Optimization of washcoat adhesion of zero-PGM catalyst on metallic substrates
AssigneeClean Diesel Technologies, Inc.
InventorsZahra Nazarpoor, Sen Kitazumi, Johnny T. Ngo
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Abstract
Solutions to the problem of washcoat and/or overcoat adhesion loss of ZPGM catalyst on metallic substrates are disclosed. Present disclosure provides a novel process for improving WCA to metallic substrates of ZPGM catalyst systems. Reduction of WCA loss and improved catalyst activity may be enabled by the selection of processing parameters determined from variations of pH and addition of binder to overcoat slurry, and particle size of washcoat. Processing parameters may be applied to a plurality of metallic substrates of different geometries and cell densities.
Claims9
A method for manufacturing a catalyst system, the method comprising:
- providing at least one substrate;
- depositing a washcoat onto the substrate;
- adjusting a pH of at least one chemical slurry suitable for deposition on the substrate and comprising at least one ZPGM catalyst, wherein the chemical slurry comprises alumina or doped alumina, or a mixture thereof, an oxygen storage material, copper oxide, and cerium oxide;
- and
- depositing the at least one chemical slurry overlying the washcoat, wherein the average particle size of the at least one chemical slurry is about 7 μm, and the pH is about 6.8 and wherein loading of the copper oxide is from 10 g/L to 15 g/L and the loading of the cerium oxide is from 12 g/L to 18 g/L.
A method for manufacturing a catalyst system, the method comprising:
- providing at least one substrate;
- depositing a washcoat on the substrate:
- adjusting a pH of at least one chemical slurry suitable for deposition on the substrate and comprising at least one ZPGM catalyst, wherein the at least one chemical slurry comprises alumina as a binder;
- and
- depositing the at least one chemical slurry on the substrate, wherein the pH of the at least one chemical slurry is about 6.8 and wherein the average particle size of the at least one chemical slurry is about 7 μm and wherein loading of a copper oxide is from 10 g/L to 15 g/L and the loading of a cerium oxide is from 12 g/L to 18 g/L.
Dependencies are inferred from the claim text.