Substrate and a method of manufacturing a substrate
AssigneeIP2Ipo Innovations Limited
InventorsBenjamin Francis Knatchbull Kingsbury, Kang Li, Zhentao Wu
Life of this patent
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Abstract
A substrate and a method of manufacturing a catalytic substrate body arranged within the catalytic convertor such that a principal flow of fluid through the catalytic convertor flows along a surface of the substrate body, wherein said surface has a plurality of openings to micro-channels that extend away from said surface; and at least a portion of the surface of the substrate body comprises a catalytically active material, wherein the substrate body is in the form of a pellet; a sheet; solid elongated bodies; solid rods; a solid body having a plurality of bores; a non-tubular elongated body; a non-hollow body; a sheet curved in the form or a spiral; or a combination thereof.
Claims20
A catalytic convertor comprising:
- a substrate body including a first surface, a second surface located opposite the first surface, and a plurality of microchannels including openings on the first surface, each microchannel of the plurality extending in a same direction toward the second surface as all other microchannels of the plurality and of the substrate body, the substrate body arranged within the catalytic convertor such that a principal flow of fluid through the catalytic convertor flows along the first surface of the substrate body,
- wherein:
- the substrate body and at least a portion of the first surface comprises a catalytically active material;
- the openings having widths falling in the range 5 μm to 200 μm;
- the substrate body is in the form of a sheet;
- and
- the sheet has a thickness and the microchannels extend at least 80% of the sheet thickness.
A catalytic convertor substrate having a plurality of microchannels each extending in a same direction from a first surface toward a second surface as all other microchannels of the plurality and of the substrate body, each microchannel has an opening having widths falling in the range 5 μm to 200 μm on the first surface formed by providing a suspension containing a substrate material in particulate form and a polymer in a first solvent, the substrate material comprises a catalytically active material;
- introducing the suspension into a mould or extruding the suspension;
- contacting the suspension with a second solvent to remove at least some of the first solvent from the suspension and thereby form a green body having the micro-channels and said polymer;
- removing at least a portion of a surface layer of said green body;
- sintering the green body;
- forming the green body into a sheet having a thickness;
- and
- forming the micro-channels to extend at least 80% of the sheet thickness.
A catalytic convertor comprising:
- a substrate body arranged within the catalytic convertor such that a principal flow of fluid through the catalytic convertor flows along a first surface of the substrate body,
- wherein:
- the substrate body comprises a catalytically active material, a second surface located opposite that of the first surface, and a plurality of microchannels, each microchannel being substantially uniform extending in a same direction toward the second surface from the first surface;
- as all other microchannels of the plurality and of the substrate body,
- said first surface of the substrate body has a plurality of openings to the micro-channels, the openings having widths falling in the range 5 μm to 200 μm;
- and at least a portion of said surface comprises a catalytically active coating;
- the substrate body is in the form of a sheet having a thickness;
- and
- the micro-channels extend at least 80% of the sheet thickness.
Dependencies are inferred from the claim text.