Substrate having catalyst compositions on surfaces of opposite sides

• US 7,326,669 B2
• Filed: 09/20/2001
• Issued: 02/05/2008
• Est. Priority Date: 09/20/2001
• Status: Active Grant

• Current Assignee: Honda Giken Kogyo Kabushiki Kaisha (Honda Motor Company)
• Original Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Inventors: Nomura, Tadashi, Kimura, Eisuke, He, Ting
• Primary Examiner(s): Nguyen; Cam N.
• Application Number:
  US09/957,209
• Publication Number:
  US 20030054953A1
• Time in Patent Office: 2,329 Days
• Field of Search: 502325-327, 502330-335, 502/337, 502344-348, 502/352, 502/355, 502/439, 502/339, 427/453, 427/456, 427/471, 427123-1266
• US Class Current: 502/327
• CPC Class Codes: B01D 53/885 Devices in general for catalytic purification of waste gases
• CPC Class Codes: B01J 19/0093 Microreactors, e.g. miniaturised or microfabricated reactors laboratory containers with capillary fluid transport in microfabricated channels or chambers B01L3/5027
• CPC Class Codes: B01J 2219/00783 Laminate assemblies, i.e. the reactor comprising a stack of plates
• CPC Class Codes: B01J 2219/00835 Comprising catalytically active material
• CPC Class Codes: B01J 2219/00873 Heat exchange
• CPC Class Codes: B01J 2219/2465 Two reactions in indirect heat exchange with each other
• CPC Class Codes: B01J 23/54 combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
• CPC Class Codes: B01J 23/63 with rare earths or actinides
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 37/0215 Coating
• CPC Class Codes: B01J 37/0238 via the gaseous phase-sublimation
• CPC Class Codes: B01J 37/349 making use of flames, plasmas or lasers
• CPC Class Codes: C01B 2203/0227 containing a catalytic reforming step
• CPC Class Codes: C01B 2203/0283 containing a CO-shift step, i.e. a water gas shift step
• CPC Class Codes: C01B 2203/0811 by combustion of fuel
• CPC Class Codes: C01B 2203/1035 Catalyst coated on equipment surfaces, e.g. reactor walls
• CPC Class Codes: C01B 3/16 using catalysts
• CPC Class Codes: C01B 3/384 the catalyst being continuously externally heated
• CPC Class Codes: Y02P 20/52 using catalysts, e.g. selective catalysts

Abstract

A bi-laterally surfaced substrate in which the first surface consists of one or more than one of cerium oxide, aluminum oxide, tin oxide manganese oxide, copper oxide, cobalt oxide, nickel oxide, praseodymium oxide, terbium oxide, ruthenium, rhodium, palladium, silver, iridium, platinum and gold and the second surface consists of one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold and micro channel micro component reactors including such substrates in a predetermined formed shape and methods for making the same utilizing a thermal spray on one side and a physical deposition process on the other side.

Claims

1. A foldable metallic substrate comprising a separator plate for a micro component reaction chamber, the separator plate capable of being longitudinally folded linearly along paths spaced a predetermined distance apart, the paths corresponding to apexes of micro channels having a predetermined height determined by the separation of first and second plates defining the interior height of the reaction chamber, the substrate having two opposite sides comprising first and second surfaces, the first surface consisting of a coating of one or more than one of cerium oxide, aluminum oxide, tin oxide, manganese oxide, copper oxide, cobalt oxide, nickel oxide, praseodymium oxide, terbium oxide, ruthenium, rhodium, palladium, silver, iridium, platinum and gold, the second surface consisting of a coating of one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold.

2. The substrate of claim 1 wherein the first surface comprises a coating of particles having a nominal diameter size distribution range of <

1 micron.

3. The substrate of claim 1 wherein the second surface comprises a coating having a nominal thickness of <

100 nanometers.

4. The substrate of claim 1;

claim 2 or claim 3 comprising a thin metallic film.

5. The substrate of claim 4 comprising a nickel-based alloy.

6. The substrate of claim 1 wherein the folds along the paths are curvilinear.

7. The substrate of claim 1 wherein the folds along the paths are angular.

8. The substrate of claim 1 wherein the folds are formed in the substrate by stamping.

9. The substrate of claim 6;

claim 7 or claim 8 wherein the plate is folded and apexes of the folds on each side of the substrate are bonded by brazing to the first and second plates to form enclosed longitudinally extending micro channels defined by the apexes of the folds.

10. The substrate of claim 1 wherein the coating on the first surface consists of a mixture of ceria and palladium.

11. The substrate of claim 1 wherein the coating on the second surface consists of palladium.

12. The substrate of claim 1 wherein the coating on the first surface has a thickness in the nominal range of greater than approximately thirty microns (30 μ

m).

13. The substrate of claim 1 wherein the first surface has a porosity of at least 50%.

14. The substrate of claim 1 wherein the adhesion of the coating on at least one of the surfaces withstands a processing temperature up to approximately 1000°

C.

15. A micro component reaction chamber including first and second metallic plates that define the interior height of the reaction chamber and a folded metallic separator plate disposed between the interior sides of the first and second plates, the separator plate being longitudinally folded along linear paths spaced a predetermined distance apart, the paths corresponding to spaced apart apexes that define micro channels having a predetermined height determined by the separation of first and second plates defining the interior height of the reaction chamber and a predetermined width determined by the separation of the apexes in the folds of the separator plate, the substrate having two opposite sides comprising first and second surfaces, the first surface consisting of a coating of one or more than one of cerium oxide, aluminum oxide, tin oxide, manganese oxide, copper oxide, cobalt oxide, nickel oxide, praseodymium oxide, terbium oxide, ruthenium, rhodium, palladium, silver, iridium, platinum and gold having a thickness in the nominal range of greater than approximately thirty microns, the second surface consisting of a coating of one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold.