Foam catalyst support for exhaust purification
AssigneeUltramet
InventorsThomas F. Fay, III, Raffaele La Ferla, Andrew J. Sherman, Edwin P. Stankiewicz
Life of this patent
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Abstract
A method of producing an acoustic baffle/catalyst foam support material and the resultant material. A polyurethane open cell foam material is provided having a density between 10-100 ppi. The polyurethane foam is infiltrated with a resin material to produce an impregnated foam. The impregnated foam is pyrolized to form a carbon skeleton forming a carbon foam. The carbon foam skeleton is coated with one or more of the following group of materials to a relative density of five to thirty five (5-35) percent, the group of materials being SiC, Si.sub.3 N.sub.4, MoSi.sub.2 or high temperature metal.
Claims29
A method of producing an acoustic baffle/catalyst foam support material including the following steps:
- providing a polyurethane open cell foam material having a pore density between ten and 100 pores per inch,
- providing a resin material,
- infiltrating the polyurethane foam with the resin material to produce an impregnated foam,
- pyrolizing the impregnated foam to form a carbon foam skeleton, and
- coating the carbon foam skeleton with one or more of the following group of materials without blocking said pores to produce a coated foam support comprising five to thirty five percent solid compared to sixty five to ninety five percent voids, the group of materials being SiC, Si.sub.3 N.sub.4, MoSi.sub.2 or metal which withstands temperatures in excess of 900.degree. C., and
- applying a catalyst to the coated carbon foam skeleton without blocking said pores, and wherein such catalyst is a metal or metals from the platinum group, and
- recovering said acoustic baffle/catalyst foam support material, said acoustic baffle/catalyst foam support material having a through-flow configuration.
An acoustic baffle/catalyst support including:
- an open cell carbon foam skeleton,
- a surface coating on the carbon foam skeleton forming a support comprising five to thirty five percent solid compared to sixty five to ninety five percent voids,
- wherein the surface coating is formed by one or more of the following group of materials SiC, Si.sub.3 N.sub.4, MoSi.sub.2 or metal which withstands temperatures in excess of 900.degree. C., and
- a catalytic layer on the surface coating and wherein such catalytic layer is formed from a platinum group metal or metals, said acoustic baffle/catalyst support having opposed sides and being adapted to permit fluid to flow through said voids from one of said opposed sides to the other.
Dependencies are inferred from the claim text.