Advanced catalysts for automotive applications
First Claim
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.
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Accused Products
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.
623 Citations
34 Claims
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1. A method of making a catalytic converter comprising:
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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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. - View Dependent Claims (14, 15, 16, 17, 18, 19)
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20. A method of making a three-way catalytic converter comprising:
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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. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28)
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29. A method of making a two-way catalytic converter comprising:
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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. - View Dependent Claims (30, 31, 32, 33, 34)
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Specification