Catalyst-containing polymer coatings formed by chemical grafting
AssigneeCatalytic Industrial Group, Inc.
InventorsPaul Thottathil, Satyabrata Mukherjee, Purushothaman Kesavan, John Ryan
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Abstract
The present invention relates to coating compositions and methods of forming catalyst-containing coatings on substrates for catalytic heater devices. The coatings are formed by a chemical grafting method, which chemically bonds the coating (and catalysts contained therein) to the substrate. The resulting coatings have high temperature resistance and inhibit or prevent catalyst migration to the substrate, thereby maintaining catalytic activity and desired temperatures over prolonged use.
Claims26
A method of forming a catalyst-containing polymer coating on a catalytic heater substrate, the method comprising:
- providing a liquid coating composition comprising:
- a washcoat base comprising a catalyst material, and
- a chemical grafting admixture comprising one or more monomers and/or prepolymers, one or more grafting initiators, and one or more coupling agents dispersed or dissolved in a solvent system;
- and
- applying the liquid coating composition to a surface of the substrate and forming the catalyst-containing polymer coating thereon.
A catalytic heater comprising a catalyst-containing polymer coating chemically bonded to a substrate, the polymer coating comprising a polymer matrix comprising a catalyst material secured therein.
A composition useful for forming a catalyst-containing polymer coating on a substrate, the composition comprising:
- a washcoat base comprising a catalyst material;
- and
- a chemical grafting admixture comprising one or more monomers and/or prepolymers, one or more grafting initiators, and one or more coupling agents dispersed or dissolved in a solvent system.
Dependencies are inferred from the claim text.