Minimizing Washcoat Adhesion Loss of Zero-PGM Catalyst Coated on Metallic Substrate
First Claim
1. A catalytic system, comprising:
- at least one substrate;
a washcoat suitable for deposition on the substrate, the washcoat comprising at least one oxide solid further comprising at least one carrier metal oxide;
an overcoat suitable for deposition on the substrate, the overcoat comprising at least one ZPGM catalyst;
wherein adhesion of the washcoat is affected by one selected from the group consisting of the pH of the overcoat, at least one binder in the overcoat, ab average particle size of the overcoat, rheology of the overcoat, and combinations thereof.
3 Assignments
0 Petitions
Accused Products
Abstract
Solutions to the problem of washcoat and/or overcoat adhesion loss of ZPGM catalyst on metallic substrates are disclosed. Present disclosure provides an enhanced 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 variation of rheological properties by the solid content of the overcoat slurry and variation of the overcoat slurry particle size distribution to produce desirable homogeneity, specific loading, and adherence of the coating on metallic substrates. Processing parameters may be applied to a plurality of metallic substrates of different geometries and cell densities.
-
Citations
20 Claims
-
1. A catalytic system, comprising:
-
at least one substrate; a washcoat suitable for deposition on the substrate, the washcoat comprising at least one oxide solid further comprising at least one carrier metal oxide; an overcoat suitable for deposition on the substrate, the overcoat comprising at least one ZPGM catalyst; wherein adhesion of the washcoat is affected by one selected from the group consisting of the pH of the overcoat, at least one binder in the overcoat, ab average particle size of the overcoat, rheology of the overcoat, and combinations thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
-
Specification