Exhaust treatment apparatus containing catalyst members having electric arc sprayed substrates and methods of using the same
OwnerMichael P. Galligan, Albert K. Bond +1inventors
InventorsMichael P. Galligan, Albert K. Bond, Joseph C. Dettling
Life of this patent
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Abstract
Electric arc spraying a metal onto a substrate produces an anchor layer on the substrate that serves as a surprisingly superior intermediate layer for a catalytic material deposited thereon. Spalling of catalytic material is resisted even when subjected to the harsh conditions imposed by small engines or in a close-coupled position for a larger engine.
Claims29
A catalyst member comprising:
- a carrier substrate having an anchor layer disposed thereon by electric arc spraying;
- and
- catalytic material disposed on the carrier substrate.
A catalyst member comprising:
- a carrier substrate comprising at least two regions of different substrate densities disposed for fluid flow from one region to the other;
- and
- a catalytic material deposited on the at least two substrate regions of different surface area densities.
A catalyst member comprising:
- an open carrier substrate having an anchor layer disposed thereon by thermal spraying;
- and
- catalytic material disposed on the carrier.
A method for manufacturing a catalyst member comprising:
- depositing by electric arc spraying a metal feedstock onto a substrate to provide a metal anchor layer on the substrate, and
- depositing a catalytic material onto the substrate.
A method for manufacturing a catalyst member comprising:
- electric arc spraying a metal feedstock onto at least one substrate to provide at least one anchor layer-coated substrate;
- depositing onto the at least one anchor layer-coated substrate a catalytic material comprised of a bulk refractory metal oxide having dispersed thereon one or more catalytically active components to provide at least one catalyzed substrate;
- and
- incorporating the at least one catalyzed substrate into a body configured to define an inlet opening and an outlet opening and so configuring and disposing the at least one catalyzed substrate between the inlet and outlet openings to define a plurality of fluid flow paths therebetween.
An exhaust treatment apparatus comprising:
- a catalyzed substrate comprising a metal substrate defining a plurality of fluid flow passages therethrough and having thereon an anchor layer electric arc sprayed thereon and a catalytic material disposed on the anchor layer, the catalytic material comprising a bulk refractory metal oxide having dispersed thereon one or more catalytically active metal components;
- and
- a canister having an inlet opening and an outlet opening and within which the catalyzed metal substrate is enclosed, the catalyzed metal substrate being disposed between the inlet and outlet openings, whereby at least some of a fluid flowing through the canister between the inlet and outlet openings thereof is constrained to follow the fluid flow paths and thereby contact the catalyzed metal substrate.
Dependencies are inferred from the claim text.