JP2016123890A - Honeycomb type monolith catalyst, and production method thereof - Google Patents

Honeycomb type monolith catalyst, and production method thereof Download PDF

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JP2016123890A
JP2016123890A JP2014263733A JP2014263733A JP2016123890A JP 2016123890 A JP2016123890 A JP 2016123890A JP 2014263733 A JP2014263733 A JP 2014263733A JP 2014263733 A JP2014263733 A JP 2014263733A JP 2016123890 A JP2016123890 A JP 2016123890A
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catalyst
cell
passage
cell wall
cell passage
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JP6565184B2 (en
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由子 水野
Yoshiko Mizuno
由子 水野
保明 山口
Yasuaki Yamaguchi
保明 山口
芳彰 田中
Yoshiaki Tanaka
芳彰 田中
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Nissan Motor Co Ltd
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Abstract

PROBLEM TO BE SOLVED: To suppress clogging of an inlet port of a cell passage of a honeycomb type monolith catalyst with phosphorus particles or the like in an exhaust gas.SOLUTION: A honeycomb type monolith catalyst 1 including a carrier 2 made of porous ceramic has a plurality of cell passages 3 that penetrate in the axial direction. The cell passage 3 has a thin cell wall 4. A relatively-thinner first catalyst metal layer 7 is formed on the surface 4a of the cell wall 4 between the upstream side end face 4b of the cell wall 4 and a point a predetermined length L1 distant from the end face along the axial direction, while a relatively-thicker second catalyst metal layer 8 is formed on the rest of the surface 4a of the cell passage 3. A substantial width W1 gets thus thinner at the upstream side end face 4b of the cell wall 4 of the cell passage 3 leading to a larger inlet port of the cell passage 3. Consequently, a deposition amount of phosphorus particles conveyed from the upstream side of the exhaust gas passage is reduced on the upstream side end face 4b. Clogging caused by deposition of the particles on the end face 4b is thus suppressed at the inlet port of the cell passage 3.SELECTED DRAWING: Figure 3

Description

本発明は、多孔質材料からなる担体を用いた排気浄化用のハニカム型モノリス触媒およびその製造方法に関する。   The present invention relates to a honeycomb monolith catalyst for exhaust purification using a carrier made of a porous material and a method for producing the same.

特許文献１には、内燃機関の排気通路に介装されるハニカム型モノリス触媒が開示されている。上記触媒は、軸方向に貫通した複数のセル通路を備えており、各セル通路の表面には、一定の厚さを有した触媒層が、軸方向に沿って連続的に形成されている。   Patent Document 1 discloses a honeycomb monolith catalyst interposed in an exhaust passage of an internal combustion engine. The catalyst includes a plurality of cell passages penetrating in the axial direction, and a catalyst layer having a certain thickness is continuously formed along the axial direction on the surface of each cell passage.

特開２００５−１８０１９７号公報JP 2005-180197 A

セル通路のセル壁の上流側の端面には、排気通路の上流側から運ばれてきた排気ガス中のリン等の粒子が堆積し経時的に増加する。そして、この端面における粒子の堆積量が多くなると、セル通路の入口を徐々に覆い、最終的にはセル通路の入口を閉塞させてしまうという問題がある。   Particles such as phosphorus in the exhaust gas carried from the upstream side of the exhaust passage accumulate on the end face on the upstream side of the cell wall of the cell passage and increase with time. Then, when the amount of accumulated particles on the end face increases, there is a problem that the inlet of the cell passage is gradually covered and finally the inlet of the cell passage is closed.

本発明は、軸方向に貫通する複数のセル通路を有する多孔質材料からなる担体を用いた排気浄化用のハニカム型モノリス触媒に関し、上記複数のセル通路の各々のセル壁の表面には、触媒層が形成されており、各セル通路の入口側の触媒層の厚さが、該セル通路の中間部の触媒層の厚さよりも薄い。   The present invention relates to a honeycomb monolith catalyst for exhaust purification using a carrier made of a porous material having a plurality of cell passages penetrating in the axial direction, and a catalyst is formed on the surface of each cell wall of the plurality of cell passages. A layer is formed, and the thickness of the catalyst layer on the inlet side of each cell passage is thinner than the thickness of the catalyst layer in the middle portion of the cell passage.

従って、セル通路のセル壁の上流側端面の実質的な幅が細くなり、粒子の堆積が抑制される一方で、セル通路の入口が拡大される。   Accordingly, the substantial width of the upstream end face of the cell wall of the cell passage is narrowed, and particle deposition is suppressed, while the entrance of the cell passage is enlarged.

本発明によれば、排気通路の上流側から運ばれてきた排気ガス中のリン等の粒子のセル壁上流側端面への堆積量を減少するとともに、上記粒子の堆積によるセル通路の入口の閉塞を生じにくくすることができる。   According to the present invention, the amount of accumulation of particles such as phosphorus in the exhaust gas carried from the upstream side of the exhaust passage on the end surface on the upstream side of the cell wall is reduced, and the entrance of the cell passage is blocked by the accumulation of the particles. Can be made difficult to occur.

本発明に係るハニカム型モノリス触媒の一例を示す斜視図である。It is a perspective view which shows an example of the honeycomb type | mold monolith catalyst which concerns on this invention. 図１の触媒の１つのセル通路を排気ガス流れ方向から見た説明図である。It is explanatory drawing which looked at one cell channel | path of the catalyst of FIG. 1 from the exhaust gas flow direction. 本発明の第１の実施例におけるセル通路の断面図である。It is sectional drawing of the cell channel | path in the 1st Example of this invention. 触媒金属の粒径の大きさと触媒金属層の厚さとの関係を示すグラフである。It is a graph which shows the relationship between the magnitude | size of the particle size of a catalyst metal, and the thickness of a catalyst metal layer. セル間距離とセル通路の入口が閉塞されるまでの時間との関係を示すグラフである。It is a graph which shows the relationship between the time until the distance between cells and the entrance of a cell channel | path are obstruct | occluded. 図３の実施例の触媒の製造方法を示す工程説明図である。It is process explanatory drawing which shows the manufacturing method of the catalyst of the Example of FIG. 本発明の第２の実施例を示す図３と同様の断面図である。It is sectional drawing similar to FIG. 3 which shows the 2nd Example of this invention. 本発明の第３の実施例を示す図３と同様の断面図である。It is sectional drawing similar to FIG. 3 which shows the 3rd Example of this invention. 担体の気孔率の大きさと触媒金属層の厚さとの関係を示すグラフである。It is a graph which shows the relationship between the magnitude | size of the porosity of a support | carrier, and the thickness of a catalyst metal layer. 本発明の第４の実施例を示す図３と同様の断面図である。It is sectional drawing similar to FIG. 3 which shows the 4th Example of this invention.

図１は、本発明に係るモノリス触媒の一例を示している。触媒１は、多孔質セラミックスで形成された円柱状の担体２を備えている。担体２は、軸方向に貫通する複数のセル通路３を備えており、全体としてハニカム状に形成されている。セル通路３は、図２に示すように、薄いセル壁４によって断面矩形状に囲まれており、該セル壁４の表面４ａには、触媒金属を適宜分散した触媒スラリで一様にコーティングすることにより、上流側入口部を除き一定の厚さを有した触媒金属層５が形成されている。このように構成された触媒１は、触媒コンバータの耐熱容器内で保持され、例えば三元触媒としてガソリン機関の排気通路に介装される。   FIG. 1 shows an example of a monolith catalyst according to the present invention. The catalyst 1 includes a columnar carrier 2 made of porous ceramics. The carrier 2 includes a plurality of cell passages 3 penetrating in the axial direction, and is formed in a honeycomb shape as a whole. As shown in FIG. 2, the cell passage 3 is surrounded by a thin cell wall 4 in a rectangular shape, and the surface 4a of the cell wall 4 is uniformly coated with a catalyst slurry appropriately dispersed with a catalyst metal. Thus, the catalytic metal layer 5 having a constant thickness is formed except for the upstream side inlet portion. The catalyst 1 configured as described above is held in a heat-resistant container of a catalytic converter, and is inserted, for example, in the exhaust passage of a gasoline engine as a three-way catalyst.

図３は、本発明の第１の実施例における触媒１の１つのセル通路３の上流側部分を示す、軸方向に沿った断面図である。ここで、図の左側が、上記セル通路３の上流側に対応しており、図の矢印６で示すように、排気通路の上流側からの排気が、セル通路３の入口へと流れる。セル壁４の表面４ａには、セル壁４の上流側端面４ｂから軸方向に沿って第１の所定の長さＬ１までは、第１の触媒金属層７が形成されており、ここから下流側端面４ｃまで（軸方向に沿ったセル通路３の残部となる第２の所定の長さＬ２）は、第２の触媒金属層８が形成されている。第１の触媒金属層７および第２の触媒金属層８は、同じ触媒金属からなり、触媒スラリのコーティングにより形成される層７，８の一部がセル壁４の細孔へと浸透している。ここで、第１の触媒金属層７となる触媒スラリは、第２の触媒金属層８よりもセル壁４の内部へと浸透し易いものとなっている。従って、各々のスラリの乾燥後の最終的な状態では、第１の触媒金属層７のセル壁４の表面４ａからの厚さＴ１が、第２の触媒金属層８の表面４ａからの厚さＴ２よりも薄く形成されている。   FIG. 3 is a cross-sectional view along the axial direction showing an upstream portion of one cell passage 3 of the catalyst 1 in the first embodiment of the present invention. Here, the left side of the figure corresponds to the upstream side of the cell passage 3, and the exhaust from the upstream side of the exhaust passage flows to the inlet of the cell passage 3 as indicated by the arrow 6 in the figure. A first catalytic metal layer 7 is formed on the surface 4a of the cell wall 4 from the upstream side end face 4b of the cell wall 4 to the first predetermined length L1 along the axial direction, from which the first catalytic metal layer 7 is formed downstream. A second catalytic metal layer 8 is formed up to the side end face 4c (second predetermined length L2 which is the remaining portion of the cell passage 3 along the axial direction). The first catalyst metal layer 7 and the second catalyst metal layer 8 are made of the same catalyst metal, and a part of the layers 7 and 8 formed by the coating of the catalyst slurry penetrates into the pores of the cell wall 4. Yes. Here, the catalyst slurry that becomes the first catalyst metal layer 7 is more easily penetrated into the cell wall 4 than the second catalyst metal layer 8. Therefore, in the final state after drying of each slurry, the thickness T1 from the surface 4a of the cell wall 4 of the first catalytic metal layer 7 is the thickness from the surface 4a of the second catalytic metal layer 8. It is formed thinner than T2.

次に、図４のグラフを参照して、多孔質セラミックスからなる担体２の気孔率を一定とした場合の触媒金属の粒径の大きさと触媒金属層の厚さとの関係を説明する。ここで、担体２の気孔率とは、セル壁４の体積に対するセル壁４の細孔の空間の割合を示すものである。図示するように、触媒金属の粒径が小さいほど、セル壁４の表面４ａからの触媒金属層の厚さは薄くなる。これは、セル壁４の表面４ａに触媒スラリをコーティングしたときに、相対的に小さい粒径を有した触媒金属の方が、相対的に大きい粒径を有した触媒金属よりもセル壁４の細孔に浸透し易いためである。   Next, the relationship between the catalyst metal particle size and the thickness of the catalyst metal layer when the porosity of the carrier 2 made of porous ceramics is constant will be described with reference to the graph of FIG. Here, the porosity of the carrier 2 indicates the ratio of the space of the pores of the cell wall 4 to the volume of the cell wall 4. As shown in the drawing, the smaller the particle size of the catalyst metal, the thinner the thickness of the catalyst metal layer from the surface 4a of the cell wall 4 is. This is because when the catalyst slurry is coated on the surface 4 a of the cell wall 4, the catalyst metal having a relatively small particle size is larger in the cell wall 4 than the catalyst metal having a relatively large particle size. This is because it easily penetrates into the pores.

このような触媒金属の粒径の大きさと触媒金属層の厚さとの関係に基づいて、第１の触媒金属層７の触媒金属の粒径を相対的に小さくするともに、第２の触媒金属層８の触媒金属の粒径を相対的に大きくすることにより、図３に示すように、セル通路３の入口側の相対的に薄い第１の触媒金属層７と、セル通路３の残部の相対的に厚い第２の触媒金属層８とが形成されている。   Based on the relationship between the size of the particle size of the catalyst metal and the thickness of the catalyst metal layer, the particle size of the catalyst metal of the first catalyst metal layer 7 is made relatively small, and the second catalyst metal layer. By making the particle size of the catalyst metal 8 relatively large, as shown in FIG. 3, the relatively thin first catalyst metal layer 7 on the inlet side of the cell passage 3 and the remaining portion of the cell passage 3 A thick second catalytic metal layer 8 is formed.

セル通路３の入口側の第１の触媒金属層７が、セル通路３の残部の第２の触媒金属層８よりも薄く形成されているので、結果として、セル壁４の上流側端面４ｂの実質的な幅Ｗ１が細くなり、触媒金属層７，８の内側に構成される実質的なセル通路３の入口側のセル間距離Ｄ１がセル通路３の残部のセル間距離Ｄ２よりも拡大される。従って、排気通路の上流側から運ばれてきた排気ガス中のリン等の粒子の上記上流側端面４ｂへの堆積量が減少するとともに、端面４ｂにおける粒子の堆積の増加に伴うセル通路３の入口の閉塞を生じにくくすることができる。   Since the first catalytic metal layer 7 on the inlet side of the cell passage 3 is formed thinner than the second catalytic metal layer 8 on the remaining portion of the cell passage 3, as a result, the upstream end face 4b of the cell wall 4 The substantial width W1 is narrowed, and the inter-cell distance D1 on the inlet side of the substantial cell passage 3 configured inside the catalytic metal layers 7 and 8 is larger than the inter-cell distance D2 in the remaining portion of the cell passage 3. The Accordingly, the amount of particles such as phosphorus in the exhaust gas carried from the upstream side of the exhaust passage is reduced on the upstream end surface 4b, and the inlet of the cell passage 3 with the increase in particle deposition on the end surface 4b. It is possible to make it difficult to cause occlusion.

図５には、セル間距離とセル通路３の入口が閉塞されるまでの時間との関係が示されている。図示するように、セル間距離が長いほど、セル通路３の入口がリン等の粒子により閉塞されるまでの時間が長くなる。   FIG. 5 shows the relationship between the inter-cell distance and the time until the entrance of the cell passage 3 is closed. As shown in the figure, the longer the distance between the cells, the longer the time until the entrance of the cell passage 3 is blocked by particles such as phosphorus.

次に、図６を参照して、図３の実施例の触媒１の製造方法を説明する。まず、工程（ａ）において、担体２を焼成する。このとき、担体２は、気孔率が上流側端面４ｂから下流側端面４ｃまで全体的に一定になるように焼成される。次に、工程（ｂ）において、セル壁４の上流側端面４ｂが下側となる向きで、焼成後の担体２の下端部のみを、相対的に小さい粒径を有した触媒金属を含む第１の触媒スラリ９に浸漬する。つまり、セル壁４の表面４ａに、上流側端面４ｂから上記第１の所定の長さＬ１（図３）だけ第１の触媒スラリ９によってコーティングを行う。次に、工程（ｃ）において、セル壁４の表面４ａにコーティングされた第１の触媒スラリ９を乾燥する。これにより、セル通路３の入口側におけるセル壁４の表面４ａに、相対的に薄い第１の触媒金属層７が形成される。次に、工程（ｄ）において、担体２を工程（ａ）の向きから反転させてセル壁４の下流側端面４ｃが下側となる向きとし、相対的に大きい粒径を有した触媒金属を含む第２の触媒スラリ１０に長さＬ２の範囲で浸漬する。これにより、セル壁４の表面４ａは、下流側端面４ｃから上記第２の所定の長さＬ２だけ第２の触媒スラリ１０によってコーティングされる。そして、工程（ｅ）において、セル壁４の残りの表面４ａにコーティングされた第２の触媒スラリ１０を乾燥する。これにより、セル通路３の入口部を除く残りの表面４ａに、相対的に厚い第２の触媒金属層８が形成される。なお、触媒金属の粒径の大きさは、触媒金属を複数の金属製ボールと一緒に撹拌して粉砕処理を施すことにより調整される。なお、図３に示すように、第１の触媒金属層７および第２の触媒金属層８が、境界面で僅かに重なるようにすることが望ましい。   Next, with reference to FIG. 6, the manufacturing method of the catalyst 1 of the Example of FIG. 3 is demonstrated. First, in the step (a), the carrier 2 is fired. At this time, the carrier 2 is baked so that the porosity is generally constant from the upstream end face 4b to the downstream end face 4c. Next, in the step (b), only the lower end portion of the calcined carrier 2 containing the catalyst metal having a relatively small particle diameter is oriented in such a direction that the upstream end face 4b of the cell wall 4 is on the lower side. 1 is immersed in the catalyst slurry 9. That is, the surface 4a of the cell wall 4 is coated with the first catalyst slurry 9 for the first predetermined length L1 (FIG. 3) from the upstream end face 4b. Next, in the step (c), the first catalyst slurry 9 coated on the surface 4a of the cell wall 4 is dried. Thereby, a relatively thin first catalytic metal layer 7 is formed on the surface 4 a of the cell wall 4 on the inlet side of the cell passage 3. Next, in the step (d), the support 2 is reversed from the direction of the step (a) so that the downstream end surface 4c of the cell wall 4 faces downward, and a catalyst metal having a relatively large particle size is obtained. It immerses in the 2nd catalyst slurry 10 to be contained in the range of length L2. Thus, the surface 4a of the cell wall 4 is coated with the second catalyst slurry 10 from the downstream end face 4c by the second predetermined length L2. Then, in the step (e), the second catalyst slurry 10 coated on the remaining surface 4a of the cell wall 4 is dried. As a result, a relatively thick second catalytic metal layer 8 is formed on the remaining surface 4 a excluding the inlet of the cell passage 3. The particle size of the catalyst metal is adjusted by stirring the catalyst metal together with a plurality of metal balls and performing pulverization. In addition, as shown in FIG. 3, it is desirable that the first catalytic metal layer 7 and the second catalytic metal layer 8 are slightly overlapped at the boundary surface.

図７は、本発明の第２の実施例における触媒１の１つのセル通路３の上流側部分を示す、軸方向に沿った断面図である。図３の実施例とは異なり、図７のセル壁４の内側には、触媒金属が殆ど浸透していない。上記セル壁４の表面４ａには、セル通路３の入口側部分には相対的に薄い第１の触媒金属層７が形成され、セル通路３の中間部を含む残部には相対的に厚い第２の触媒金属層８が形成されている。この実施例では、第１の触媒金属層７は、乾燥した状態で層７の嵩密度が高くなり、かつ厚さが相対的に薄くなる触媒スラリを用いて形成されている。一方、第２の触媒金属層８は、乾燥した状態で層８の嵩密度が低くなり、かつ厚さが相対的に厚くなる触媒スラリを用いて形成されている。   FIG. 7 is a cross-sectional view along the axial direction showing an upstream portion of one cell passage 3 of the catalyst 1 in the second embodiment of the present invention. Unlike the embodiment of FIG. 3, the catalyst metal hardly penetrates inside the cell wall 4 of FIG. On the surface 4 a of the cell wall 4, a relatively thin first catalytic metal layer 7 is formed on the inlet side portion of the cell passage 3, and a relatively thick first portion is formed on the remaining part including the middle portion of the cell passage 3. Two catalytic metal layers 8 are formed. In this embodiment, the first catalytic metal layer 7 is formed using a catalyst slurry in which the bulk density of the layer 7 becomes high and the thickness becomes relatively thin in a dry state. On the other hand, the second catalytic metal layer 8 is formed using a catalyst slurry in which the bulk density of the layer 8 is low and the thickness is relatively thick in a dry state.

図８は、本発明の第３の実施例における触媒１の１つのセル通路３の上流側部分を示す、軸方向に沿った断面図である。図８のセル壁４の表面４ａには、単一の触媒金属層１１が、セル壁４の上流側端面４ｂから下流側端面４ｃまで連続的に形成されている。この実施例では、多孔質セラミックスからなる担体２の気孔率を部分的に異ならせることで、セル通路３の入口側の薄肉部１１ａと、セル通路３の残部の厚肉部１１ｂと、が形成されている。   FIG. 8 is a cross-sectional view along the axial direction showing an upstream portion of one cell passage 3 of the catalyst 1 in the third embodiment of the present invention. A single catalytic metal layer 11 is continuously formed on the surface 4 a of the cell wall 4 in FIG. 8 from the upstream end face 4 b to the downstream end face 4 c of the cell wall 4. In this embodiment, by partially varying the porosity of the carrier 2 made of porous ceramic, a thin portion 11a on the inlet side of the cell passage 3 and a thick portion 11b of the remaining portion of the cell passage 3 are formed. Has been.

具体的には、図８の触媒１では、図６の工程（ａ）において、担体２の焼成時間を第１の所定の長さＬ１の部分と第２の所定の長さＬ２の部分とで変えることにより、担体２の気孔率を、第１の所定の長さＬ１の部分で相対的に大きくするとともに、第２の所定の長さＬ２の部分で相対的に小さくしてある。このように構成された担体２を、所定の大きさの粒径を有した触媒金属を含む触媒スラリに、セル壁４の上流側端面４ｂから下流側端面４ｃまで全体的に浸漬することにより、触媒スラリが、気孔率の大きい担体２の長さＬ１の部分ではより浸透し易くなる。従って、上記のような厚さの異なる薄肉部１１ａと厚肉部１１ｂとが形成される。なお、担体２の気孔率の大きさは、該担体２の材料の配合を変えることによっても調整することができる。   Specifically, in the catalyst 1 of FIG. 8, in the step (a) of FIG. 6, the calcination time of the carrier 2 is changed between the first predetermined length L1 portion and the second predetermined length L2 portion. By changing the ratio, the porosity of the carrier 2 is relatively increased at the first predetermined length L1 and relatively decreased at the second predetermined length L2. By immersing the carrier 2 thus configured in a catalyst slurry containing a catalyst metal having a predetermined particle size from the upstream end surface 4b to the downstream end surface 4c of the cell wall 4, The catalyst slurry is more easily penetrated in the portion of the length L1 of the carrier 2 having a large porosity. Accordingly, the thin portion 11a and the thick portion 11b having different thicknesses as described above are formed. The porosity of the carrier 2 can be adjusted by changing the composition of the material of the carrier 2.

次に、図９を参照して、担体２の気孔率の大きさと触媒金属層の厚さとの関係を説明する。図示したように、担体２の気孔率が大きいほど、細孔内にスラリが浸透するため、触媒金属層の厚さが薄くなる。   Next, the relationship between the porosity of the carrier 2 and the thickness of the catalytic metal layer will be described with reference to FIG. As shown in the figure, the larger the porosity of the carrier 2, the more the slurry penetrates into the pores, so the thickness of the catalyst metal layer becomes thinner.

図１０は、本発明の第４の実施例における触媒１の１つのセル通路３の上流側部分を示す、軸方向に沿った断面図である。図１０では、図３の実施例と同様の担体２のセル壁４の表面４ａに、下流側端面４ｃから第２の所定の長さＬ２まで第３の触媒金属層１２が形成されている。即ち、表面４ａには、セル通路３の入口側の長さＬ１を除いて、第３の触媒金属層１２が形成されている。そして、セル壁４の残りの表面４ａおよび第３の触媒金属層１２の上面１２ａの上に重ねて、同じ触媒スラリからなる第４の触媒金属層１３が形成されている。従って、セル通路３の入口側の層の厚さＴ１が、セル通路３の残部の層の厚さＴ２よりも相対的に薄く形成されている。   FIG. 10 is a cross-sectional view along the axial direction showing an upstream portion of one cell passage 3 of the catalyst 1 in the fourth embodiment of the present invention. In FIG. 10, a third catalytic metal layer 12 is formed on the surface 4a of the cell wall 4 of the carrier 2 similar to the embodiment of FIG. 3 from the downstream end face 4c to the second predetermined length L2. That is, the third catalytic metal layer 12 is formed on the surface 4a except for the length L1 on the inlet side of the cell passage 3. A fourth catalyst metal layer 13 made of the same catalyst slurry is formed on the remaining surface 4 a of the cell wall 4 and the upper surface 12 a of the third catalyst metal layer 12. Therefore, the thickness T1 of the layer on the inlet side of the cell passage 3 is formed to be relatively thinner than the thickness T2 of the remaining layer of the cell passage 3.

図１０の触媒１は、所定の大きさの粒径を有した触媒金属を含む触媒スラリに、セル壁４の下流側端面４ｃから第２の所定の長さＬ２だけ焼成後の担体２を浸漬して乾燥した後に、この担体２の下流側端面４ｃから上流側端面４ｂまでの全体を上記触媒スラリに浸漬して乾燥することにより製造される。   The catalyst 1 of FIG. 10 immerses the carrier 2 after firing for a second predetermined length L2 from the downstream end face 4c of the cell wall 4 in a catalyst slurry containing a catalytic metal having a particle size of a predetermined size. Then, after drying, the whole of the carrier 2 from the downstream end face 4c to the upstream end face 4b is dipped in the catalyst slurry and dried.

なお、図６に示した実施例では、相対的に薄い第１の触媒金属層７を先に形成する例を開示したが、相対的に厚い第２の触媒金属層８を先に形成するようにしても良い。   In the embodiment shown in FIG. 6, the example in which the relatively thin first catalytic metal layer 7 is formed first is disclosed. However, the relatively thick second catalytic metal layer 8 is formed first. Anyway.

また、触媒組立時の方向性をなくすために、入口側端部のみでなく、出口側端部を含む両端部について触媒層を中間部よりも薄く形成するようにしても良い。   Moreover, in order to eliminate the directionality at the time of catalyst assembly, the catalyst layer may be formed thinner than the intermediate portion not only at the inlet side end but also at both ends including the outlet side end.

２・・・担体
３・・・セル通路
４・・・セル壁
７・・・第１の触媒金属層
８・・・第２の触媒金属層
１１・・・触媒金属層
１２・・・第３の触媒金属層
１３・・・第４の触媒金属層 2 ... carrier 3 ... cell passage 4 ... cell wall 7 ... first catalyst metal layer 8 ... second catalyst metal layer 11 ... catalyst metal layer 12 ... third Catalyst metal layer 13 ... fourth catalyst metal layer

Claims (4)

軸方向に貫通する複数のセル通路を有する多孔質材料からなる担体を用いた排気浄化用のハニカム型モノリス触媒であって、上記複数のセル通路の各々のセル壁の表面には、触媒層が形成されており、各セル通路の入口側の触媒層の厚さが、該セル通路の中間部の触媒層の厚さよりも薄いことを特徴とするハニカム型モノリス触媒。   A honeycomb monolith catalyst for exhaust purification using a carrier made of a porous material having a plurality of cell passages penetrating in the axial direction, wherein a catalyst layer is formed on the surface of each cell wall of the plurality of cell passages. A honeycomb type monolith catalyst, which is formed, and wherein the thickness of the catalyst layer on the inlet side of each cell passage is thinner than the thickness of the catalyst layer in the middle portion of the cell passage. 上記セル壁の表面には、上記セル通路の入口側を除いて第１の触媒層が形成されており、上記入口側の表面および上記第１の触媒層の上に重ねて、第２の触媒層が形成されていることを特徴とする請求項１に記載の内燃機関のハニカム型モノリス触媒。   A first catalyst layer is formed on the surface of the cell wall except for the inlet side of the cell passage, and the second catalyst is stacked on the inlet side surface and the first catalyst layer. The honeycomb monolith catalyst for an internal combustion engine according to claim 1, wherein a layer is formed. 上記セル壁の表面の細孔に、触媒金属を含む触媒スラリを浸透させることにより、各セル通路の入口側の触媒層の厚さが、該セル通路の中間部の触媒層の厚さよりも薄く形成されていることを特徴とする請求項１に記載のハニカム型モノリス触媒。   By impregnating the catalyst slurry containing the catalyst metal into the pores on the surface of the cell wall, the thickness of the catalyst layer on the inlet side of each cell passage is thinner than the thickness of the catalyst layer in the middle portion of the cell passage. The honeycomb type monolith catalyst according to claim 1, wherein the honeycomb type monolith catalyst is formed. 軸方向に貫通する複数のセル通路を有する多孔質材料からなる担体を用いた排気浄化用のハニカム型モノリス触媒を製造する方法であって、
上記複数のセル通路を有する担体を焼成し、
各セル通路の表面の細孔への浸透が異なり、かつ乾燥後の厚さが異なる第１の触媒スラリと第２の触媒スラリとを調整し、
各セル通路のセル壁の端面から所定の長さだけ上記担体を上記第１の触媒スラリに浸漬して乾燥し、
上記担体の残りの部分を第２の触媒スラリに浸漬して乾燥することを特徴とするハニカム型モノリス触媒の製造方法。 A method for producing a honeycomb monolith catalyst for exhaust purification using a support made of a porous material having a plurality of cell passages penetrating in the axial direction,
Firing the carrier having the plurality of cell passages,
Adjusting the first catalyst slurry and the second catalyst slurry having different penetrations into the pores on the surface of each cell passage and different thicknesses after drying;
The carrier is immersed in the first catalyst slurry for a predetermined length from the end surface of the cell wall of each cell passage and dried.
A method for producing a honeycomb type monolith catalyst, wherein the remaining part of the carrier is immersed in a second catalyst slurry and dried.
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