Nano-sized functional binder
AssigneeBASF SE
InventorsGary A. Gramiccioni, Jaya L. Mohanan, John K. Hochmuth, Kenneth R. Brown, Brian Todd Jones
Life of this patent
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Abstract
Described are catalytic articles comprising a substrate having a washcoat on the substrate, the washcoat containing a catalytic component having a first average (D50) particle size and a functional binder component having a second average (D50) particle size in the range of about 10 nm to about 1000 nm, wherein the ratio of the first average (D50) particle size to the second average (D50) particle size is greater than about 10:1. The catalytic articles are useful in methods and systems to purify exhaust gas streams from an engine.
Claims24
A catalytic article for purification of exhaust gases of combustion engines comprising a substrate having a washcoat on the substrate, the washcoat containing a catalytic component having a first average (D50) particle size and a functional binder component having a second average (D50) particle size of about 10 nm to about 1000 nm,
- wherein the ratio of the first average (D50) particle size to the second average (D50) particle size is greater than about 10:1.
A method of preparing a washcoat, the method comprising
- providing a first catalyst component, optionally milled, having a first particle size distribution of d10>about 1.0 μm, d50 about 3 μm to about 5 μm, and d90 about 9 μm to about 13 μm;
- providing a second catalyst component, optionally milled, having a second particle size distribution of d10>about 1.0 μm, d50 about 3 μm to about 5 μm, and d50 about 9 μm to about 13 μm;
- mixing the first catalyst component and the second catalyst component in an aqueous solution to provide a catalytic component having a first average (D50) particle size;
- and
- combining the aqueous solution of the catalytic component with a functional binder component to provide a washcoat, wherein the functional binder component has a second average (D50) particle size of about 10 nm to about 1000 nm,
- wherein the ratio of the first average (D50) particle size to the second average (D50) particle size is greater than about 10:1.
Dependencies are inferred from the claim text.