Advanced catalysts for automotive applications

• US 9,308,524 B2
• Filed: 09/12/2014
• Issued: 04/12/2016
• Est. Priority Date: 12/15/2009
• Status: Active Grant

• Current Assignee: Umicore AG & Company KG (Umicore S.A.)
• Original Assignee: SDC Materials,Inc.
• Inventors: Yin, Qinghua, Qi, Xiwang, Biberger, Maximilian A.
• Primary Examiner(s): Nguyen, Cam N.
• Application Number:
  US14/485,545
• Publication Number:
  US 20150141236A1
• Time in Patent Office: 578 Days
• Field of Search: 502261-263, 502/327, 502332-334, 502/339, 502/355, 502/415, 502/439, 502/527.12, 502/527.13, 977/773, 977/775
• US Class Current: 1/1
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 23/42 Platinum
• CPC Class Codes: B01J 23/44 Palladium
• CPC Class Codes: B01J 23/464 Rhodium
• CPC Class Codes: B01J 23/8926 Copper and noble metals
• CPC Class Codes: B01J 35/23 in a colloidal state
• 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 37/00 Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
• CPC Class Codes: B01J 37/009 Preparation by separation, e.g. by filtration, decantation, screening
• CPC Class Codes: B01J 37/0211 using a colloidal suspension
• CPC Class Codes: B01J 37/32 Freeze drying, i.e. lyophilisation
• CPC Class Codes: B01J 37/349 making use of flames, plasmas or lasers
• CPC Class Codes: B28B 23/0087 Lightweight aggregates for making lightweight articles
• CPC Class Codes: B32B 37/14 characterised by the properties of the layers
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: B82Y 40/00 Manufacture or treatment of nanostructures
• CPC Class Codes: C23C 4/134 Plasma spraying
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Embodiments of present inventions are directed to an advanced catalyst. The advanced catalyst includes a honeycomb structure with an at least one nano-particle on the honeycomb structure. The advanced catalyst used in diesel engines is a two-way catalyst. The advanced catalyst used in gas engines is a three-way catalyst. In both the two-way catalyst and the three-way catalyst, the at least one nano-particle includes nano-active material and nano-support. The nano-support is typically alumina. In the two-way catalyst, the nano-active material is platinum. In the three-way catalyst, the nano-active material is platinum, palladium, rhodium, or an alloy. The alloy is of platinum, palladium, and rhodium.

Claims

1. A method of making a catalytic converter comprising:

loading feed material into a plasma reactor, the feed material comprising active material and a support material;

vaporizing the active material and the support material in the plasma reactor thereby forming a vapor cloud of active material and support material;

condensing the vapor cloud of active material and support material, thereby forming solidified nanoparticles comprising nano-active material and nano-support material; and

applying a wash coat comprising the solidified nanoparticles comprising nano-active material and nano-support material to a substrate to produce a catalytic converter.

2. The method of claim 1, wherein the nano-active material comprises platinum.

3. The method of claim 1, wherein the nano-active material comprises palladium.

4. The method of claim 1, wherein the nano-active material comprises rhodium.

5. The method of claim 1, wherein the nano-active material is an alloy.

6. The method of claim 1, wherein the nano-support comprises alumina.

7. The method of claim 1, wherein the nano-support comprises a partially reduced alumina surface, the partially reduced alumina surface configured to limit movement of the nano-active material on a surface of the nano-support.

8. The method of claim 1, wherein the feed material comprises a plurality of different active materials.

9. The method of claim 8, wherein the support material comprises alumina.

10. The method of claim 8, wherein the different active materials include platinum, palladium, and rhodium.

11. The method of claim 1, wherein the wash coat comprises micron sized oxide particles.

12. The method of claim 1, wherein the wash coat comprises micron sized alumina particles.

13. A method of making a catalytic converter comprising

loading a first feed material into a plasma reactor, the first feed material comprising first active material and a first support material;

vaporizing the first active material and the first support material in the plasma reactor thereby forming a vapor cloud of first active material and first support material;

condensing the vapor cloud of first active material and first support material, thereby forming solidified first nanoparticles comprising first nano-active material and first nano-support material;

loading a second feed material into a plasma reactor, the second feed material comprising second active material and a second support material;

vaporizing the second active material and the second support material in the plasma reactor thereby forming a vapor cloud of second active material and second support material;

condensing the vapor cloud of second active material and second support material, thereby forming solidified second nanoparticles comprising second nano-active material and second nano-support material; and

applying the first nanoparticles comprising first nano-active material and first nano-support material and the second nanoparticles comprising second nano-active material and second nano-support material to a substrate to produce a catalytic converter.

14. The method of claim 13, further comprising:

loading a third feed material into a plasma reactor, the third feed material comprising third active material and a third support material;

vaporizing the third active material and the third support material in the plasma reactor thereby forming a vapor cloud of third active material and third support material;

condensing the vapor cloud of third active material and third support material, thereby forming solidified third nanoparticles comprising third nano-active material and third nano-support material; and

applying the third nanoparticles comprising third nano-active material and third nano-support material to the substrate.

15. The method of claim 14, wherein at least one of the first support material, the second support material, and the third support material comprises alumina.

16. The method of claim 14, wherein the third active material comprises rhodium.

17. The method of claim 14, wherein the first active material comprises platinum, the second active material comprises palladium, and the third active material comprises rhodium.

18. The method of claim 13, wherein the first active material comprises platinum.

19. The method of claim 13, wherein the second active material comprises palladium.

20. A method of making a three-way catalytic converter comprising:

loading a first feed material into a plasma reactor, the first feed material comprising an oxidation active material and a first support material;

vaporizing the first oxidation active material and the first support material in the plasma reactor thereby forming a vapor cloud of oxidation active material and first support material;

condensing the vapor cloud of oxidation material and first support material, thereby forming solidified oxidation nanoparticles comprising oxidation nano-active material and first nano-support material;

loading a second feed material into a plasma reactor, the second feed material comprising reduction active material and a second support material;

vaporizing the reduction active material and the second support material in the plasma reactor thereby forming a vapor cloud of reduction active material and second support material;

condensing the vapor cloud of reduction active material and second support material, thereby forming solidified reduction nanoparticles comprising reduction nano-active material and second nano-support material; and

applying the oxidation nanoparticles comprising oxidation nano-active material and first nano-support material, and the reduction nanoparticles comprising reduction nano-active material and second nano-support material to a substrate.

21. The method of claim 20, wherein the oxidation active material comprises platinum.

22. The method of claim 20, wherein the oxidation active material comprises palladium.

23. The method of claim 20, wherein the reduction active material comprises rhodium.

24. The method of claim 20, wherein the oxidation active material is an alloy.

25. The method of claim 20, wherein the first support comprises alumina.

26. The method of claim 20, wherein the first support material comprises a partially reduced alumina surface, the partially reduced alumina surface configured to limit movement of the nano-active material on a surface of the nano-support.

27. The method of claim 20, further comprising:

loading a third feed material into a plasma reactor, the third feed material comprising second oxidation active material and a third support material;

vaporizing the second oxidation active material and the third support material in the plasma reactor thereby forming a vapor cloud of second oxidation active material and third support material;

condensing the vapor cloud of second oxidation active material and third support material, thereby forming solidified second oxidation nanoparticles comprising second oxidation nano-active material and third nano-support material; and

applying the second oxidation nanoparticles comprising second oxidation nano-active material and third nano-support material to the substrate.

28. The method of claim 27, wherein the oxidation active material comprises platinum, the second oxidation active material comprises palladium, and the reductive active material comprises rhodium.

29. A method of making a two-way catalytic converter comprising:

loading a feed material into a plasma reactor, the first feed material comprising a first oxidation active material and a first support material;

vaporizing the first oxidation active material and the first support material in the plasma reactor thereby forming a vapor cloud of first oxidation active material and first support material;

condensing the vapor cloud of first oxidation material and first support material, thereby forming solidified oxidation nanoparticles comprising first oxidation nano-active material and first nano-support material; and

applying the oxidation nanoparticles comprising first oxidation nano-active material and first nano-support material to a substrate.

30. The method of claim 29, wherein the first oxidation active material comprises platinum.

31. The method of claim 29, wherein the first nano-support material comprises alumina.

32. The method of claim 29, wherein the first nano-support material comprises a partially reduced alumina surface, the partially reduced alumina surface configured to limit movement of the first nano-active material on a surface of the first nano-support material.

33. The method of claim 29, wherein the first oxidation active material comprises palladium.

34. The method of claim 29, wherein the first oxidation active material is an alloy.