High porosity metal oxide catalyst coatings

A catalytic device comprising:

• an automobile radiator;
• and
• a catalyst composition coated onto the automobile radiator, the catalyst composition comprising:
• a manganese oxide catalyst, wherein at least about 15% of a total number of manganese atoms in the manganese oxide catalyst are dispersed as crystallites within about 10 nanometers of an outer surface of the catalyst composition as detectable by surface X-ray photoelectron spectroscopy (XPS), wherein at least 50% of the manganese oxide catalyst is in amorphous form, and wherein a cumulative pore volume of the manganese oxide catalyst is from 1.2 mL/g to 2 mL/g;
• a support material impregnated with the manganese oxide catalyst;
• and
• at least two acrylic binders, wherein a first acrylic binder of the at least two acrylic binders exhibits a glass transition temperature of about 20° C. or less, wherein a second acrylic binder of the at least two acrylic binders exhibits a glass transition temperature of greater than about 20° C., wherein a total binder concentration including the first acrylic binder and the second acrylic binder is less than about 16% based on a total weight of the catalyst composition, and wherein the concentrations of the first acrylic binder and the second acrylic binder are selected such that an ultrasonic washcoat adhesion weight loss of the catalyst composition when adhered to a substrate is less than 1.60%.

A method of forming a manganese oxide catalyst, the method comprising:

• mixing a manganese compound with a support material to form a manganese-impregnated support;
• calcining the manganese-impregnated support to form the manganese oxide catalyst, wherein at least about 15% of a total number of manganese atoms in the manganese oxide catalyst are dispersed as crystallites within about 10 nanometers of an outer surface of the catalyst composition as detectable by surface X-ray photoelectron spectroscopy (XPS), wherein at least 50% of the manganese oxide catalyst is in amorphous form, and wherein a cumulative pore volume of the manganese oxide catalyst is from 1.2 mL/g to 2 mL/g;
• and
• incorporating the manganese oxide catalyst into a slurry comprising at least two acrylic binders, wherein a first acrylic binder of the at least two acrylic binders exhibits a glass transition temperature of about 20° C. or less, wherein a second acrylic binder of the at least two acrylic binders exhibits a glass transition temperature of greater than about 20° C., wherein a total binder concentration including the first acrylic binder and the second acrylic binder is less than about 16% based on a total weight of the catalyst, and wherein the concentrations of the first acrylic binder and the second acrylic binder are selected such that an ultrasonic washcoat adhesion weight loss of the catalyst when adhered to a substrate is less than 1.60%.