Advanced catalysts for automotive applications
AssigneeSDCmaterials, Inc.
InventorsQinghua Yin, Xiwang Qi, Maximilian A. Biberger
Life of this patent
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Abstract
Embodiments of present inventions are directed to an advanced catalyst. The advanced catalyst includes a honeycomb structure with an at least one nano-particle on the honeycomb structure. The advanced catalyst used in diesel engines is a two-way catalyst. The advanced catalyst used in gas engines is a three-way catalyst. In both the two-way catalyst and the three-way catalyst, the at least one nano-particle includes nano-active material and nano-support. The nano-support is typically alumina. In the two-way catalyst, the nano-active material is platinum. In the three-way catalyst, the nano-active material is platinum, palladium, rhodium, or an alloy. The alloy is of platinum, palladium, and rhodium.
Claims34
A method of making a catalytic converter comprising:
- loading feed material into a plasma reactor, the feed material comprising active material and a support material;
- vaporizing the active material and the support material in the plasma reactor thereby forming a vapor cloud of active material and support material;
- condensing the vapor cloud of active material and support material, thereby forming solidified nanoparticles comprising nano-active material and nano-support material;
- and
- applying a wash coat comprising the solidified nanoparticles comprising nano-active material and nano-support material to a substrate to produce a catalytic converter.
A method of making a catalytic converter comprising
- loading a first feed material into a plasma reactor, the first feed material comprising first active material and a first support material;
- vaporizing the first active material and the first support material in the plasma reactor thereby forming a vapor cloud of first active material and first support material;
- condensing the vapor cloud of first active material and first support material, thereby forming solidified first nanoparticles comprising first nano-active material and first nano-support material;
- loading a second feed material into a plasma reactor, the second feed material comprising second active material and a second support material;
- vaporizing the second active material and the second support material in the plasma reactor thereby forming a vapor cloud of second active material and second support material;
- condensing the vapor cloud of second active material and second support material, thereby forming solidified second nanoparticles comprising second nano-active material and second nano-support material;
- and
- applying the first nanoparticles comprising first nano-active material and first nano-support material and the second nanoparticles comprising second nano-active material and second nano-support material to a substrate to produce a catalytic converter.
A method of making a three-way catalytic converter comprising:
- loading a first feed material into a plasma reactor, the first feed material comprising an oxidation active material and a first support material;
- vaporizing the first oxidation active material and the first support material in the plasma reactor thereby forming a vapor cloud of oxidation active material and first support material;
- condensing the vapor cloud of oxidation material and first support material, thereby forming solidified oxidation nanoparticles comprising oxidation nano-active material and first nano-support material;
- loading a second feed material into a plasma reactor, the second feed material comprising reduction active material and a second support material;
- vaporizing the reduction active material and the second support material in the plasma reactor thereby forming a vapor cloud of reduction active material and second support material;
- condensing the vapor cloud of reduction active material and second support material, thereby forming solidified reduction nanoparticles comprising reduction nano-active material and second nano-support material;
- and
- applying the oxidation nanoparticles comprising oxidation nano-active material and first nano-support material, and the reduction nanoparticles comprising reduction nano-active material and second nano-support material to a substrate.
A method of making a two-way catalytic converter comprising:
- loading a feed material into a plasma reactor, the first feed material comprising a first oxidation active material and a first support material;
- vaporizing the first oxidation active material and the first support material in the plasma reactor thereby forming a vapor cloud of first oxidation active material and first support material;
- condensing the vapor cloud of first oxidation material and first support material, thereby forming solidified oxidation nanoparticles comprising first oxidation nano-active material and first nano-support material;
- and
- applying the oxidation nanoparticles comprising first oxidation nano-active material and first nano-support material to a substrate.
Dependencies are inferred from the claim text.