Method for forming coating layer containing magnesium on metal support, catalyst support and catalytic converter, including coating layer containing magnesium formed by the same method

Patent metadata

Field	Value
Publication number	US-10017873-B1
Application number	US-201715681021-A
Country	US
Kind code	B1
Filing date	Aug 18, 2017
Priority date	Apr 10, 2017
Publication date	Jul 10, 2018
Grant date	Jul 10, 2018

Abstract

An embodiment of the invention provides a method for forming a magnesium (Mg)-containing coating layer on the surface of a metal support, which comprises a first step of preparing a precursor solution containing a magnesium component, a second step of forming a precipitate on the surface of a metal support by immersing and aging the metal support in the precursor solution prepared in the first step, and a third step of forming a magnesium-containing coating layer on the surface of the metal support by calcinating the precipitate formed in the second step.

First claim

What is claimed is:

1. A method for forming a magnesium (Mg)-containing coating layer on a surface of a metal support, the method comprising:
a first step of preparing a precursor solution containing a magnesium component;
a second step of forming a precipitate on the surface of the metal support by immersing and aging the metal support in the precursor solution prepared in the first step; and
a third step of forming a magnesium-containing coating layer on the surface of the metal support by calcinating the precipitate formed in the second step.

2. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 1 , wherein in the first step, the precursor solution is prepared by adding a precipitant to a solution in which a magnesia precursor is dissolved in distilled water.

3. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 2 , wherein the magnesia precursor is any one or more of magnesium nitrate (Mg(NO 3 ) 2 .6H 2 O), magnesium chloride (MgCl 2 .6H 2 O), and magnesium acetate ((CH 3 COO) 2 Mg.4H 2 O).

4. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 2 , wherein the precipitant is urea (CO(NH 2 ) 2 ).

5. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 2 , wherein the magnesia precursor in the precursor solution has a concentration ranging from 50 to 1000 mM.

6. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 2 , wherein the precursor solution has a pH ranging from 5 to 10.

7. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 1 , wherein in the second step, the metal support is immersed in the precursor solution at 25 to 200° C. for 0.5 to 100 hours to form a precipitate.

8. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 7 , wherein in the second step, the metal support is immersed in the precursor solution at 25 to 90° C. to form a precipitate.

9. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 7 , wherein in the second step, the metal support is immersed in the precursor solution for 0.5 to 72 hours to form a precipitate.

10. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 1 , wherein in the third step, calcination of the precipitate is performed at 200 to 1200° C.

11. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 10 , wherein in the third step, calcination of the precipitate is performed at 500 to 1000° C.

12. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 1 , wherein in the third step, calcination of the precipitate is performed under an oxidizing atmosphere.

13. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 1 , prior to the first step, further comprising an alumina (Al 2 O 3 ) coating step to cause an alumina layer to be coated on the surface of the metal support.

14. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 1 , wherein in the first step, the precursor solution is prepared by adding a precipitant to a solution in which a magnesia precursor and an alumina precursor are dissolved in distilled water.

15. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 14 , wherein the alumina precursor is any one or more of aluminum nitrate (Al(NO 3 ) 2 .9H 2 O), aluminum chloride (AlCl 3 .6H 2 O), and aluminum acetate (C 2 H 5 AlO 4 ).

16. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 14 , wherein the precursor solution has a pH ranging from 1.5 to 10.

17. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 1 , wherein the metal support is made of any one material, or an alloy of two or more, selected from the group consisting of a FeCr alloy, stainless steel, aluminum, titanium, and SiC.

18. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 1 , wherein the metal support is in the form of felt, mat, mesh, foam, foil, monolith, or pin.

19. The method for forming a magnesium-containing coating layer on a surface of a metal support according to claim 1 , wherein prior to the first step, any one or more of an electrochemical surface treatment step and a heat treatment step is performed for the metal support.

20. A metal support comprising a magnesium-containing coating layer formed by the method according to claim 1 .

21. A catalytic converter adapted to have catalysts carried on the magnesium-containing coating layer of the metal support according to claim 20 .

Assignees

• Korea Inst Energy Res

Inventors

• Koo Kee Young
• Yoon Wang Lai
• Jung Un Ho
• Im Hyo Been

Classifications

• C23C18/1279

  performed under reactive atmosphere, e.g. oxidising or reducing atmospheres · CPC title

• B01J37/08

  Heat treatment {(B01J37/0009, B01J37/0018 take precedence)} · CPC title

• B01J37/035

  Precipitation on carriers · CPC title

• C23C18/1283

  Control of temperature, e.g. gradual temperature increase, modulation of temperature · CPC title

• C23C18/1225

  Deposition of multilayers of inorganic material · CPC title