Methods and Processes of Coating Zero-PGM Catalysts including with Cu, Mn, Fe for TWC Applications
First Claim
5-1. The process of claim 1, wherein the stability of the catalytic system has increased stability.
2 Assignments
0 Petitions
Accused Products
Abstract
Variations of coating processes of Cu—Mn—Fe ZPGM catalyst materials for TWC applications are disclosed. The disclosed coating processes for Cu—Mn—Fe spinel materials are enabled in the preparation ZPGM catalyst samples according to a plurality of catalyst configurations, which may include an alumina only washcoat layer coated on a suitable ceramic substrate, and an overcoat layer with or without an impregnation layer, including Cu—Mn—Fe spinel and doped Zirconia support oxide, prepared according to variations of disclosed coating processes. Activity measurements are considered under variety of lean condition to rich condition to analyze the influence of disclosed coating processes on TWC performance of ZPGM catalysts for a plurality of TWC applications. Different coating processes may substantially increase thermal stability and TWC activity, providing improved levels of NOx conversion that may lead to cost effective manufacturing solutions for ZPGM-TWC systems.
25 Citations
26 Claims
-
5-1. The process of claim 1, wherein the stability of the catalytic system has increased stability.
-
6-2. The process of claim 1, wherein the HC T50 is less than or equal to 61°
- C.
-
13. A catalytic system, comprising:
-
a substrate; a washcoat applied to said substrate, wherein the substrate comprises alumina; an overcoat applied to said washcoat, said overcoat comprising at least one support oxide comprising doped ZrO2, wherein the doped ZrO2comprises Nb2O5-ZrO2; and a catalyst comprising at least one layer of Cu—
Mn spinel applied to said overcoat;wherein the at least one catalyst is substantially free of platinum group metals. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26)
-
Specification