassium Inorganic materials 0.000 description 16
- 238000000746 purification Methods 0.000 description 15
- 239000011230 binding agent Substances 0.000 description 14
- 230000008021 deposition Effects 0.000 description 12
- 229910052744 lithium Inorganic materials 0.000 description 12
- 238000012937 correction Methods 0.000 description 11
- 238000009825 accumulation Methods 0.000 description 10
- 238000012360 testing method Methods 0.000 description 10
- 238000002485 combustion reaction Methods 0.000 description 8
- 238000000635 electron micrograph Methods 0.000 description 8
- 239000010970 precious metal Substances 0.000 description 8
- 229910052788 barium Inorganic materials 0.000 description 7
- 230000003647 oxidation Effects 0.000 description 7
- 238000007254 oxidation reaction Methods 0.000 description 7
- 239000013618 particulate matter Substances 0.000 description 6
- 238000000638 solvent extraction Methods 0.000 description 6
- 230000000694 effects Effects 0.000 description 5
- 239000007864 aqueous solution Substances 0.000 description 4
- 230000033228 biological regulation Effects 0.000 description 4
- 229910052796 boron Inorganic materials 0.000 description 4
- 239000011247 coating layer Substances 0.000 description 4
- 238000002791 soaking Methods 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 239000002131 composite material Substances 0.000 description 3
- 239000010419 fine particle Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 2
- 238000006555 catalytic reaction Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
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- 229910052717 sulfur Inorganic materials 0.000 description 2
- 230000008646 thermal stress Effects 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- 229910010413 TiO 2 Inorganic materials 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
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- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 1
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- 229910052727 yttrium Inorganic materials 0.000 description 1
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、ディーゼルエンジ
ンからの排ガス中に含まれるパティキュレート（粒子状
物質）を補集するとともに、排ガス中の有害成分を浄化
するディーゼル排ガス浄化用触媒に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a diesel exhaust gas purification catalyst which collects particulates (particulate matter) contained in exhaust gas from a diesel engine and purifies harmful components in the exhaust gas.
【０００２】[0002]
【従来の技術】ガソリンエンジンについては、排ガスの
厳しい規制とそれに対処できる技術の進歩とにより、排
ガス中の有害成分は確実に減少されてきている。しか
し、ディーゼルエンジンについては、有害成分がパティ
キュレート（粒子状物質：炭素微粒子、サルフェート等
の硫黄系微粒子、高分子量炭化水素微粒子）として排出
されるという特異な事情から、規制も技術の進歩もガソ
リンエンジンに比べて遅れている。2. Description of the Related Art With regard to gasoline engines, harmful regulations in exhaust gas have been steadily reduced due to strict regulations on exhaust gas and progress in technology capable of coping with the regulations. However, for diesel engines, regulations and technological advances have not been achieved due to the unique circumstances in which harmful components are emitted as particulates (particulate matter: carbon fine particles, sulfur-based fine particles such as sulfate, high-molecular-weight hydrocarbon fine particles). Behind the engine.
【０００３】現在までに開発されているディーゼルエン
ジン用排ガス浄化装置としては、大きく分けてトラップ
型の排ガス浄化装置（ウォールフロー）と、オープン型
の排ガス浄化装置（ストレートフロー）とが知られてい
る。このうちトラップ型の排ガス浄化装置としては、セ
ラミック製の目封じタイプのハニカム体（ディーゼルパ
ティキュレートフィルタ（以下ＤＰＦとする））が知ら
れてる。このＤＰＦは、セラミックハニカム構造体のセ
ル下流端の開口部を目詰めしたガス流入側セルと、セル
上流端の開口部を目詰めしたガス流出側セルと、ガス流
入側セルとガス流出側セルを区画し、ガス流通の際のフ
ィルタとなるセル隔壁、つまりフィルタ隔壁を持つもの
である。このＤＰＦによると排ガスはフィルタ隔壁の細
孔で濾過され、パティキュレートはこのフィルタ隔壁に
捕集されることで排出が抑制される。As an exhaust gas purifying apparatus for diesel engines which has been developed so far, a trap type exhaust gas purifying apparatus (wall flow) and an open type exhaust gas purifying apparatus (straight flow) are known. . Among them, as a trap type exhaust gas purifying device, a ceramic plugging type honeycomb body (diesel particulate filter (hereinafter referred to as DPF)) is known. This DPF includes a gas inflow side cell in which the opening at the cell downstream end of the ceramic honeycomb structure is clogged, a gas outflow side cell in which the opening at the cell upstream end is clogged, a gas inflow side cell and a gas outflow side cell. And has a cell partition wall that serves as a filter during gas flow, that is, a filter partition wall. According to this DPF, the exhaust gas is filtered by the pores of the filter partition wall, and the particulates are collected by the filter partition wall, so that the discharge is suppressed.
【０００４】しかしＤＰＦでは、パティキュレートの堆
積によって圧損が上昇するため、何らかの手段で堆積し
たパティキュレートを定期的に除去して再生する必要が
ある。However, in the DPF, since the pressure loss increases due to the accumulation of particulates, it is necessary to periodically remove the particulates accumulated by some means to regenerate them.
【０００５】従来は、圧損が上昇した場合にバーナある
いは電気ヒータ等で堆積したパティキュレートを燃焼さ
せることでＤＰＦを再生することが行われている。しか
しながらこの場合には、パティキュレートの堆積量が多
いほど燃焼時の温度が上昇し、それによる熱応力でＤＰ
Ｆが破損する場合もある。Conventionally, when the pressure loss increases, the DPF is regenerated by burning the particulates accumulated by a burner or an electric heater. In this case, however, the temperature at the time of combustion rises as the amount of particulate accumulation increases, and the thermal stress caused by this increases DP.
F may be damaged.
【０００６】そこで近年では、ＤＰＦのセル隔壁にアル
ミナなどからコート層を形成し、そのコート層にＰｔな
どの貴金属からなる酸化触媒を担持させた連続再生式Ｄ
ＰＦが開発されている。この連続再生式ＤＰＦによれ
ば、捕集されたパティキュレートが酸化触媒によって比
較的低温で酸化・燃焼されるため、パティキュレートを
捕集と同時にあるいは捕集と連続して燃焼させることで
ＤＰＦを再生することができる。この連続再生式ＤＰＦ
は、触媒反応が比較的低温で生じること、およびパティ
キュレート捕集量が比較的少ないうちに燃焼できること
から、ＤＰＦに作用する熱応力が小さく、熱による破損
が防止されるという利点がある。Therefore, in recent years, a continuous regeneration type D in which a coating layer made of alumina or the like is formed on the cell partition wall of the DPF, and an oxidation catalyst made of a noble metal such as Pt is carried on the coating layer.
PF is being developed. According to this continuous regeneration type DPF, since the collected particulates are oxidized and burned at a relatively low temperature by the oxidation catalyst, the particulates are burned at the same time as the collection or continuously with the collection. Can be played. This continuous regeneration type DPF
Has an advantage that the thermal stress acting on the DPF is small and damage due to heat can be prevented because the catalytic reaction occurs at a relatively low temperature and the catalyst can be burned while the amount of collected particulates is relatively small.
【０００７】しかしこのような連続再生式ＤＰＦにおい
ても、フィルタ本体の径方向の外周部は、排ガスの流通
が少なくまた外気への放熱が大きいために、温度が下が
り易い傾向にある。このことから、この部分においては
パティキュレートの酸化・燃焼が良好に行われ難く、Ｄ
ＰＦを再生した後でもパティキュレートの燃え残りが生
じ、フィルタ隔壁に目詰まりを起こすこともある。However, even in such a continuous regeneration type DPF, the temperature of the outer peripheral portion of the filter body in the radial direction tends to drop because the exhaust gas is less distributed and the heat is radiated to the outside air more. From this, it is difficult to oxidize and burn particulates well in this portion, and D
Even after the PF is regenerated, the unburned particulates may remain and the filter partition walls may be clogged.
【０００８】さらに、フィルタ本体の排ガス流れの下流
部は、パティキュレートが燃焼する際にもっとも高温と
なる部分である。このため、このフィルタ本体の排ガス
流れの下流部でのパティキュレートの堆積が進行する
と、パティキュレート燃焼の際にこの部分はより高温と
なり、ＤＰＦ溶損の起点となることもある。Further, the downstream part of the exhaust gas flow of the filter body is the part where the particulates become the highest temperature when burning. For this reason, if particulates accumulate in the downstream portion of the exhaust gas flow of the filter body, this portion becomes higher in temperature during particulate combustion, which may be the starting point of DPF melting loss.
【０００９】このようにパティキュレートがＤＰＦ内で
偏った堆積をすることにより目詰まりや溶損をおこした
ＤＰＦは、排ガスの浄化能が低下するために交換する必
要があるが、ＤＰＦを頻繁に交換することはコスト面か
ら好ましくない。[0009] The DPF that has been clogged or melted due to uneven deposition of particulates in the DPF in this way needs to be replaced because the ability to purify exhaust gas decreases, but the DPF is frequently used. Replacing is not preferable in terms of cost.
【００１０】一方、溶損を起こさないためにはパティキ
ュレートの堆積量が溶損が生じる量に達する前にＤＰＦ
の再生処理を行うことが必要である。その方法としてＤ
ＰＦ前後の排ガス圧力から圧損を検知してＤＰＦの再生
処理のタイミングを見極める方法が用いられている。On the other hand, in order to prevent the melting loss, the DPF is deposited before the amount of particulates accumulated reaches the amount causing the melting loss.
It is necessary to perform the reproduction processing of. The method is D
A method is used in which the pressure loss is detected from the exhaust gas pressure before and after the PF to determine the timing of the DPF regeneration process.
【００１１】しかしＤＰＦ内でパティキュレートが偏っ
て堆積すると、ＤＰＦ全体の圧損はさほど上昇しない場
合でも、部分的なパティキュレート堆積量は溶損が生じ
る量に達している場合があり、このため、ＤＰＦ溶損が
生じるパティキュレートの堆積量を感度良く検知するこ
とは困難であった。However, if the particulates are unevenly deposited in the DPF, even if the pressure loss of the entire DPF does not increase so much, the partial particulate deposition amount may reach the amount causing the melting loss. It has been difficult to detect with high sensitivity the amount of particulate accumulation that causes DPF melting loss.
【００１２】また、ＤＰＦにコートする触媒層のコート
量を単に多くして、圧損の上昇によるパティキュレート
堆積を検知する感度である、圧損感度を向上させると、
ＤＰＦの初期圧損が増大するという問題が生じる。Further, if the coating amount of the catalyst layer coated on the DPF is simply increased to improve the pressure loss sensitivity, which is the sensitivity for detecting the particulate accumulation due to the increase of the pressure loss,
There is a problem that the initial pressure loss of the DPF increases.
【００１３】[0013]
【発明が解決しようとする課題】本発明は上記事情を考
慮してなされたもので、初期圧損の増大を抑制しつつ圧
損感度を高めたディーゼル排ガス浄化用フィルタ型触媒
を得ることを目的とした。SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object thereof is to obtain a filter catalyst for purifying diesel exhaust gas in which the pressure drop sensitivity is enhanced while suppressing the increase in the initial pressure drop. .
【００１４】[0014]
【課題を解決するための手段】前記課題を解決する本発
明のディーゼル排ガス浄化用フィルタ型触媒は、セラミ
ックハニカム構造体であって、セル下流端の開口部を目
詰めしたガス流入孔と、セル上流端の開口部を目詰めし
たガス流出孔と、該ガス流入孔と該ガス流出孔を区画し
ガス流通の際のフィルタとなるフィルタ隔壁とを持つフ
ィルタ本体と、多孔質酸化物と貴金属とを含む触媒層と
を有するディーゼル排ガス浄化用フィルタ型触媒であ
り、該触媒層は少なくとも該フィルタ本体の特定部位の
該フィルタ隔壁上に粒径１μｍ以下の該多孔質酸化物を
主成分とするコート部を有することを特徴とする。A filter catalyst for purifying diesel exhaust gas according to the present invention for solving the above-mentioned problems is a ceramic honeycomb structure, and has gas inlet holes in which openings at cell downstream ends are clogged, and cells. A filter main body having a gas outlet hole with which the opening at the upstream end is clogged, a filter partition that divides the gas inlet hole and the gas outlet hole and serves as a filter during gas flow, a porous oxide and a noble metal And a catalyst layer containing a catalyst layer for purifying diesel exhaust gas, wherein the catalyst layer is a coat mainly composed of the porous oxide having a particle size of 1 μm or less on at least the filter partition wall at a specific portion of the filter body. It is characterized by having a part.
【００１５】少なくとも該フィルタ本体の特定部位の該
フィルタ隔壁上に粒径１μｍ以下の該多孔質酸化物を主
成分とするコート部を有する触媒層は、フィルタ隔壁の
細孔径１０μｍ以下の細孔に優先的に充填される。従っ
て、本発明のディーゼル排ガス浄化用フィルタ型触媒に
おいては、この細孔径１０μｍ以下の細孔は、多孔質酸
化物によって充填されているか、あるいは細孔径が更に
小さい状態になっている。このため、フィルタ隔壁にパ
ティキュレートが堆積した場合には圧損が上昇し易くな
り、このことから圧損の上昇によってパティキュレート
の堆積を堆積初期に検知することができ、圧損感度が向
上する。A catalyst layer having a coating part having a particle size of 1 μm or less as a main component of the porous oxide on at least a specific portion of the filter body on the filter partition wall has pores with a pore size of 10 μm or less. Filled preferentially. Therefore, in the filter catalyst for purifying diesel exhaust gas of the present invention, the pores having a pore diameter of 10 μm or less are filled with a porous oxide or have a smaller pore diameter. Therefore, when the particulate matter is deposited on the filter partition wall, the pressure loss is likely to increase, which makes it possible to detect the particulate matter accumulation due to the increased pressure loss at the initial stage of the deposition and improve the pressure loss sensitivity.
【００１６】上記特定部位は、上記フィルタ本体の径方
向の外周部とすることもできるし、上記フィルタ本体の
排ガス流れ下流部とすることもできる。また、上記特定
部位のフィルタ隔壁上の上記触媒層は、コート量が上記
特定部位を除く部分のフィルタ隔壁上のコート量より多
くすることができる。The specific portion may be an outer peripheral portion of the filter body in the radial direction, or may be an exhaust gas flow downstream portion of the filter body. Further, the catalyst layer on the filter partition wall of the specific portion may have a coating amount larger than the coating amount on the filter partition wall of the portion excluding the specific portion.
【００１７】上記特定部位のガス流出孔を区画するフィ
ルタ隔壁上の前記触媒層は、平均粒径１μｍ以下の多孔
質酸化物からなる第１コート部と、第１コート部表面に
形成され平均粒径１〜５μｍの多孔質酸化物からなる第
２コート部とから構成することができる。The catalyst layer on the filter partition wall that defines the gas outflow holes at the specific portion has a first coat portion made of a porous oxide having an average grain size of 1 μm or less, and an average grain formed on the surface of the first coat portion. The second coating portion may be made of a porous oxide having a diameter of 1 to 5 μm.
【００１８】また、上記触媒層には、さらに、ＮＯX吸
蔵材が含まれることが好ましい。Further, it is preferable that the catalyst layer further contains a NO x storage material.
【００１９】[0019]
【発明の実施の形態】本発明のディーゼル排ガス浄化用
フィルタ型触媒は、フィルタ本体と、触媒層とを有す
る。BEST MODE FOR CARRYING OUT THE INVENTION The filter catalyst for purifying diesel exhaust gas according to the present invention has a filter body and a catalyst layer.
【００２０】フィルタ本体は多孔質セラミックハニカム
構造体であって、ガス流入孔と、ガス流出孔と、これら
を区画し、ガス流通の際のフィルタとなるフィルタ隔壁
とを有する。ここで多孔質セラミックハニカム構造体
は、１〜１．５ｍｍ程度のセル径を有する蜂の巣状のセ
ル複合体からなるものであり、該セル複合体の各セルは
セル孔がフィルタ隔壁によって囲まれて形成される。フ
ィルタ隔壁は０．２〜０．４ｍｍ程度の壁厚を持つ。The filter body is a porous ceramic honeycomb structure, and has gas inflow holes, gas outflow holes, and filter partition walls that partition the gas inflow holes and serve as a filter during gas flow. Here, the porous ceramic honeycomb structure is composed of a honeycomb-shaped cell composite having a cell diameter of about 1 to 1.5 mm, and each cell of the cell composite has cell pores surrounded by filter partition walls. It is formed. The filter partition wall has a wall thickness of about 0.2 to 0.4 mm.
【００２１】またガス流入孔とは、排ガスがフィルタ本
体に進入する際の入口となるセル孔であり、排ガス上流
側に位置するセル上流端が開口し、排ガス下流側に位置
するセル下流端が目詰めされて閉口したセル孔である。
また、ガス流出孔とは、排ガスがフィルタ本体を流通す
る際に排ガスの出口となるセル孔であり、セル上流端が
目詰めされて閉口し、セル下流端が開口したセル孔であ
る。ガス流入孔からフィルタ本体に進入した排ガスはフ
ィルタ隔壁を通過し、浄化されてガス流出孔から排出さ
れる。ここで、フィルタ隔壁はその内部および／または
表面にガス流通の際のガス流路となる細孔を有する。こ
のフィルタ隔壁における細孔の割合、つまり気孔率は５
０〜８０％の範囲であることが好ましく、この細孔は平
均細孔径１０μｍ〜４０μｍの範囲であることが好まし
い。The gas inflow hole is a cell hole that serves as an inlet when exhaust gas enters the filter body. The cell upstream end located on the exhaust gas upstream side is open, and the cell downstream end located on the exhaust gas downstream side is open. It is a closed and closed cell hole.
The gas outflow hole is a cell hole that serves as an outlet of the exhaust gas when the exhaust gas flows through the filter body, and is a cell hole in which the upstream end of the cell is closed and closed, and the downstream end of the cell is opened. Exhaust gas that has entered the filter body from the gas inflow hole passes through the filter partition wall, is purified, and is discharged from the gas outflow hole. Here, the filter partition wall has pores inside and / or on the surface thereof that serve as gas flow paths during gas flow. The ratio of pores in this filter partition wall, that is, the porosity is 5
It is preferably in the range of 0 to 80%, and the pores preferably have an average pore diameter of 10 μm to 40 μm.
【００２２】フィルタ本体は耐熱性セラミックスで形成
されており、押出し成形等の従来の方法で作られたもの
を使用できる。具体的には市販の多孔質ハニカム型セラ
ミック製ＤＰＦを使用することもでき、原料としては一
般的に使用される耐熱性セラミックス原料を用いること
ができる。また、良好な排ガスの浄化を行うためにはガ
ス流出孔およびガス流入孔からなるセル密度が４５ｃｅ
ｌｌｓ／ｃｍ2以上であることが好ましい。The filter body is made of heat-resistant ceramics, and one manufactured by a conventional method such as extrusion molding can be used. Specifically, a commercially available DPF made of a porous honeycomb ceramic can be used, and as the raw material, a commonly used heat-resistant ceramic raw material can be used. Further, in order to perform good purification of exhaust gas, the cell density of the gas outflow holes and the gas inflow holes is 45 ce.
It is preferably lls / cm 2 or more.
【００２３】触媒層は、多孔質酸化物と貴金属とを含
む。The catalyst layer contains a porous oxide and a noble metal.
【００２４】ここで多孔質酸化物とは、比表面積が大き
い酸化物であり、この多孔質酸化物としては一般に使用
されるものを用いることができるが、Ａｌ2Ｏ3、ＺｒＯ
2、ＣｅＯ2、ＴｉＯ2、ＳｉＯ2などの酸化物あるいはこ
れらの複数種からなる複合酸化物を使用することが好ま
しい。Here, the porous oxide is an oxide having a large specific surface area. As the porous oxide, those generally used can be used, but Al 2 O 3 and ZrO are used.
It is preferable to use oxides such as 2 , CeO 2 , TiO 2 , and SiO 2 or composite oxides composed of a plurality of these.
【００２５】貴金属としては、触媒反応によってパティ
キュレートの酸化を促進する、酸化触媒となり得る貴金
属であれば用いることができるが、Ｐｔ、Ｒｈ、Ｐｄ、
Ｉｒ、Ｒｕなどの白金族の貴金属から選ばれた一種ある
いは複数種を用いることが好ましい。As the noble metal, any noble metal that promotes the oxidation of particulates by a catalytic reaction and can serve as an oxidation catalyst can be used. Pt, Rh, Pd,
It is preferable to use one or more selected from platinum group precious metals such as Ir and Ru.
【００２６】本発明のディーゼル排ガス浄化用フィルタ
型触媒において、触媒層は少なくとも該フィルタ本体の
特定部位の該フィルタ隔壁上に粒径１μｍ以下の該多孔
質酸化物を主成分とするコート部を有する。In the filter catalyst for purifying diesel exhaust gas according to the present invention, the catalyst layer has at least a coating portion having a particle diameter of 1 μm or less as a main component on the filter partition wall at a specific portion of the filter body. .
【００２７】ここで、触媒層は通常の方法で形成するこ
とができる。つまり、フィルタ隔壁に多孔質酸化物をコ
ートしてコート層を形成し、そのコート層に貴金属を担
持させても良いし、多孔質酸化物に貴金属を担持させた
触媒粉末をフィルタ隔壁にコートしてもよい。Here, the catalyst layer can be formed by a usual method. That is, the filter partition wall may be coated with a porous oxide to form a coat layer, and the coating layer may be loaded with a noble metal, or the filter partition wall may be coated with a catalyst powder in which a porous oxide is loaded with a noble metal. May be.
【００２８】平均粒径１μｍ以下の多孔質酸化物をフィ
ルタ隔壁にコートする場合、多孔質酸化物はフィルタ隔
壁の細孔径１０μｍ以下の細孔に優先的に充填され、細
孔径が４０〜１００μｍの細孔は残存する割合が高い。When the filter partition wall is coated with a porous oxide having an average particle size of 1 μm or less, the porous oxide is preferentially filled in the pores of the filter partition wall having a pore size of 10 μm or less, and the pore size of 40 to 100 μm. The percentage of pores remaining is high.
【００２９】したがって、触媒層が粒径１μｍ以下の多
孔質酸化物を主成分とするコート部を有することで、フ
ィルタ隔壁の細孔径１０μｍ以下の細孔の大部分には触
媒層が充填され、あるいは触媒層によって細孔径が更に
小さい状態となる。このような触媒層が形成されたフィ
ルタ隔壁は気孔率が４５〜６０％となり、平均細孔径が
１５〜２０μｍとなる。Therefore, since the catalyst layer has the coating portion containing a porous oxide having a particle diameter of 1 μm or less as a main component, most of the pores of the filter partition wall having a pore diameter of 10 μm or less are filled with the catalyst layer, Alternatively, the pore size becomes smaller due to the catalyst layer. The filter partition wall on which such a catalyst layer is formed has a porosity of 45 to 60% and an average pore diameter of 15 to 20 μm.
【００３０】平均粒径３μｍの触媒粉末をフィルタ本体
の体積１リットルあたり７５ｇコートしたＤＰＦの電子
顕微鏡写真を図１に示し、平均粒径０．６μｍの触媒粉
末をフィルタ本体の体積１リットルあたり７５ｇコート
したＤＰＦの電子顕微鏡写真を図２に示す。図中で白色
の部分が触媒層である。図１の平均粒径３μｍの触媒粉
末がコートされたＤＰＦと比較して図２の平均粒径０．
６μｍの触媒粉末がコートされたＤＰＦは、細孔径の小
さい細孔に触媒粉末が充填されていることが判る。An electron micrograph of a DPF coated with 75 g of catalyst powder having an average particle size of 3 μm per 1 liter volume of the filter body is shown in FIG. 1, and 75 g of catalyst powder having an average particle size of 0.6 μm per 1 liter volume of the filter body. An electron micrograph of the coated DPF is shown in FIG. The white portion in the figure is the catalyst layer. As compared with the DPF coated with a catalyst powder having an average particle size of 3 μm in FIG.
It can be seen that the DPF coated with 6 μm of catalyst powder has the catalyst powder filled in the pores having a small pore size.
【００３１】一般的なディーゼル排ガス浄化用フィルタ
型触媒では、細孔径１０μｍ以下の細孔が残存してい
る。このようなディーゼル排ガス浄化用フィルタ型触媒
において、細孔径１０μｍ以下の細孔はパティキュレー
トの捕集にあまり関与しないがガスの流路となり得る。
このため、細孔径の大きな他の細孔がパティキュレート
を捕集して目詰まりしている場合でも、この細孔径１０
μｍ以下の細孔によってガスの流通が行われるために圧
損はあまり上昇せず、従って圧損感度はあまり高くな
い。In a general diesel exhaust gas purifying filter type catalyst, pores having a pore diameter of 10 μm or less remain. In such a filter catalyst for purifying diesel exhaust gas, pores having a pore diameter of 10 μm or less do not contribute much to the collection of particulates, but can serve as gas passages.
Therefore, even when other pores having a large pore diameter collect the particulates and become clogged, this pore diameter 10
Since the gas is circulated through the pores of μm or less, the pressure loss does not increase so much, and the pressure loss sensitivity is not so high.
【００３２】一方、本発明のディーゼル排ガス浄化用フ
ィルタ型触媒では、パティキュレートの捕集にあまり関
与しない細孔径１０μｍ以下の細孔には触媒粉末が充填
されているためにガス流通の経路とはならないので、細
孔によるパティキュレートの捕集と、フィルタ本体の圧
損の上昇との関係はより直接的なものとなり、圧損感度
が向上する。On the other hand, in the filter catalyst for purifying diesel exhaust gas of the present invention, since the catalyst powder is filled in the pores having a pore diameter of 10 μm or less, which does not contribute much to the collection of particulates, the gas flow path is not formed. Therefore, the relationship between the collection of particulates by the pores and the increase in the pressure loss of the filter body becomes more direct, and the pressure loss sensitivity is improved.
【００３３】また、本発明のディーゼル排ガス浄化用フ
ィルタ型触媒では細孔径１０μｍ以下の細孔には触媒粉
末が充填されているが、平均細孔径１０〜１００μｍの
細孔が残存しているので、パティキュレートが堆積して
いない状態ではこの細孔径１０〜１００μｍの細孔によ
ってガスの流通が行われ、初期圧損はあまり上昇しな
い。Further, in the diesel exhaust gas purifying filter catalyst of the present invention, the catalyst powder is filled in the pores having a pore diameter of 10 μm or less, but the pores having an average pore diameter of 10 to 100 μm remain. In the state where particulates are not deposited, the gas is circulated through the pores having a pore diameter of 10 to 100 μm, and the initial pressure loss does not increase so much.
【００３４】このことから本発明のディーゼル排ガス浄
化用フィルタ型触媒は、パティキュレートの捕集能を保
ち、初期圧損の増大を防ぎつつパティキュレート堆積を
堆積初期に感度良く検知することができる。このことに
よってパティキュレート堆積量が溶損が生じる量に達す
る前にＤＰＦの再生を行うことが可能となるため、パテ
ィキュレートの堆積の進行に起因するＤＰＦの劣化を防
ぐことができる。From the above, the filter catalyst for purifying diesel exhaust gas according to the present invention can detect particulate accumulation with high sensitivity at the initial stage of deposition while maintaining the ability to collect particulates and preventing an increase in initial pressure loss. This makes it possible to regenerate the DPF before the amount of particulate accumulation reaches the amount at which melting damage occurs, and therefore it is possible to prevent deterioration of the DPF due to the progress of particulate accumulation.
【００３５】本発明のディーゼル排ガス浄化用フィルタ
型触媒において、フィルタ隔壁にコートされる平均粒径
１μｍ以下の多孔質酸化物の量は、フィルタ本体の体積
１リットルあたり５０ｇ〜２００ｇであることが好まし
く、貴金属の量はフィルタ本体の体積１リットルあたり
１ｇ〜５ｇが好ましい。これより多くなるとフィルタ本
体の圧損が上昇し、これより少なくなるとパティキュレ
ートの酸化・燃焼が良好に行われない。なお、本明細書
においてフィルタ本体の体積とは、フィルタ本体の嵩の
量を表す。In the filter catalyst for purifying diesel exhaust gas of the present invention, the amount of the porous oxide having an average particle size of 1 μm or less coated on the filter partition wall is preferably 50 g to 200 g per 1 liter of the volume of the filter body. The amount of the noble metal is preferably 1 g to 5 g per 1 liter volume of the filter body. If it is more than this range, the pressure loss of the filter main body rises, and if it is less than this range, the oxidation and combustion of particulates cannot be performed well. In the present specification, the volume of the filter body represents the volume of the filter body.
【００３６】本発明のディーゼル排ガス浄化用フィルタ
型触媒において、触媒層には少なくともフィルタ本体の
特定部位のフィルタ隔壁上に粒径１μｍ以下の多孔質酸
化物を主成分とするコート部を有する。In the diesel exhaust gas purifying filter type catalyst of the present invention, the catalyst layer has a coating portion containing a porous oxide having a particle size of 1 μm or less as a main component on at least the filter partition wall at a specific portion of the filter body.
【００３７】上述したように、触媒層が粒径１μｍ以下
の多孔質酸化物を主成分とするコート部を有すること
で、ディーゼル排ガス浄化用フィルタ型触媒は、パティ
キュレートの捕集能を保ち、初期圧損の増大を防ぎつつ
パティキュレート堆積を堆積初期に感度良く検知するこ
とができる。ここで、この粒径１μｍ以下の多孔質酸化
物を主成分とするコート部が設けられる部位は、少なく
ともフィルタ本体の特定部位のフィルタ隔壁上であれば
よい。すなわち、フィルタ本体全体の隔壁上に設けるこ
ともできるし、フィルタ本体の特定部位のフィルタ隔壁
上にのみ設けることもできる。As described above, since the catalyst layer has the coated portion containing a porous oxide having a particle diameter of 1 μm or less as a main component, the diesel exhaust gas purifying filter type catalyst maintains the ability to collect particulates, It is possible to detect particulate deposition with high sensitivity at the initial stage of deposition while preventing an increase in initial pressure loss. Here, the site where the coating part containing a porous oxide having a particle size of 1 μm or less as a main component is provided may be at least on the filter partition wall of a specific site of the filter body. That is, it may be provided on the partition wall of the entire filter body, or may be provided only on the filter partition wall of a specific portion of the filter body.
【００３８】本発明のディーゼル排ガス浄化用フィルタ
型触媒において、特定部位はフィルタ本体の径方向の外
周部とすることが好ましく、また、フィルタ本体の排ガ
ス流れ方向の下流部とすることが好ましい。In the filter catalyst for purifying diesel exhaust gas according to the present invention, it is preferable that the specific portion is located at an outer peripheral portion in the radial direction of the filter body, and also at a downstream portion in the exhaust gas flow direction of the filter body.
【００３９】そして、特定部位のフィルタ隔壁上の触媒
層は、コート量が特定部位を除く部分のフィルタ隔壁上
のコート量よりも多いことが望ましい。It is desirable that the coating amount of the catalyst layer on the filter partition wall at the specific portion is larger than the coating amount on the filter partition wall at the portion excluding the specific portion.
【００４０】ここで、フィルタ本体の径方向の外周部の
範囲は、フィルタ本体の径方向の内周部とフィルタ本体
の径方向の外周部の体積の比率が１：２〜４：１となる
ような範囲である。Here, in the range of the radial outer peripheral portion of the filter body, the volume ratio of the radial inner peripheral portion of the filter main body to the radial outer peripheral portion of the filter main body is 1: 2 to 4: 1. It is such a range.
【００４１】また、フィルタ本体の排ガス流れの下流部
の範囲は、フィルタ本体の排ガス流れの上流部とフィル
タ本体の排ガス流れの下流部の体積の比率が１：２〜
２：１となるような範囲である。Further, in the range of the downstream portion of the exhaust gas flow of the filter body, the volume ratio of the upstream portion of the exhaust gas flow of the filter body to the downstream portion of the exhaust gas flow of the filter body is 1: 2.
The range is 2: 1.
【００４２】一般にＤＰＦにおいてフィルタ本体の径方
向の外周部（以下、外周部と呼ぶ）は、排ガスの流通が
少なく、外気への放熱が大きい。このことから、この外
周部は温度が下がり易く、パティキュレートの酸化・燃
焼が良好に行われ難い。その結果、この外周部はパティ
キュレートが堆積し易い傾向にある。Generally, in the DPF, the outer peripheral portion of the filter body in the radial direction (hereinafter referred to as the outer peripheral portion) has a small amount of circulation of exhaust gas and a large amount of heat radiation to the outside air. For this reason, the temperature of this outer peripheral portion is likely to drop, and it is difficult to oxidize and burn particulates favorably. As a result, particulates tend to accumulate on this outer peripheral portion.
【００４３】本発明のディーゼル排ガス浄化用フィルタ
型触媒では、この外周部に位置するフィルタ隔壁に形成
される触媒層が粒径１μｍ以下の多孔質酸化物を主成分
とするコート部を有することが好ましい。In the filter catalyst for purifying diesel exhaust gas of the present invention, the catalyst layer formed on the filter partition wall located on the outer peripheral portion may have a coating portion containing a porous oxide having a particle diameter of 1 μm or less as a main component. preferable.
【００４４】外周部に位置するフィルタ隔壁に形成され
る触媒層を粒径１μｍ以下の多孔質酸化物を主成分とす
るコート部とすることでパティキュレートが堆積し易い
外周部において、前述したように、パティキュレートの
堆積量を感度良く検知することができ、パティキュレー
トが堆積した場合でも、溶損が生じる前にＤＰＦの再生
を行うことができる。By forming the catalyst layer formed on the filter partition wall located on the outer peripheral portion as a coating portion containing a porous oxide having a particle diameter of 1 μm or less as a main component, the outer peripheral portion where particulates are easily deposited is as described above. Moreover, the amount of particulates deposited can be detected with high sensitivity, and even if particulates are deposited, the DPF can be regenerated before melting damage occurs.
【００４５】また、外周部を特定部位とし、この外周部
に位置するフィルタ隔壁上の触媒層のコート量を特定部
位を除く部分のコート量より多くすることで、この部分
の熱容量が増大し、外周部における温度の低下が防止さ
れてパティキュレートの酸化・燃焼が良好に行われる。Further, by setting the outer peripheral portion as the specific portion and making the coating amount of the catalyst layer on the filter partition wall located at the outer peripheral portion larger than the coating amount of the portion excluding the specific portion, the heat capacity of this portion increases, The temperature drop in the outer peripheral portion is prevented, and the particulates are satisfactorily oxidized and burned.
【００４６】以下、このコート量の多い特定部位を多コ
ート部と呼ぶ。Hereinafter, the specific portion having a large amount of coating will be referred to as a multi-coated portion.
【００４７】フィルタ本体の径方向の内周部にコートさ
れる平均粒径１μｍ以下の多孔質酸化物の量は、フィル
タ本体の体積１リットルあたり５０ｇ〜２００ｇである
ことが好ましく、外周部にコートする平均粒径１μｍ以
下の多孔質酸化物の量は、フィルタ本体の体積１リット
ルあたり１５０ｇ〜３００ｇであることが好ましい。The amount of the porous oxide having an average particle diameter of 1 μm or less coated on the radially inner portion of the filter body is preferably 50 g to 200 g per 1 liter of the filter body, and the amount of the porous oxide coated on the outer portion is preferably. The amount of the porous oxide having an average particle size of 1 μm or less is preferably 150 g to 300 g per 1 liter of the volume of the filter body.
【００４８】さらに、フィルタ本体のガス流れの上流部
にコートする平均粒径１μｍ以下の多孔質酸化物の量
は、フィルタ本体１リットルあたり５０ｇ〜２００ｇで
あることが好ましく、下流部にコートする平均粒径１μ
ｍ以下の多孔質酸化物の量は、フィルタ本体の体積１リ
ットルあたり１５０ｇ〜３００ｇであることが好まし
い。Further, the amount of the porous oxide having an average particle size of 1 μm or less coated on the upstream side of the gas flow of the filter body is preferably 50 to 200 g per liter of the filter body, and the average amount coated on the downstream side is average. Particle size 1μ
The amount of the porous oxide of m or less is preferably 150 g to 300 g per liter of the volume of the filter body.
【００４９】本発明のディーゼル排ガス浄化用フィルタ
型触媒において、ＤＰＦにまず多孔質酸化物のコート層
を形成し、その後貴金属やＮＯX吸蔵材を担持した場合
には、多コート部における貴金属やＮＯX吸蔵材の担持
密度が下がる。このため、貴金属やＮＯX吸蔵材の粒成
長や硫黄被毒を抑制することができ、触媒層の触媒耐久
性やＮＯX浄化耐久性が向上する。[0049] In the diesel exhaust gas purifying filter catalyst of the present invention to form a coating layer of first porous oxide DPF, followed when carrying the precious metal and the NO X storage material, precious metals and NO in the multi-coated portion X The storage density of the occlusion material decreases. Therefore, it is possible to suppress grain growth and sulfur poisoning of the precious metal and the NO x storage material, and improve the catalyst durability and NO x purification durability of the catalyst layer.
【００５０】本発明のディーゼル排ガス浄化用フィルタ
型触媒では、特定部位のガス流出孔を区画するフィルタ
隔壁上の触媒層は平均粒径１μｍ以下の多孔質酸化物か
らなる第１コート部と、第１コート部表面に形成され平
均粒径１〜５μｍの多孔質酸化物からなる第２コート部
とからなる。In the diesel exhaust gas purifying filter catalyst of the present invention, the catalyst layer on the filter partition wall that defines the gas outflow holes at a specific portion has a first coat portion made of a porous oxide having an average particle diameter of 1 μm or less, The second coat portion is formed on the surface of the first coat portion and is made of a porous oxide having an average particle diameter of 1 to 5 μm.
【００５１】ここで、平均粒径１〜５μｍの触媒粉末と
は、貴金属と平均粒径１〜５μｍの多孔質酸化物とから
なる触媒粉末のことである。Here, the catalyst powder having an average particle size of 1 to 5 μm is a catalyst powder composed of a noble metal and a porous oxide having an average particle size of 1 to 5 μm.
【００５２】平均粒径０．６μｍの触媒粉末をフィルタ
本体の体積１リットルあたり１５０ｇコートしたＤＰＦ
の電子顕微鏡写真を図３に示し、平均粒径０．６μｍの
触媒粉末をフィルタ本体の体積１リットルあたり１２０
ｇコートし、その上層に平均粒径３μｍの触媒粉末を３
０ｇコートしたＤＰＦの電子顕微鏡写真を図４に示す。
図中で白色の部分が触媒層である。触媒層が全面に分散
している図３のＤＰＦと比較して、図４のＤＰＦは触媒
層が図中下面に多く偏在していることから、図中下面に
位置するガス流出孔を区画するフィルタ隔壁には触媒層
が多く形成されていることが判る。DPF coated with 150 g of catalyst powder having an average particle size of 0.6 μm per liter of the filter body.
3 shows an electron micrograph of the catalyst powder having an average particle size of 0.6 μm per 120 liters of the filter body.
g coating, and 3 layers of catalyst powder with an average particle size of 3 μm on top of it.
An electron micrograph of 0 g coated DPF is shown in FIG.
The white portion in the figure is the catalyst layer. Compared with the DPF of FIG. 3 in which the catalyst layer is dispersed over the entire surface, the DPF of FIG. 4 has a large number of catalyst layers unevenly distributed on the lower surface in the figure, and thus defines gas outflow holes located on the lower surface in the figure. It can be seen that many catalyst layers are formed on the filter partition walls.
【００５３】この平均粒径１〜５μｍの触媒粉末は、ガ
ス流出孔を区画するフィルタ隔壁の表面付近の細孔径１
０μｍ以下の細孔に優先的にコートされる。このことか
ら、ガス流出孔を区画するフィルタ隔壁の細孔径１０μ
ｍ以下の細孔に充填される触媒粉末はより多くなる。こ
れによりパティキュレートが堆積した場合の圧損はさら
に上昇するため、パティキュレートの堆積をより早く検
知することができる。The catalyst powder having an average particle size of 1 to 5 μm has a pore diameter of 1 in the vicinity of the surface of the filter partition wall that defines the gas outflow holes.
The pores of 0 μm or less are preferentially coated. From this, the pore size of the filter partition wall that defines the gas outflow holes is 10 μm.
More catalyst powder fills the pores of m or less. As a result, the pressure loss when the particulates are deposited is further increased, so that the particulate deposition can be detected earlier.
【００５４】一般にＤＰＦにおいて、パティキュレート
はガス流入孔を区画するフィルタ隔壁に補集され、ガス
流出孔を区画するフィルタ隔壁はパティキュレートの捕
集には関与しない。本発明のディーゼル排ガス浄化用フ
ィルタ型触媒では、このパティキュレートの捕集に関与
しないガス流出孔を区画するフィルタ隔壁のコート量を
多くすることで、ガス流入孔を区画するフィルタ隔壁で
のパティキュレートの捕集能を維持しつつ、圧損感度を
さらに向上させることができる。Generally, in the DPF, the particulates are collected in the filter partition wall defining the gas inflow hole, and the filter partition wall defining the gas outflow hole does not participate in the collection of the particulates. In the filter catalyst for purifying diesel exhaust gas of the present invention, by increasing the coating amount of the filter partition wall that partitions the gas outflow hole that is not involved in the collection of the particulates, the particulates in the filter partition wall that partition the gas inflow hole The pressure drop sensitivity can be further improved while maintaining the collection ability of
【００５５】ここで、第１コート部と第２コート部とが
形成された特定部位のコート量は、特定部位を除く部分
のコート量より多い量とすることもできるし、また、同
じ量とすることもできる。つまり、特定部位における第
１コート部のコート量を特定部位を除く部分のコート量
より少なくし、その上層に第２コート部をさらにコート
することで、特定部位のコート量と特定部位以外の部分
のコート量とを等しいコート量とすることもできる。ま
た、フィルタ隔壁全体に同じコート量で第１コート部を
形成し、その後に特定部位にのみ第２コート部をコート
することで特定部位のコート量を特定部位以外の部分の
コート量より多くすることもできる。この場合、上述し
た多コート部による効果と第２コート部による効果との
両方の効果が得られるため、より好ましい。Here, the coating amount of the specific portion where the first coating portion and the second coating portion are formed may be larger than the coating amount of the portion other than the specific portion, or the same amount. You can also do it. That is, the coating amount of the first coating portion in the specific portion is made smaller than the coating amount of the portion excluding the specific portion, and the second coating portion is further coated on the upper portion thereof, so that the coating amount of the specific portion and the portion other than the specific portion are It is also possible to set the same coat amount as the above coat amount. Further, the first coat portion is formed on the entire filter partition wall with the same coat amount, and then the second coat portion is coated only on the specific portion, so that the coat amount of the specific portion is larger than the coat amount of the portion other than the specific portion. You can also In this case, both the effect of the multi-coat portion and the effect of the second coat portion described above can be obtained, which is more preferable.
【００５６】フィルタ隔壁にコートされる平均粒径１μ
ｍ以下の多孔質酸化物の量は、フィルタ本体の体積１リ
ットルあたり５０ｇ〜２００ｇであることが好ましく、
平均粒径１〜５μｍの多孔質酸化物の量は、フィルタ本
体の体積１リットルあたり２０ｇ〜１００ｇであること
が好ましい。これより多くなるとフィルタ本体の圧損が
上昇し、これより少なくなるとパティキュレートの酸化
・燃焼が良好に行われない。Average particle size of 1 μm coated on filter partition wall
The amount of the porous oxide of m or less is preferably 50 g to 200 g per 1 liter of the volume of the filter body,
The amount of the porous oxide having an average particle size of 1 to 5 μm is preferably 20 g to 100 g per 1 liter of the volume of the filter body. If it is more than this range, the pressure loss of the filter main body rises, and if it is less than this range, the oxidation and combustion of particulates cannot be performed well.
【００５７】さらに、ガス流出孔を区画するフィルタ隔
壁に多くの触媒粉末がコートされることから、多孔質酸
化物のコート後に貴金属とＮＯX吸蔵材とを担持すれ
ば、貴金属とＮＯX吸蔵材との担持密度を低くして担持
量を多くすることができる。このため、貴金属やＮＯX
吸蔵材の耐久性が向上するとともに活性が向上する。Furthermore, since a large amount of catalyst powder is coated on the filter partition walls that define the gas outflow holes, if the precious metal and the NO x storage material are carried after the porous oxide is coated, the precious metal and the NO x storage material will be supported. The supporting density can be decreased to increase the supporting amount. Therefore, precious metals and NO x
The durability and the activity of the storage material are improved.
【００５８】本発明のディーゼル排ガス浄化用フィルタ
型触媒において、平均粒径１〜５μｍの触媒粉末を上層
に持つ多コート部は、フィルタ本体の径方向の外周部お
よび／またはフィルタ本体の排ガス流れ方向の下流部に
位置するガス流出孔を区画するフィルタ隔壁に形成する
ことが好ましい。In the filter catalyst for purifying diesel exhaust gas according to the present invention, the multi-coated portion having the catalyst powder having an average particle diameter of 1 to 5 μm in the upper layer is the outer peripheral portion in the radial direction of the filter body and / or the exhaust gas flow direction of the filter body. It is preferable to form the filter partition wall that partitions the gas outflow hole located in the downstream portion of the.
【００５９】この構成において、平均粒径１〜５μｍの
多孔質酸化物が、外周部に位置するガス流出孔を区画す
るフィルタ隔壁に多くコートされる。外周部に触媒層が
多く形成されることで、この部分の熱容量が上がり、温
度の低下が防止される。このことからパティキュレート
の堆積が起こり易い外周部においてパティキュレートの
酸化・燃焼が良好に行われ、パティキュレートの堆積が
抑制される。また、この構成によるとパティキュレート
の堆積をより初期に検知することができ、パティキュレ
ートの堆積量が溶損が生じる量に達することをより確実
に防止することが可能となる。In this structure, a large amount of the porous oxide having an average particle size of 1 to 5 μm is coated on the filter partition wall which defines the gas outflow holes located in the outer peripheral portion. Since the catalyst layer is formed in a large amount on the outer peripheral portion, the heat capacity of this portion is increased and the temperature is prevented from lowering. From this fact, the particulates are satisfactorily oxidized and burned in the outer peripheral portion where the particulates are likely to be deposited, and the particulates are suppressed from being deposited. Further, according to this configuration, it is possible to detect the deposition of particulates at an earlier stage, and it is possible to more reliably prevent the deposition amount of particulates from reaching the amount that causes melt loss.
【００６０】また平均粒径１〜５μｍの触媒粉末を上層
に持つ多コート部が、下流部に位置するガス流出孔を区
画するフィルタ隔壁に形成されることで、パティキュレ
ートの堆積を感度良く検知することができ、パティキュ
レートの堆積量が溶損が生じる量に達することをさらに
確実に防止することが可能となる。Further, the multi-coated portion having the catalyst powder having an average particle diameter of 1 to 5 μm as the upper layer is formed on the filter partition wall which defines the gas outflow hole located in the downstream portion, so that the deposition of particulates can be detected with high sensitivity. Therefore, it is possible to more reliably prevent the accumulated amount of particulates from reaching the amount causing melt loss.
【００６１】外周部に位置するガス流出孔を区画するフ
ィルタ隔壁の多コート部にコートする平均粒径１〜５μ
ｍの多孔質酸化物の量はフィルタ本体の体積１リットル
あたり２０ｇ〜１００ｇであることが好ましい。また、
下流部に位置するガス流出孔を区画するフィルタ隔壁の
多コート部にコートする平均粒径１〜５μｍの触媒粉末
の量は、フィルタ本体の体積１リットルあたり２０ｇ〜
１００ｇであることが好ましい。これより多くなるとフ
ィルタ本体の圧損が上昇し、これより少なくなるとパテ
ィキュレートの酸化・燃焼が良好に行われない。Average particle size of 1 to 5 μm coated on the multi-coated portion of the filter partition wall which defines the gas outflow holes located on the outer peripheral portion.
The amount of the porous oxide of m is preferably 20 to 100 g per 1 liter of the volume of the filter body. Also,
The amount of the catalyst powder having an average particle size of 1 to 5 μm, which coats the multi-coated portion of the filter partition wall that defines the gas outflow holes located in the downstream portion, is 20 g per 1 liter of the volume of the filter body.
It is preferably 100 g. If it is more than this range, the pressure loss of the filter main body rises, and if it is less than this range, the oxidation and combustion of particulates cannot be performed well.
【００６２】また、本発明の多コート部はＮＯX吸蔵材
を含むことができる。ＮＯX吸蔵材を含む触媒層は、排
ガス中のＮＯXを浄化するＮＯX浄化能が向上する。Further, the multi-coat part of the present invention may contain a NO x storage material. The catalyst layer containing the NO X storage material has an improved NO X purification ability for purifying NO X in the exhaust gas.
【００６３】ＮＯX吸蔵材としては、Ｋ、Ｎａ、Ｌｉ、
Ｃｓなどのアルカリ金属、Ｂａ、Ｃａなどのアルカリ土
類、Ｌａ、Ｙなどの希土類から選ばれる少なくとも一つ
を用いることができる。As the NO X storage material, K, Na, Li,
At least one selected from alkali metals such as Cs, alkaline earths such as Ba and Ca, and rare earths such as La and Y can be used.
【００６４】また、触媒層に含まれるＮＯX吸蔵材の量
は、フィルタ本体１リットルあたり０．２〜０．５ｍｌ
であることが好ましい。これより多くなると貴金属がＮ
ＯX吸蔵剤で覆われるため活性が低下し、これより少な
くなるとＮＯX浄化が良好に行われない。The amount of the NO X storage material contained in the catalyst layer is 0.2 to 0.5 ml per liter of the filter body.
Is preferred. When the amount is more than this, the precious metal is N
Since it is covered with the O x storage agent, the activity is lowered, and if it is less than this, NO x purification is not performed well.
【００６５】[0065]
【実施例】以下、本発明の実施例を添付図面を基にして
説明する。Embodiments of the present invention will be described below with reference to the accompanying drawings.
【００６６】（実施例１）本発明の実施例１のディーゼ
ル排ガス浄化用フィルタ型触媒のガス流路に平行な断面
図を図５に示す。(Embodiment 1) FIG. 5 shows a sectional view of the filter catalyst for purifying diesel exhaust gas according to Embodiment 1 of the present invention, which is parallel to the gas passage.
【００６７】本実施例１のディーゼル排ガス浄化用フィ
ルタ型触媒は、フィルタ本体１と、触媒層２とを有し、
触媒層２はフィルタ本体１の径方向の外周部３に位置す
るフィルタ隔壁４に多く形成された多コート部２ａを有
している。The diesel exhaust gas purifying filter type catalyst of the first embodiment has a filter body 1 and a catalyst layer 2.
The catalyst layer 2 has a large number of multi-coated portions 2a formed on the filter partition walls 4 located on the outer peripheral portion 3 in the radial direction of the filter body 1.
【００６８】フィルタ本体１の材料としては端面の面積
１３０ｃｍ2、長さ１５０ｍｍのコージェライト製多孔
質ハニカム構造体を用いた。この多孔質ハニカム構造体
は容積２リットル、気孔率６０％、セル密度４６．５ｃ
ｅｌｌｓ／ｃｍ2、壁厚０．３ｍｍであり、ガス流入孔
５となるセル孔のセル下流端と、ガス流出孔６となるセ
ル孔のセル上流端とを本体と同材のコージェライトより
なる目詰め栓７で目詰めしてフィルタ本体１としたもの
である。As the material of the filter body 1, a cordierite porous honeycomb structure having an end face area of 130 cm 2 and a length of 150 mm was used. This porous honeycomb structure has a volume of 2 liters, a porosity of 60%, and a cell density of 46.5c.
ells / cm 2 , the wall thickness is 0.3 mm, and the cell downstream end of the cell hole serving as the gas inflow hole 5 and the cell upstream end of the cell hole serving as the gas outflow hole 6 are made of the same material as the main body. The filter body 1 is clogged with a clogging plug 7.
【００６９】触媒層２は多孔質酸化物としての平均粒径
０．５〜１μｍのＡｌ2Ｏ3と、貴金属としてのＰｔと、
ＮＯX吸蔵材としてのＢａ，Ｋ，Ｌｉとを含み、フィル
タ本体１の径方向の外周部３に位置するフィルタ隔壁４
に多く形成された。フィルタ本体１の径方向の外周部３
の範囲は、フィルタ本体１の径方向の内周部８とフィル
タ本体１の径方向の外周部３の体積の比率が１：１とな
る範囲である。The catalyst layer 2 comprises Al 2 O 3 having a mean particle size of 0.5 to 1 μm as a porous oxide, and Pt as a noble metal.
Including NO X Ba as storage material, K, and Li, filter partition walls 4 positioned on the outer peripheral portion 3 in the radial direction of the filter body 1
Was formed in many. Radial outer peripheral portion 3 of the filter body 1
The above range is a range in which the volume ratio of the radially inner peripheral portion 8 of the filter body 1 to the radially outer peripheral portion 3 of the filter body 1 is 1: 1.
【００７０】本実施例１において平均粒径１μｍ以下の
Ａｌ2Ｏ3は、フィルタ本体１の径方向の内周部７に位置
するフィルタ隔壁４には、フィルタ本体の体積１リット
ルあたり１５０ｇコートされ、外周部３に位置するフィ
ルタ隔壁４にはフィルタ本体の体積１リットルあたり１
８０ｇコートされた。In Example 1, Al 2 O 3 having an average particle size of 1 μm or less is coated on the filter partition wall 4 located on the radially inner peripheral portion 7 of the filter body 1 at a rate of 150 g per liter of the filter body. In the filter partition wall 4 located on the outer peripheral portion 3, 1 per 1 liter of the volume of the filter body
80g was coated.
【００７１】Ｐｔは、フィルタ隔壁４全面に均一にコー
トされ、フィルタ本体１の体積１リットルあたり３ｇコ
ートされた。また、Ｂａ，Ｋ，Ｌｉも、同様にフィルタ
隔壁全面に均一にコートされ、フィルタ本体１の体積１
リットルあたり０．３ｍｏｌコートされた。Pt was uniformly coated on the entire surface of the filter partition wall 4, and 3 g per 1 liter volume of the filter body 1. Similarly, Ba, K, and Li are uniformly coated on the entire surface of the filter partition wall, and the volume of the filter body 1
0.3 mol was coated per liter.
【００７２】以下に本実施例１のディーゼル排ガス浄化
用フィルタ型触媒の製作方法を示す。The method of producing the filter catalyst for purifying diesel exhaust gas according to the first embodiment will be described below.
【００７３】平均粒径０．５〜１μｍのＡｌ2Ｏ3粉末９
５重量％、アルミナバインダ５重量％を含むスラリーを
調製し、このスラリーにフィルタ本体を浸漬した。浸漬
後に余分なスラリーを取り除き５００℃で３０分間焼成
した。この工程によってＡｌ 2Ｏ3をフィルタ本体のフィ
ルタ隔壁全体に均一にコートした。Al having an average particle size of 0.5 to 1 μm2O3Powder 9
A slurry containing 5% by weight of alumina binder and 5% by weight of alumina binder.
It prepared and the filter main body was immersed in this slurry. Soaking
Remove excess slurry afterwards and bake at 500 ℃ for 30 minutes
did. This process makes Al 2O3The filter body
The entire partition wall was evenly coated.
【００７４】次に平均粒径０．５〜１μｍのＡｌ2Ｏ3が
コートされたフィルタ本体の径方向の内周部を樹脂板に
よってマスキングした。マスキングされたフィルタ本体
を、平均粒径０．５〜１μｍのＡｌ2Ｏ3粉末９５重量
％、アルミナバインダ５重量％を含むスラリーに再度浸
漬し、その後に余分なスラリーを取り除き５００℃で３
０分間焼成した。Next, the inner peripheral portion in the radial direction of the filter body coated with Al 2 O 3 having an average particle size of 0.5 to 1 μm was masked with a resin plate. The masked filter body is re-immersed in a slurry containing 95% by weight of Al 2 O 3 powder having an average particle size of 0.5 to 1 μm and 5% by weight of an alumina binder.
Bake for 0 minutes.
【００７５】以上の工程でフィルタ本体の径方向外周部
に位置するフィルタ隔壁にＡｌ2Ｏ3を多くコートした多
コート部２ａを形成した。Through the above steps, the multi-coated portion 2a in which a large amount of Al 2 O 3 was coated was formed on the filter partition wall located on the outer peripheral portion in the radial direction of the filter body.
【００７６】一方、５重量％のジニトロジアミン白金水
溶液を調製した。このジニトロジアミン白金水溶液を、
Ａｌ2Ｏ3がコートされたフィルタ本体のガス流入孔側セ
ルに注入し、ガス流出孔側セルから吸引することによっ
てＰｔをガス流入孔を区画するフィルタ隔壁のＡｌ2Ｏ3
に吸着担持させた。また同様にジニトロジアミン白金水
溶液をガス流出孔に注入して、Ｐｔをガス流出孔を区画
するフィルタ隔壁のＡｌ2Ｏ3に吸着担持させた。その後
５００℃で３０分間焼成してＡｌ2Ｏ3とＰｔとを含む触
媒層を形成した。On the other hand, a 5 wt% dinitrodiamine platinum aqueous solution was prepared. This dinitrodiamine platinum aqueous solution,
Al 2 O 3 is injected into the gas inlet side cells of the filter body coated, Al 2 O 3 filter barrier rib partitioning the gas inlet of Pt by sucking the gas outflow hole side cells
Was adsorbed and supported on. Similarly, an aqueous solution of dinitrodiamine platinum was injected into the gas outflow holes, and Pt was adsorbed and supported on Al 2 O 3 of the filter partition wall defining the gas outflow holes. Then, it was baked at 500 ° C. for 30 minutes to form a catalyst layer containing Al 2 O 3 and Pt.
【００７７】さらにフィルタ本体が吸水可能な水量をあ
らかじめ測っておき、その水量にＫ，Ｂａ，Ｌｉの硝酸
塩をそれぞれ０．４ｍｏｌ／Ｌとなるように溶かした水
溶液を調整し、フィルタ本体をこの水溶液に浸して吸水
担持した。その後２５０℃で乾燥し、５００℃で３０分
間焼成してＡｌ2Ｏ3とＰｔとＫ，Ｂ，Ｌｉとを含む触媒
層を形成した。これにより本発明の実施例１のディーゼ
ル排ガス浄化用フィルタ型触媒を得た。Further, the amount of water that can be absorbed by the filter body is measured in advance, and an aqueous solution prepared by dissolving nitrates of K, Ba and Li in each of the water amounts to 0.4 mol / L is prepared. It was soaked in water and supported by absorbing water. Then, it was dried at 250 ° C. and baked at 500 ° C. for 30 minutes to form a catalyst layer containing Al 2 O 3 , Pt, K, B and Li. As a result, a filter catalyst for purifying diesel exhaust gas of Example 1 of the present invention was obtained.
【００７８】（実施例２）本発明の実施例２のディーゼ
ル排ガス浄化用フィルタ型触媒のガス流路に平行な断面
図を図６に示す。(Embodiment 2) FIG. 6 shows a sectional view of a filter catalyst for purifying diesel exhaust gas according to a second embodiment of the present invention which is parallel to the gas passage.
【００７９】本実施例２のディーゼル排ガス浄化用フィ
ルタ型触媒は、フィルタ本体９と、触媒層１０とを有
し、触媒層１０はフィルタ本体の排ガス流れの下流部１
１に位置するフィルタ隔壁１２に多く形成された多コー
ト部１０ａを有している。また、本実施例２のディーゼ
ル排ガス浄化用フィルタ型触媒は、多コート部が形成さ
れる部分と、コート方法以外は実施例１と同様に製造さ
れた。The filter catalyst for purifying diesel exhaust gas according to the second embodiment has a filter body 9 and a catalyst layer 10. The catalyst layer 10 is a downstream portion 1 of the exhaust gas flow of the filter body.
The filter partition 12 located at No. 1 has a large number of multi-coated portions 10a. Further, the filter catalyst for purifying diesel exhaust gas of the present Example 2 was manufactured in the same manner as in Example 1 except for the portion where the multi-coated portion was formed and the coating method.
【００８０】本実施例２のディーゼル排ガス浄化用フィ
ルタ型触媒はフィルタ本体９と、触媒層１０と、ガス流
入孔１３と、ガス流出孔１４と、ガス流入孔１３とガス
流出孔１４とを区画しフィルタ本体９の排ガス流れ方向
の下流部１１に位置するフィルタ隔壁１２と、ガス流入
孔１３とガス流出孔１４とを区画しフィルタ本体９の排
ガス流れ方向の上流部１５に位置するフィルタ隔壁１２
と、目詰め栓１６とを有する。ここで、フィルタ本体９
の排ガス流れの下流部１１の範囲は、フィルタ本体９の
排ガス流れの上流部１５とフィルタ本体９の排ガス流れ
の下流部１１の体積の比率が２：１となるような範囲で
ある。The diesel exhaust gas purifying filter type catalyst of the second embodiment is divided into a filter body 9, a catalyst layer 10, a gas inflow hole 13, a gas outflow hole 14, a gas inflow hole 13 and a gas outflow hole 14. The filter partition wall 12 located in the downstream portion 11 of the filter body 9 in the exhaust gas flow direction and the filter partition wall 12 located in the upstream portion 15 of the filter body 9 in the exhaust gas flow direction that partition the gas inflow hole 13 and the gas outflow hole 14.
And a plug 16. Here, the filter body 9
The range of the downstream portion 11 of the exhaust gas flow is such that the volume ratio between the upstream portion 15 of the exhaust gas flow of the filter body 9 and the downstream portion 11 of the exhaust gas flow of the filter body 9 is 2: 1.
【００８１】本実施例２において平均粒径０．５〜１μ
ｍのＡｌ2Ｏ3は、フィルタ本体９の排ガス流れの上流部
１５に位置するフィルタ隔壁１２には、フィルタ本体の
体積１リットルあたり１５０ｇコートされ、下流部１１
に位置するフィルタ隔壁１２にはフィルタ本体の体積１
リットルあたり１８０ｇコートされた。また、Ｐｔおよ
びＫは、実施例１と同様にコートされた。In Example 2, the average particle size is 0.5 to 1 μm.
m of Al 2 O 3 is coated on the filter partition wall 12 located at the upstream portion 15 of the exhaust gas flow of the filter body 9 in an amount of 150 g per liter of the volume of the filter body, and the downstream portion 11
The filter partition 12 located at
180 g was coated per liter. Also, Pt and K were coated in the same manner as in Example 1.
【００８２】以下に本実施例２のディーゼル排ガス浄化
用フィルタ型触媒の製作方法を示す。The method for producing the filter catalyst for purifying diesel exhaust gas according to the second embodiment will be described below.
【００８３】平均粒径０．５〜１μｍのＡｌ2Ｏ3粉末９
５重量％、アルミナバインダ５重量％を含むスラリーを
調製し、このスラリーにフィルタ本体を浸漬した。浸漬
後に余分なスラリーを取り除き５００℃で３０分間焼成
した。この工程によってＡｌ 2Ｏ3をフィルタ本体のフィ
ルタ隔壁全体に均一にコートした。Al having an average particle size of 0.5 to 1 μm2O3Powder 9
A slurry containing 5% by weight of alumina binder and 5% by weight of alumina binder.
It prepared and the filter main body was immersed in this slurry. Soaking
Remove excess slurry afterwards and bake at 500 ℃ for 30 minutes
did. This process makes Al 2O3The filter body
The entire partition wall was evenly coated.
【００８４】次に平均粒径０．５〜１μｍのＡｌ2Ｏ3が
コートされたフィルタ本体の排ガス流れ方向の下流部の
みを、平均粒径０．５〜１μｍのＡｌ2Ｏ3粉末９５重量
％、アルミナバインダ５重量％を含むスラリーに再度浸
漬し、その後に余分なスラリーを取り除き５００℃で３
０分間焼成した。Next, only the downstream portion in the exhaust gas flow direction of the filter body coated with Al 2 O 3 having an average particle size of 0.5 to 1 μm was treated with 95% by weight of Al 2 O 3 powder having an average particle size of 0.5 to 1 μm. %, 5% by weight of alumina binder, and then dip it again to remove excess slurry.
Bake for 0 minutes.
【００８５】以上の工程でフィルタ本体の排ガス流れ方
向の下流部に位置するフィルタ隔壁にＡｌ2Ｏ3を多くコ
ートした。Through the above steps, the filter partition wall located downstream of the filter body in the exhaust gas flow direction was coated with a large amount of Al 2 O 3 .
【００８６】さらに、実施例１と同様にＰｔとＫ，Ｂ，
Ｌｉとをフィルタ隔壁のＡｌ2Ｏ3に担持させてＡｌ2Ｏ3
とＰｔとＫ、Ｂ，Ｌｉとを含む触媒層を形成した。これ
により本発明の実施例２のディーゼル排ガス浄化用フィ
ルタ型触媒を得た。Further, as in the first embodiment, Pt and K, B,
By supporting Li and Al 2 O 3 on the filter partition wall, Al 2 O 3
To form a catalyst layer containing Pt, K, B, and Li. As a result, a filter catalyst for purifying diesel exhaust gas of Example 2 of the present invention was obtained.
【００８７】（実施例３）本発明の実施例３のディーゼ
ル排ガス浄化用フィルタ型触媒のガス流路に平行な断面
図を図７に示す。(Embodiment 3) FIG. 7 shows a sectional view of a filter catalyst for purifying diesel exhaust gas according to a third embodiment of the present invention, which is parallel to the gas passage.
【００８８】本実施例３のディーゼル排ガス浄化用フィ
ルタ型触媒は、フィルタ本体１７と、触媒層１８とを有
し、触媒層１８はフィルタ本体の径方向の外周部１９に
位置するガス流出孔２０を区画するフィルタ隔壁２１に
多く形成された多コート部１８ａを有している。また、
本実施例３のディーゼル排ガス浄化用フィルタ型触媒
は、多コート部の構成と、コート方法以外は実施例１と
同様に製造された。The diesel exhaust gas purifying filter type catalyst of the third embodiment has a filter body 17 and a catalyst layer 18, and the catalyst layer 18 is a gas outlet hole 20 located at an outer peripheral portion 19 in the radial direction of the filter body. The multi-coating portion 18a is formed in large numbers on the filter partition wall 21 that partitions the partition. Also,
The diesel exhaust gas purifying filter-type catalyst of Example 3 was manufactured in the same manner as in Example 1 except for the structure of the multi-coating section and the coating method.
【００８９】本実施例３のディーゼル排ガス浄化用フィ
ルタ型触媒はフィルタ本体１７と、触媒層１８と、フィ
ルタ本体１７の径方向の外周部１９に位置するガス流出
孔２０を区画するフィルタ隔壁２１と、フィルタ本体１
７の径方向の内周部２２に位置するガス流出孔２０を区
画するフィルタ隔壁２１と、ガス流入孔２３と、目詰め
栓２４とを有する。ここで、フィルタ本体１７の径方向
の外周部１９の範囲は、実施例１のフィルタ本体１の径
方向の外周部３と同じものとした。The diesel exhaust gas purifying filter type catalyst according to the third embodiment includes a filter body 17, a catalyst layer 18, and a filter partition wall 21 defining a gas outflow hole 20 located at an outer peripheral portion 19 of the filter body 17 in the radial direction. , Filter body 1
7 has a filter partition wall 21 for partitioning the gas outflow hole 20 located on the inner peripheral portion 22 in the radial direction of 7, a gas inflow hole 23, and a plug 24. Here, the range of the radial outer peripheral portion 19 of the filter body 17 is the same as the radial outer peripheral portion 3 of the filter body 1 of the first embodiment.
【００９０】本実施例３では、平均粒径０．５〜１μｍ
のＡｌ2Ｏ3をフィルタ隔壁２１全体に均一に１５０ｇ／
Ｌコートして第１コート部を形成し、その後外周部１９
に位置するガス流出孔２０を区画するフィルタ隔壁２１
にのみ平均粒径３μｍのＡｌ 2Ｏ3を３０ｇ／Ｌコートし
て第２コート部を形成することで多コート部１８ａを形
成した。また、ＰｔおよびＫ，Ｂａ，Ｌｉは、実施例１
と同様にコートされた。In the third embodiment, the average particle size is 0.5 to 1 μm.
Al2O3Uniformly over the entire filter partition 21 of 150 g /
L coat to form the first coat portion, and then the outer peripheral portion 19
Filter partition wall 21 for partitioning the gas outflow hole 20 located in the
Al with an average particle size of 3 μm 2O3Coated with 30 g / L
To form the second coat portion to form the multi-coat portion 18a.
I made it. In addition, Pt and K, Ba and Li are the same as those in Example 1.
Was coated as well.
【００９１】以下に本実施例３のディーゼル排ガス浄化
用フィルタ型触媒の製作方法を示す。The method for producing the filter catalyst for purifying diesel exhaust gas according to the third embodiment will be described below.
【００９２】平均粒径０．５〜１μｍのＡｌ2Ｏ3粉末９
５重量％、アルミナバインダ５重量％を含むスラリーを
調製し、このスラリーにフィルタ本体を浸漬した。浸漬
後に余分なスラリーを取り除き５００℃で３０分間焼成
した。この工程によってＡｌ 2Ｏ3をフィルタ本体のフィ
ルタ隔壁全体に均一にコートし第１コート部を形成し
た。Al having an average particle size of 0.5 to 1 μm2O3Powder 9
A slurry containing 5% by weight of alumina binder and 5% by weight of alumina binder.
It prepared and the filter main body was immersed in this slurry. Soaking
Remove excess slurry afterwards and bake at 500 ℃ for 30 minutes
did. This process makes Al 2O3The filter body
The entire partition wall is coated uniformly to form the first coating
It was
【００９３】次に平均粒径０．５〜１μｍのＡｌ2Ｏ3が
コートされたフィルタ本体の径方向の外周部に位置する
ガス流出孔内に、平均粒径３μｍのＡｌ2Ｏ3粉末９５重
量％、アルミナバインダ５重量％を含むスラリーを注入
し、その後にフィルタ本体の径方向の外周部に位置する
ガス流出孔からこのスラリーを吸引した。その後このフ
ィルタ本体を５００℃で３０分間焼成し、外周部の第１
コート部上に第２コート部を形成した。Next, the Al 2 O 3 powder 95 having an average particle size of 3 μm is placed in the gas outflow holes located at the outer peripheral portion in the radial direction of the filter body coated with Al 2 O 3 having an average particle size of 0.5 to 1 μm. A slurry containing 50% by weight of alumina binder and 5% by weight of alumina binder was injected, and then the slurry was sucked from gas outflow holes located in the outer peripheral portion of the filter body in the radial direction. After that, the filter body is baked at 500 ° C. for 30 minutes, and the first
A second coat portion was formed on the coat portion.
【００９４】以上の工程でフィルタ本体の径方向の外周
部に第１コート部と第２コート部とからなる多コート部
１８ａを形成した。Through the above steps, the multi-coated portion 18a including the first coated portion and the second coated portion was formed on the outer peripheral portion of the filter body in the radial direction.
【００９５】さらに、実施例１と同様にＰｔとＫとをフ
ィルタ隔壁のＡｌ2Ｏ3に担持させてＡｌ2Ｏ3とＰｔとＫ
とを含む触媒層を形成した。これにより本発明の実施例
３のディーゼル排ガス浄化用フィルタ型触媒を得た。Furthermore, as in Example 1, Pt and K were supported on Al 2 O 3 of the filter partition wall to form Al 2 O 3 and Pt and K.
A catalyst layer containing and was formed. As a result, a filter catalyst for purifying diesel exhaust gas of Example 3 of the present invention was obtained.
【００９６】（実施例４）本発明の実施例４のディーゼ
ル排ガス浄化用フィルタ型触媒のガス流路に平行な断面
図を図８に示す。(Embodiment 4) FIG. 8 shows a sectional view of a filter catalyst for purifying diesel exhaust gas according to a fourth embodiment of the present invention which is parallel to the gas passage.
【００９７】本実施例４のディーゼル排ガス浄化用フィ
ルタ型触媒は、フィルタ本体２５と、触媒層２６とを有
し、触媒層２６はフィルタ本体２５の排ガス流れの下流
部２７に位置するガス流出孔２８を区画するフィルタ隔
壁２９に多く形成された多コート部２６ａを有してい
る。また、本実施例４のディーゼル排ガス浄化用フィル
タ型触媒は、多コート部の構成と、コート方法以外は実
施例２と同様に製造された。The filter catalyst for purifying diesel exhaust gas according to the fourth embodiment has a filter body 25 and a catalyst layer 26, and the catalyst layer 26 is a gas outlet hole located at a downstream portion 27 of the exhaust gas flow of the filter body 25. The filter partition wall 29 partitioning 28 has a large number of multi-coated portions 26a. Further, the filter catalyst for purifying diesel exhaust gas of the present Example 4 was manufactured in the same manner as in Example 2 except for the structure of the multi-coat part and the coating method.
【００９８】本実施例４のディーゼル排ガス浄化用フィ
ルタ型触媒はフィルタ本体２５と、触媒層２６と、フィ
ルタ本体２５の排ガス流れの下流部２７に位置するガス
流出孔２８を区画するフィルタ隔壁２９と、フィルタ本
体２５の排ガス流れの上流部３０に位置するガス流出孔
２８を区画するフィルタ隔壁２９と、ガス流入孔３１
と、目詰め栓３２とを有する。ここで、フィルタ本体２
５の排ガス流れの下流部２７の範囲は、実施例２のフィ
ルタ本体８の排ガス流れの下流部１２と同じものとし
た。The diesel exhaust gas purifying filter type catalyst according to the fourth embodiment includes a filter body 25, a catalyst layer 26, and a filter partition wall 29 defining a gas outlet hole 28 located at a downstream portion 27 of the exhaust gas flow of the filter body 25. A filter partition wall 29 for partitioning a gas outlet hole 28 located at an upstream portion 30 of the exhaust gas flow of the filter body 25, and a gas inlet hole 31.
And a plug plug 32. Here, the filter body 2
The range of the downstream portion 27 of the exhaust gas flow of No. 5 was the same as that of the downstream portion 12 of the exhaust gas flow of the filter body 8 of the second embodiment.
【００９９】本実施例４では、平均粒径０．５〜１μｍ
のＡｌ2Ｏ3をフィルタ隔壁２９全体に均一に１５０ｇ／
Ｌコートして第１コート部を形成し、その後下流部２７
に位置するガス流出孔２８を区画するフィルタ隔壁２９
にのみ、平均粒径３μｍのＡｌ2Ｏ3を３０ｇ／Ｌコート
して第２コート部を形成することで、多コート部２６ａ
を形成した。また、ＰｔおよびＫ，Ｂａ，Ｌｉは、実施
例１と同様にコートされた。In Example 4, the average particle size is 0.5 to 1 μm.
Of Al 2 O 3 of 150 g /
L coat to form the first coat part, and then the downstream part 27
Filter partition 29 that defines the gas outflow hole 28 located at
Only, the second coat portion is formed by coating 30 g / L of Al 2 O 3 having an average particle diameter of 3 μm to form the second coat portion 26a.
Was formed. Further, Pt, K, Ba and Li were coated in the same manner as in Example 1.
【０１００】以下に本実施例４のディーゼル排ガス浄化
用フィルタ型触媒の製作方法を示す。The method of producing the filter catalyst for purifying diesel exhaust gas according to the fourth embodiment will be described below.
【０１０１】平均粒径０．５〜１μｍのＡｌ2Ｏ3粉末９
５重量％、アルミナバインダ５重量％を含むスラリーを
調製し、このスラリーにフィルタ本体を浸漬した。浸漬
後に余分なスラリーを取り除き５００℃で３０分間焼成
した。この工程によってＡｌ 2Ｏ3をフィルタ本体のフィ
ルタ隔壁全体に均一にコートし、第１コート部を形成し
た。Al having an average particle size of 0.5 to 1 μm2O3Powder 9
A slurry containing 5% by weight of alumina binder and 5% by weight of alumina binder.
It prepared and the filter main body was immersed in this slurry. Soaking
Remove excess slurry afterwards and bake at 500 ℃ for 30 minutes
did. This process makes Al 2O3The filter body
The entire partition wall is coated uniformly to form the first coating part.
It was
【０１０２】次に平均粒径０．５〜１μｍのＡｌ2Ｏ3が
コートされたフィルタ本体の排ガス流れの下流部を、平
均粒径３μｍのＡｌ2Ｏ3粉末９５重量％、アルミナバイ
ンダ５重量％を含むスラリーに浸漬し、その後にフィル
タ本体のガス流入孔からこのスラリーを吸引した。その
後、このフィルタ本体を５００℃で３０分間焼成し第２
コート部を形成した。Next, the downstream portion of the exhaust gas flow of the filter body coated with Al 2 O 3 having an average particle size of 0.5 to 1 μm was treated with 95% by weight of Al 2 O 3 powder having an average particle size of 3 μm and 5% by weight of an alumina binder. % Of the slurry, and then the slurry was sucked from the gas inflow hole of the filter body. After that, the filter body is baked at 500 ° C. for 30 minutes and then the second
A coated part was formed.
【０１０３】以上の工程でフィルタ本体の排ガス流れの
下流部に多コート部を形成した。さらに、実施例１と同
様にＰｔとＫ，Ｂａ，Ｌｉとをフィルタ隔壁のＡｌ2Ｏ3
に担持させてＡｌ2Ｏ3とＰｔとＫ，Ｂａ，Ｌｉとを含む
触媒層を形成した。これにより本発明の実施例４のディ
ーゼル排ガス浄化用フィルタ型触媒を得た。Through the above steps, the multi-coat portion was formed in the downstream of the exhaust gas flow of the filter body. Further, as in Example 1, Pt, K, Ba, and Li were mixed with Al 2 O 3 of the filter partition wall.
To form a catalyst layer containing Al 2 O 3 , Pt, K, Ba, and Li. As a result, a filter catalyst for purifying diesel exhaust gas of Example 4 of the present invention was obtained.
【０１０４】実施例１，２に対して、実施例３，４で
は、外周部又は下流部のコート量を増してもガス流入孔
でのガス流通抵抗が増さなかった。In contrast to Examples 1 and 2, in Examples 3 and 4, the gas flow resistance in the gas inflow hole was not increased even if the coating amount at the outer peripheral portion or the downstream portion was increased.
【０１０５】（比較例１）本発明の比較例１のディーゼ
ル排ガス浄化用フィルタ型触媒のガス流路に平行な断面
図を図９に示す。(Comparative Example 1) FIG. 9 shows a sectional view parallel to the gas flow path of the filter catalyst for diesel exhaust gas purification of Comparative Example 1 of the present invention.
【０１０６】本比較例１のディーゼル排ガス浄化用フィ
ルタ型触媒は、フィルタ本体３３と、触媒層３４とを有
し、触媒層３４はフィルタ本体３３のフィルタ隔壁３７
全体に均一に形成された。また、本比較例１のディーゼ
ル排ガス浄化用フィルタ型触媒は、Ａｌ2Ｏ3の平均粒径
と、多コート部を形成しないこと以外は実施例１と同様
に製造された。The diesel exhaust gas purifying filter type catalyst of Comparative Example 1 has a filter body 33 and a catalyst layer 34, and the catalyst layer 34 is a filter partition wall 37 of the filter body 33.
It was formed uniformly throughout. The filter catalyst for purifying diesel exhaust gas of Comparative Example 1 was produced in the same manner as in Example 1 except that the average particle size of Al 2 O 3 and the formation of the multi-coated portion were not formed.
【０１０７】本比較例１のディーゼル排ガス浄化用フィ
ルタ型触媒はフィルタ本体３３と、触媒層３４と、ガス
流入孔３５とガス流出孔３６とを区画するフィルタ隔壁
３７と、目詰め栓３８とを有する。The diesel exhaust gas purifying filter type catalyst of Comparative Example 1 includes a filter body 33, a catalyst layer 34, a filter partition wall 37 for partitioning a gas inflow hole 35 and a gas outflow hole 36, and a plug 38. Have.
【０１０８】本比較例１において、Ａｌ2Ｏ3は平均粒径
３μｍのものを用いた。平均粒径３μｍのＡｌ2Ｏ3は、
フィルタ本体３３のフィルタ隔壁３７全体に均一にコー
トされ、フィルタ本体３３の体積１リットルあたり７５
ｇコートされた。また、ＰｔおよびＫ，Ｂａ，Ｌｉは、
実施例１と同様にコートされた。In Comparative Example 1, Al 2 O 3 having an average particle diameter of 3 μm was used. Al 2 O 3 having an average particle size of 3 μm is
The entire filter partition wall 37 of the filter body 33 is uniformly coated, and the volume of the filter body 33 is 75
g coated. Further, Pt and K, Ba, Li are
Coated as in Example 1.
【０１０９】以下に本比較例１のディーゼル排ガス浄化
用フィルタ型触媒の製作方法を示す。The method for producing the filter catalyst for purifying diesel exhaust gas of Comparative Example 1 will be described below.
【０１１０】平均粒径３μｍのＡｌ2Ｏ3粉末９５重量
％、アルミナバインダ５重量％を含むスラリーを調製
し、このスラリーにフィルタ本体を浸漬した。浸漬後に
余分なスラリーを取り除き５００℃で３０分間焼成し
た。この工程によってＡｌ2Ｏ3をフィルタ本体のフィル
タ隔壁全体に均一にコートした。A slurry containing 95% by weight of Al 2 O 3 powder having an average particle diameter of 3 μm and 5% by weight of an alumina binder was prepared, and the filter body was immersed in this slurry. After the immersion, the excess slurry was removed and the mixture was baked at 500 ° C. for 30 minutes. By this step, Al 2 O 3 was uniformly coated on the entire filter partition wall of the filter body.
【０１１１】さらに、実施例１と同様にＰｔとＫ，Ｂ
ａ，Ｌｉとをフィルタ隔壁のＡｌ2Ｏ3に担持させてＡｌ
2Ｏ3とＰｔとＫ，Ｂａ，Ｌｉとを含む触媒層を形成し
た。これにより本発明の実施例４のディーゼル排ガス浄
化用フィルタ型触媒を得た。Further, Pt, K, and B are the same as in the first embodiment.
a and Li are supported on Al 2 O 3 of the filter partition wall to form Al
A catalyst layer containing 2 O 3 , Pt, K, Ba and Li was formed. As a result, a filter catalyst for purifying diesel exhaust gas of Example 4 of the present invention was obtained.
【０１１２】（参考例）本参考例のディーゼル排ガス浄
化用フィルタ型触媒は、フィルタ本体と、触媒層とを有
し、触媒層はフィルタ本体のフィルタ隔壁全体に均一に
形成された。また、本参考例のディーゼル排ガス浄化用
フィルタ型触媒は、比較例１と同じ粒径のＡｌ2Ｏ3を用
い、このＡｌ2Ｏ3がフィルタ本体の体積１リットルあた
り１５０ｇコートされた以外は比較例１と同様に製造さ
れた。Reference Example The filter catalyst for purifying diesel exhaust gas of this Reference Example has a filter body and a catalyst layer, and the catalyst layer was formed uniformly over the entire filter partition wall of the filter body. Further, the filter catalyst for purifying diesel exhaust gas of the present reference example uses Al 2 O 3 having the same particle size as in Comparative Example 1, and except that this Al 2 O 3 is coated in an amount of 150 g per liter volume of the filter body. Prepared as in Example 1.
【０１１３】（試験・評価）実施例１〜４および比較例
１のディーゼル排ガス浄化用フィルタ型触媒について、
以下の項目についての評価試験を行った。(Test / Evaluation) Regarding the diesel exhaust gas purifying filter type catalysts of Examples 1 to 4 and Comparative Example 1,
An evaluation test was conducted on the following items.
【０１１４】＜パティキュレート堆積検知試験＞まず、
実施例１〜４および比較例１のディーゼル排ガス浄化用
フィルタ型触媒をパティキュレート発生装置に取付け、
パティキュレートを２０ｍｇ／ｍ3含有するガスを１５
０℃で各ディーゼル排ガス浄化用フィルタ型触媒に流通
させた。このときガスの温度は、パティキュレート中の
すすを燃焼させる温度に満たないため、パティキュレー
トを含有するガスを流通させるとディーゼル排ガス浄化
用フィルタ型触媒のフィルタ隔壁にはパティキュレート
中のすすが堆積する。<Particulate Deposition Detection Test> First,
The diesel exhaust gas purifying filter-type catalysts of Examples 1 to 4 and Comparative Example 1 were attached to a particulate generator,
Gas containing 20 mg / m 3 of particulates
It was passed through a filter catalyst for purifying each diesel exhaust gas at 0 ° C. At this time, the temperature of the gas is less than the temperature at which the soot in the particulates is burned, so when the gas containing the particulates is circulated, the soot in the particulates accumulates on the filter partition wall of the diesel exhaust gas purification filter-type catalyst. To do.
【０１１５】上記ガスを流通させた実施例１〜４および
比較例１のディーゼル排ガス浄化用フィルタ型触媒の圧
損を測定し、圧損が５ＫＰａまで上昇するのに要する時
間を測定した。The pressure loss of the diesel exhaust gas purifying filter type catalysts of Examples 1 to 4 and Comparative Example 1 in which the above gas was passed was measured, and the time required for the pressure loss to rise to 5 KPa was measured.
【０１１６】＜パティキュレート燃焼試験＞まず、実施
例１〜４および比較例１のディーゼル排ガス浄化用フィ
ルタ型触媒をパティキュレート発生装置に取付け、パテ
ィキュレートを２０ｍｇ／ｍ3含有するガスを３５０℃
で各ディーゼル排ガス浄化用フィルタ型触媒に流通させ
た。このときガスの温度は、実際のディーゼル車の排ガ
ス温度であるため、パティキュレートを含有するガスを
流通させるとディーゼル排ガス浄化用フィルタ型触媒の
フィルタ隔壁に捕集されたパティキュレートは燃焼し、
燃え残りのパティキュレートが堆積する。<Particulate Combustion Test> First, the diesel exhaust gas purifying filter type catalysts of Examples 1 to 4 and Comparative Example 1 were attached to a particulate generator, and a gas containing 20 mg / m 3 of particulate was 350 ° C.
And passed through each diesel exhaust gas purification filter type catalyst. Since the temperature of the gas at this time is the exhaust gas temperature of the actual diesel vehicle, when the gas containing particulates is circulated, the particulates collected in the filter partition wall of the diesel exhaust gas purification filter type catalyst burn,
Unburned particulates accumulate.
【０１１７】上記ガスを流通させた実施例１〜４および
比較例１のディーゼル排ガス浄化用フィルタ型触媒の圧
損を測定し、圧損が５ＫＰａまで上昇するのに要する時
間を測定した。The pressure loss of the diesel exhaust gas purifying filter type catalysts of Examples 1 to 4 and Comparative Example 1 in which the above gas was passed was measured, and the time required for the pressure loss to rise to 5 KPa was measured.
【０１１８】以上の実験によって求められた実施例１〜
４及び比較例１のディーゼル排ガス浄化用フィルタ型触
媒の圧損上昇に要する時間を表１に示す。また、パティ
キュレート燃焼試験の結果を実施例と比較例との圧損感
度の違いを加味して補正したＤＰＦ性能値を表１に示
す。Examples 1 to 1 obtained by the above experiment
Table 1 shows the time required for increasing the pressure loss of the filter catalysts for diesel exhaust gas purification of No. 4 and Comparative Example 1. Further, Table 1 shows DPF performance values obtained by correcting the results of the particulate combustion test in consideration of the difference in pressure loss sensitivity between the example and the comparative example.
【０１１９】[0119]
【表１】 [Table 1]
【０１２０】パティキュレート堆積検知試験において、
実施例１〜４のディーゼル排ガス浄化用フィルタ型触媒
は、比較例１と比べて圧損が上昇するまでに要する時間
が短い。パティキュレートはいずれのディーゼル排ガス
浄化用フィルタ型触媒にも同じ割合で堆積しているの
で、この結果によって本発明のディーゼル排ガス浄化用
フィルタ型触媒はパティキュレートの堆積を感度良く検
知することが可能であることがわかる。In the particulate accumulation detection test,
The diesel exhaust gas purifying filter-type catalysts of Examples 1 to 4 require a shorter time than the comparative example 1 until the pressure loss increases. Since the particulate matter is deposited on all diesel exhaust gas purification filter type catalysts at the same rate, this result enables the diesel exhaust gas purification filter type catalyst of the present invention to detect the particulate matter deposition with high sensitivity. I know there is.
【０１２１】パティキュレート燃焼試験において、実施
例および比較例のディーゼル排ガス浄化用フィルタ型触
媒の圧損が上昇するまでに要する時間には大きな違いが
みられなかった。しかし、各ディーゼル排ガス浄化用フ
ィルタ型触媒は圧損感度が異なるため、これらの結果を
単純に比較することはできない。このため、これらの結
果に圧損感度を加味して補正しＤＰＦ性能値を算出し
た。ＤＰＦ性能値を比較すると、実施例のＤＰＦ性能値
は比較例のＤＰＦ性能値と比較して明らかに大きい値を
示した。このことは、実施例のディーゼル排ガス浄化用
フィルタ型触媒は比較例のディーゼル排ガス浄化用フィ
ルタ型触媒と比較して、良好なパティキュレートＤＰＦ
性能を持つことを示す。In the particulate combustion test, no significant difference was observed in the time required for increasing the pressure loss of the diesel exhaust gas purifying filter type catalysts of Examples and Comparative Examples. However, since the diesel exhaust gas purifying filter type catalysts have different pressure drop sensitivities, these results cannot be simply compared. Therefore, the DPF performance value was calculated by adding the pressure loss sensitivity to these results and making corrections. Comparing the DPF performance values, the DPF performance value of the example showed a clearly larger value than the DPF performance value of the comparative example. This means that the filter catalyst for purifying diesel exhaust gas of the example has a better particulate DPF than the filter catalyst for purifying diesel exhaust gas of the comparative example.
It has performance.
【０１２２】＜初期圧損試験＞まず、実施例１〜４，比
較例１および参考例のディーゼル排ガス浄化用フィルタ
型触媒をエアー吸引装置に取付け、５ｍ3／ｍｉｎ，２
０℃でエアー吸引を行った。<Initial Pressure Drop Test> First, the diesel exhaust gas purifying filter type catalysts of Examples 1 to 4, Comparative Example 1 and Reference Example were attached to an air suction device, and 5 m 3 / min, 2 was applied.
Air suction was performed at 0 ° C.
【０１２３】上記エアー吸引を行った実施例１〜４，比
較例１および参考例のディーゼル排ガス浄化用フィルタ
型触媒の圧損を測定した。本試験はパティキュレート堆
積前の各フィルタの圧損、つまり初期圧損を測定するも
のである。The pressure loss of the diesel exhaust gas purifying filter type catalysts of Examples 1 to 4, Comparative Example 1 and Reference Example in which the above air suction was performed was measured. This test measures the pressure loss of each filter before particulate accumulation, that is, the initial pressure loss.
【０１２４】以上の実験によって求められた実施例１〜
４，比較例１および参考例のディーゼル排ガス浄化用フ
ィルタ型触媒の初期圧損値と、得られた圧損値を各ディ
ーゼル排ガス浄化用フィルタ型触媒にコートしたＡｌ2
Ｏ3のコート量を加味して補正した初期圧損値の補正値
とを表２に示す。Examples 1 to 1 obtained by the above experiment
4, Al 2 by coating each diesel exhaust gas purification filter type catalyst with the initial pressure loss value of the diesel exhaust gas purification filter type catalyst of Comparative Example 1 and the reference example and the obtained pressure loss value
Table 2 shows the correction value of the initial pressure loss value corrected by taking the amount of coating of O 3 into consideration.
【０１２５】[0125]
【表２】 [Table 2]
【０１２６】初期圧損試験において、実施例１〜４の各
ディーゼル排ガス浄化用フィルタ型触媒の初期圧損値お
よび補正値は、実施例１〜４と同量のＡｌ2Ｏ3をコート
した参考例や、実施例１〜４の半量のＡｌ2Ｏ3をコート
した比較例と比べて低い値を示した。このことは、本発
明のディーゼル排ガス浄化用フィルタ型触媒は、通常の
コートを行ったディーゼル排ガス浄化用フィルタ型触媒
と比較して初期圧損が低いディーゼル排ガス浄化用フィ
ルタ型触媒であることを示す。In the initial pressure drop test, the initial pressure drop value and the correction value of each of the diesel exhaust gas purifying filter type catalysts of Examples 1 to 4 were the same as those of Examples 1 to 4 in the reference example coated with Al 2 O 3. The value was lower than that of the comparative example coated with half the amount of Al 2 O 3 of Examples 1 to 4. This indicates that the diesel exhaust gas purifying filter type catalyst of the present invention is a diesel exhaust gas purifying filter type catalyst having a lower initial pressure loss as compared with the usual coated diesel exhaust gas purifying filter type catalyst.
【０１２７】[0127]
【発明の効果】本発明のディーゼル排ガス浄化用フィル
タ型触媒によれば、初期圧損の増大を抑制しつつ圧損感
度を高めることができる。EFFECTS OF THE INVENTION According to the filter catalyst for purifying diesel exhaust gas of the present invention, the sensitivity of pressure loss can be enhanced while suppressing the increase of initial pressure loss.
【図１】平均粒径３μｍの触媒粉末がコートされたＤＰ
Ｆの電子顕微鏡写真である。FIG. 1 DP coated with catalyst powder having an average particle size of 3 μm
It is an electron micrograph of F.
【図２】平均粒径０．６μｍの触媒粉末がコートされた
ＤＰＦの電子顕微鏡写真である。FIG. 2 is an electron micrograph of a DPF coated with a catalyst powder having an average particle size of 0.6 μm.
【図３】平均粒径０．６μｍの触媒粉末をフィルタ本体
の体積１リットルあたり１５０ｇコートしたＤＰＦの電
子顕微鏡写真である。FIG. 3 is an electron micrograph of a DPF coated with 150 g of catalyst powder having an average particle size of 0.6 μm per liter of the filter body.
【図４】平均粒径０．６μｍの触媒粉末をフィルタ本体
の体積１リットルあたり１２０ｇコートし、その上層に
平均粒径３μｍの触媒粉末を３０ｇコートしたＤＰＦの
電子顕微鏡写真である。FIG. 4 is an electron micrograph of a DPF in which 120 g of catalyst powder having an average particle size of 0.6 μm was coated per liter of the filter body and 30 g of catalyst powder having an average particle size of 3 μm was coated on the upper layer.
【図５】本発明の実施例１のディーゼル排ガス浄化用フ
ィルタ型触媒のガス流路に平行な断面図である。FIG. 5 is a cross-sectional view parallel to the gas flow path of the diesel exhaust gas purifying filter-type catalyst according to the first embodiment of the present invention.
【図６】本発明の実施例２のディーゼル排ガス浄化用フ
ィルタ型触媒のガス流路に平行な断面図である。FIG. 6 is a cross-sectional view parallel to a gas flow path of a filter catalyst for purifying diesel exhaust gas according to a second embodiment of the present invention.
【図７】本発明の実施例３のディーゼル排ガス浄化用フ
ィルタ型触媒のガス流路に平行な断面図である。FIG. 7 is a cross-sectional view of a filter catalyst for purifying diesel exhaust gas according to a third embodiment of the present invention, which is parallel to a gas flow path.
【図８】本発明の実施例４のディーゼル排ガス浄化用フ
ィルタ型触媒のガス流路に平行な断面図である。FIG. 8 is a cross-sectional view parallel to a gas flow path of a filter catalyst for purifying diesel exhaust gas according to a fourth embodiment of the present invention.
【図９】本発明の比較例１のディーゼル排ガス浄化用フ
ィルタ型触媒のガス流路に平行な断面図である。FIG. 9 is a cross-sectional view parallel to a gas flow path of a filter catalyst for diesel exhaust gas purification of Comparative Example 1 of the present invention.
１：フィルタ本体 ２：触媒層 ２ａ：多コート部
３：フィルタ本体の径方向の外周部 ４：フィ
ルタ隔壁 ５：ガス流入孔 ６：ガス流出孔
７：フィルタ本体の径方向の内周部1: Filter main body 2: Catalyst layer 2a: Multi-coated portion 3: Radial outer peripheral portion of filter main body 4: Filter partition wall 5: Gas inflow hole 6: Gas outflow hole
7: Radial inner circumference of filter body
─────────────────────────────────────────────────────
─────────────────────────────────────────────────── ───
【手続補正書】[Procedure amendment]
【提出日】平成１４年３月２８日（２００２．３．２
８）[Submission date] March 28, 2002 (2002.3.2)
8)
【手続補正１】[Procedure Amendment 1]
【補正対象書類名】図面[Document name to be corrected] Drawing
【補正対象項目名】図１[Name of item to be corrected] Figure 1
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【図１】 [Figure 1]
【手続補正２】[Procedure Amendment 2]
【補正対象書類名】図面[Document name to be corrected] Drawing
【補正対象項目名】図２[Name of item to be corrected] Figure 2
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【図２】 [Fig. 2]
【手続補正３】[Procedure 3]
【補正対象書類名】図面[Document name to be corrected] Drawing
【補正対象項目名】図３[Name of item to be corrected] Figure 3
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【図３】 [Figure 3]
【手続補正４】[Procedure amendment 4]
【補正対象書類名】図面[Document name to be corrected] Drawing
【補正対象項目名】図４[Name of item to be corrected] Fig. 4
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【図４】 [Figure 4]
フロントページの続き (51)Int.Cl.7 識別記号 ＦＩ テーマコート゛(参考） Ｆ０１Ｎ 3/02 ３０１ Ｆ０１Ｎ 3/08 Ａ ３２１ 3/24 Ｅ 3/08 Ｂ０１Ｄ 46/42 Ｂ 3/24 53/36 １０３Ｃ // Ｂ０１Ｄ 46/42 ＺＡＢ １０３Ｂ (72)発明者 鈴木 重治 愛知県豊田市トヨタ町１番地 トヨタ自動 車株式会社内 (72)発明者 垣花 大 愛知県豊田市トヨタ町１番地 トヨタ自動 車株式会社内 (72)発明者 沖 大祐 静岡県小笠郡大東町千浜7800番地 株式会 社キャタラー内 Ｆターム(参考） 3G090 AA02 AA06 BA08 3G091 AA18 AB02 AB09 AB13 BA01 BA14 GA06 GA18 GB01W GB05W GB06W GB07W GB10W GB17X HA14 HA18 HA21 4D048 AA06 AA14 BA03X BA14X BA15X BA30X BA31Y BA32Y BA33Y BA34Y BA41X BB02 BB14 BB16 BB17 CC41 EA04 4D058 JA32 JB06 MA44 SA08 TA02 4G069 AA03 AA08 BA01B BB04A BC03B BC04B BC13B BC32A BC33A BC69A BC75B CA03 CA13 CA18 DA06 EA19 EA27 EB18X EB18Y EC29 FA01 FA03 FB14 FB15 Front page continuation (51) Int.Cl. 7 Identification code FI theme code (reference) F01N 3/02 301 F01N 3/08 A 321 3/24 E 3/08 B01D 46/42 B 3/24 53/36 103C // B01D 46/42 ZAB 103B (72) Inventor Shigeharu Suzuki 1st Toyota Town, Toyota City, Aichi Prefecture, Toyota Motor Co., Ltd. (72) Inventor: Dai Kakihana 1st Toyota Town, Toyota City, Aichi Prefecture, Toyota Motor Co., Ltd. (72) Inventor Daisuke Oki 7800 Chihama, Daito-cho, Ogasa-gun, Shizuoka F-term inside a stocker (reference) 3G090 AA02 AA06 BA08 3G091 AA18 AB02 AB09 AB13 BA01 BA14 GA06 GA18 GB01W GB05W GB06W GB07W GB10W GB17X HA14 HA18 HA21 4D AA06 AA14 BA03X BA14X BA15X BA30X BA31Y BA32Y BA33Y BA34Y BA41X BB02 BB14 BB16 BB17 CC41 EA04 4D058 JA32 JB06 MA44 SA08 TA02 4G069 AA03 AA08 FA15 CA18CA18 CA18B18CA18B18B17B18B18B17B18ABC18B19B18ABC18B17B18ABC18B17B18ABC18B17B18ABC18B17B18ABC18B17B18ABC18B17B18ABC18B17B18ABC18BBC13B69ABC18BBC13A69BC18ABC18B17B18ABC18BBC13B69ABC13A
Claims (6)
ル下流端の開口部を目詰めしたガス流入孔と、セル上流
端の開口部を目詰めしたガス流出孔と、該ガス流入孔と
該ガス流出孔を区画しガス流通の際のフィルタとなるフ
ィルタ隔壁とを持つフィルタ本体と、多孔質酸化物と貴
金属とを含む触媒層とを有するディーゼル排ガス浄化用
フィルタ型触媒であり、 該触媒層は少なくとも該フィルタ本体の特定部位の該フ
ィルタ隔壁上に粒径１μｍ以下の該多孔質酸化物を主成
分とするコート部を有することを特徴とするディーゼル
排ガス浄化用フィルタ型触媒。1. A ceramic honeycomb structure, wherein a gas inflow hole in which an opening at a cell downstream end is clogged, a gas outflow hole in which an opening at a cell upstream end is clogged, the gas inflow hole and the gas A filter catalyst for purifying diesel exhaust gas, comprising a filter body having an outlet hole and a filter partition wall serving as a filter for gas flow, and a catalyst layer containing a porous oxide and a noble metal, wherein the catalyst layer is A filter catalyst for purifying diesel exhaust gas, which has a coating part having a particle size of 1 μm or less as a main component on the filter partition wall at least at a specific portion of the filter body.
方向の外周部であることを特徴とする請求項１に記載の
ディーゼル排ガス浄化用フィルタ型触媒。2. The filter catalyst for purifying diesel exhaust gas according to claim 1, wherein the specific portion is a radial outer peripheral portion of the filter body.
ガス流れ下流部であることを特徴とする請求項１に記載
のディーゼル排ガス浄化用フィルタ型触媒。3. The filter catalyst for purifying diesel exhaust gas according to claim 1, wherein the specific portion is an exhaust gas flow downstream portion of the filter body.
媒層は、コート量が前記特定部位を除く部分のフィルタ
隔壁上のコート量より多いことを特徴とする請求項１乃
至請求項３のいずれかに記載のディーゼル排ガス浄化用
フィルタ型触媒。4. The catalyst layer on the filter partition wall of the specific portion has a coating amount larger than the coating amount on the filter partition wall of a portion excluding the specific portion. A filter type catalyst for purifying diesel exhaust gas according to Crab.
ィルタ隔壁上の前記触媒層は、平均粒径１μｍ以下の多
孔質酸化物からなる第１コート部と、第１コート部表面
に形成され平均粒径１〜５μｍの多孔質酸化物からなる
第２コート部とからなることを特徴とする請求項１乃至
請求項４のいずれかに記載のディーゼル排ガス浄化用フ
ィルタ型触媒。5. The catalyst layer on the filter partition wall that defines the gas outflow holes in the specific portion is formed on a first coat portion made of a porous oxide having an average particle diameter of 1 μm or less, and on the surface of the first coat portion. The filter catalyst for purifying diesel exhaust gas according to any one of claims 1 to 4, comprising a second coating portion made of a porous oxide having an average particle diameter of 1 to 5 µm.
が含まれることを特徴とする請求項１乃至請求項５のい
ずれかに記載のディーゼル排ガス浄化用フィルタ型触
媒。6. The filter catalyst for purifying diesel exhaust gas according to claim 1, wherein the catalyst layer further contains a NO x storage material.
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| JP2002029457A JP3872354B2 (en) | 2002-02-06 | 2002-02-06 | Filter type catalyst for diesel exhaust gas purification |
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| JP2002029457A JP3872354B2 (en) | 2002-02-06 | 2002-02-06 | Filter type catalyst for diesel exhaust gas purification |
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| JP2003225575A true JP2003225575A (en) | 2003-08-12 |
| JP3872354B2 JP3872354B2 (en) | 2007-01-24 |
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| JP2002029457A Expired - Fee Related JP3872354B2 (en) | 2002-02-06 | 2002-02-06 | Filter type catalyst for diesel exhaust gas purification |
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| JP2005314739A (en) * | 2004-04-28 | 2005-11-10 | Cataler Corp | Noble metal solution, and noble metal catalyst manufacturing method |
| JP2006088027A (en) * | 2004-09-22 | 2006-04-06 | Mazda Motor Corp | Diesel particulate filter |
| JP2006136784A (en) * | 2004-11-11 | 2006-06-01 | Cataler Corp | Filter catalyst |
| JP2006231116A (en) * | 2005-02-22 | 2006-09-07 | Toyota Motor Corp | Exhaust gas-cleaning filter catalyst |
| JP2007224747A (en) * | 2006-02-21 | 2007-09-06 | Mitsubishi Motors Corp | Exhaust emission control filter and exhaust emission control device of diesel engine |
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| WO2018159214A1 (en) * | 2017-03-03 | 2018-09-07 | エヌ・イーケムキャット株式会社 | Filter for exhaust gas cleaning and method for manufacturing same |
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| US7781014B2 (en) | 2004-02-10 | 2010-08-24 | Cataler Corporation | Process for producing a filter catalyst |
| JP2005314739A (en) * | 2004-04-28 | 2005-11-10 | Cataler Corp | Noble metal solution, and noble metal catalyst manufacturing method |
| JP4651303B2 (en) * | 2004-04-28 | 2011-03-16 | 株式会社キャタラー | Method for producing noble metal solution and noble metal catalyst |
| JP2008510606A (en) * | 2004-08-21 | 2008-04-10 | ユミコア・アクチエンゲゼルシャフト・ウント・コムパニー・コマンディットゲゼルシャフト | Method for coating a wall flow filter with a coating composition |
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| JPWO2018159214A1 (en) * | 2017-03-03 | 2019-12-26 | エヌ・イーケムキャット株式会社 | Exhaust gas purification filter and method of manufacturing the same |
| JP7065071B2 (en) | 2017-03-03 | 2022-05-11 | エヌ・イーケムキャット株式会社 | Exhaust gas purification filter and its manufacturing method |
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