Layered catalyst composition

Abstract

A catalyst composition contains a catalytic material having having an undercoat layer containing a mixture of a fine particulate undercoat refractory metal oxide and a sol such as a silica sol, the undercoat providing good adherence to substrates, such as metal substrates, on which the catalytic material is disposed. An overlayer is coated over the underlayer and contains an overlayer refractory metal oxide, which may be the same as or different from the undercoat refractory metal oxide, and on which is dispersed one or more catalytic metal components, such as palladium and manganese components. The metal substrate may be made of, e.g., aluminum or titanium or alloys thereof, and provides a low pressure drop and lightweight catalyst, making the catalyst especially well adapted for use in aircraft to abate ozone in cabin air. A method of making the catalyst composition includes applying the undercoat to the substrate and calcining it, impregnating the overlayer refractory metal oxide with one or more catalytic metal components and depositing the overlayer over the undercoat, and calcining it.

Dependencies are inferred from the claim text.