Washcoats and coated substrates for catalytic converters and methods of making and using same
First Claim
1. A coated substrate comprising:
- a substrate; and
, coated on said substrate;
a washcoat layer comprising iron-exchanged zeolite particles, anda washcoat layer comprising catalytically active Nano-on-Nano-on-micro (NNm) particles, the catalytically active Nano-on-Nano-on-micro (NNm) particles comprising composite nanoparticles bonded to micron-sized carrier particles, and the composite nanoparticles comprising a support nanoparticle and a catalytic nanoparticle.
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Accused Products
Abstract
Disclosed are, inter alia, methods of forming coated substrates for use in catalytic converters, as well as washcoat compositions and methods suitable for using in preparation of the coated substrates, and the coated substrates formed thereby, which in some cases use iron-exchanged zeolite particles that provide enhanced performance such as lower light-off temperatures and lower pollutant levels in exhaust gases. The catalytic material is prepared by a plasma-based method, yielding catalytic material with a lower tendency to migrate on support at high temperatures, and thus less prone to catalyst aging after prolonged use. Also disclosed are catalytic converters using the coated substrates, which have favorable properties as compared to catalytic converters using catalysts deposited on substrates using solution chemistry. Also disclosed are exhaust treatment systems, and vehicles, such as diesel vehicles, particularly light-duty diesel vehicles, using catalytic converters and exhaust treatment systems using the coated substrates.
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Citations
34 Claims
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1. A coated substrate comprising:
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a substrate; and
, coated on said substrate;a washcoat layer comprising iron-exchanged zeolite particles, and a washcoat layer comprising catalytically active Nano-on-Nano-on-micro (NNm) particles, the catalytically active Nano-on-Nano-on-micro (NNm) particles comprising composite nanoparticles bonded to micron-sized carrier particles, and the composite nanoparticles comprising a support nanoparticle and a catalytic nanoparticle. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method of forming a coated substrate, the method comprising:
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a) coating a substrate with a washcoat composition comprising iron-exchanged zeolite particles; and b) coating the substrate with a washcoat composition comprising catalytically active Nano-on-Nano-on-micro (NNm) particles comprising composite nanoparticles bonded to micron-sized carrier particles, and the composite nanoparticles comprise a support nanoparticle and a catalytic nanoparticle. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34)
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Specification