Method for producing substrate having catalyst compositions on surfaces of opposite sides
First Claim
1. A method of providing different catalyst surfaces on the opposite surface sides of a metal substrate comprising:
- thermal spraying one surface of the substrate with a mixture of powders having a size greater than 10 micrometers and no more than 200 micrometers comprising
1) one or more than one of a hydroxide, carbonate, or nitrate of one or more than one of cerium, aluminum, tin, manganese, copper, cobalt, nickel, praseodymium or terbium and
2) one or more than one of a noble metal, noble metal hydroxide, noble metal carbonate, or noble metal nitrate onto the surface of the substrate such that the particles in the mixture decompose by pyrolysis to produce a mixture of, respectively on the one surface a distribution of particles of an oxide of one or more than one of cerium, aluminum, tin, manganese, copper, cobalt, nickel, praseodymium or terbium and particles of one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold, such that the sprayed mixture results in particles bonded to the surface where approximately 90% have a size less than 5 microns (μ
m); and
, subsequent to the thermal spraying, coating the surface of the substrate opposite the one surface by a physical vapor deposition process with one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold.
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Accused Products
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.
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Citations
12 Claims
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1. A method of providing different catalyst surfaces on the opposite surface sides of a metal substrate comprising:
- thermal spraying one surface of the substrate with a mixture of powders having a size greater than 10 micrometers and no more than 200 micrometers comprising
1) one or more than one of a hydroxide, carbonate, or nitrate of one or more than one of cerium, aluminum, tin, manganese, copper, cobalt, nickel, praseodymium or terbium and
2) one or more than one of a noble metal, noble metal hydroxide, noble metal carbonate, or noble metal nitrate onto the surface of the substrate such that the particles in the mixture decompose by pyrolysis to produce a mixture of, respectively on the one surface a distribution of particles of an oxide of one or more than one of cerium, aluminum, tin, manganese, copper, cobalt, nickel, praseodymium or terbium and particles of one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold, such that the sprayed mixture results in particles bonded to the surface where approximately 90% have a size less than 5 microns (μ
m); and
, subsequent to the thermal spraying, coating the surface of the substrate opposite the one surface by a physical vapor deposition process with one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold. - View Dependent Claims (2, 3, 4, 5)
- thermal spraying one surface of the substrate with a mixture of powders having a size greater than 10 micrometers and no more than 200 micrometers comprising
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6. A method of making a micro channel catalytic device comprising:
- pre-forming a metal substrate with longitudinal folds spaced a predetermined distance apart corresponding to predetermined apexes of micro channels having a predetermined width and depth;
thermal spraying a surface of the pre-formed substrate with a powder mixture of
1) metal oxide precursors comprising particulates of one or more than one of a hydroxide, carbonate, or nitrate of one or more than one of cerium, aluminum, tin, manganese, copper, cobalt, nickel, praseodymium or terbium and
2) one or more than one of a metal, metal hydroxide, metal carbonate, or metal nitrate of one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold, the mixture of powders having a size greater than 10 micrometers and no more than 200 micrometers, to produce on the surface, respectively, an oxide composition of a mixture of
1) one or more than one of cerium, aluminum, tin, manganese, copper, cobalt, nickel, praseodymium or terbium and
2) one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum or gold, whereby in the thermal spraying, the powder mixture decomposes and the composition sprayed on the surface is bonded to the surface and where approximately 90% of the particles of the composition so bonded have a size less than 5 microns (μ
m); and
, subsequent to the thermal spraying, coating the surface of the substrate opposite the first surface by a physical vapor deposition process with one or more than one of ruthenium, rhodium, palladium, silver, iridium, platinum and gold. - View Dependent Claims (7, 8, 9, 10, 11, 12)
- pre-forming a metal substrate with longitudinal folds spaced a predetermined distance apart corresponding to predetermined apexes of micro channels having a predetermined width and depth;
Specification