Catalyst coatings incorporating binder compositions

Patent metadata

Field	Value
Publication number	US-10258968-B2
Application number	US-201414528280-A
Country	US
Kind code	B2
Filing date	Oct 30, 2014
Priority date	Oct 30, 2013
Publication date	Apr 16, 2019
Grant date	Apr 16, 2019

Abstract

Disclosed in certain implementations is a catalysis composition that includes a metal catalyst and a support material impregnated with the metal catalyst.

First claim

What is claimed is:

1. A catalysis composition comprising:
a manganese oxide catalyst, wherein at least 50% of the manganese oxide catalyst is in amorphous form;
a support material impregnated with the manganese oxide catalyst;
a first binder; and
a second binder, wherein,
a coating of the catalysis composition on a substrate exhibits an ultrasonic washcoat adhesion weight loss of less than 1.60%, wherein
the support material is selected from a group consisting of ceria, lanthana, alumina, titania, silica, zirconia, carbons, metal organic framework, clay, zeolites, and combinations thereof;
wherein a cumulative pore volume of the catalysis composition is from about 0.80 mL/g to about 2.0 mL/g, an average pore radius of the catalysis composition is from about 6 nanometers to about 15 nanometers and a surface area of the catalysis composition is from about 100 m 2 /g to about 200 m 2 /g;
wherein the manganese oxide catalyst is impregnated in the support material in an amount ranging from about 10% to about 25% metal atoms by mass, based on the total composition;
the weight loss is weight difference of the coated substrate after being immersed in deionized water and exposed to ultrasonic waves at 25 kHz and 500 Watts for 5 minutes and dried at 90° C., and
wherein the first binder has a first glass transition temperature ranging from about 5° C. to about 20° C., and wherein the second binder has a second glass transition temperature that is greater than the first glass transition temperature; or
wherein the first binder has a first glass transition temperature ranging from about 70° C. to about 90° C., and wherein the second binder has a second glass transition temperature that is less than the first glass transition temperature.

2. The catalysis composition of claim 1 , wherein the ultrasonic washcoat adhesion weight loss of the substrate is less than about 1.30%.

3. The catalysis composition of claim 1 , wherein the ultrasonic washcoat adhesion weight loss of the substrate is less than about 1.15%.

4. The catalysis composition of claim 1 , wherein a mass ratio of the first binder to the second binder ranges from about 0.75 to about 1.25.

5. The catalysis composition of claim 1 , wherein at least one of the first binder or second binder is a styrene acrylic binder.

6. The catalysis composition of claim 1 , wherein the first binder has a first glass transition temperature ranging from about 5° C. to about 20° C., and wherein the second binder has a second glass transition temperature that is greater than the first glass transition temperature.

7. The catalysis composition of claim 1 , wherein the first binder has a first glass transition temperature ranging from about 8° C. to about 15° C., and wherein the second binder has a second glass transition temperature that is greater than the first glass transition temperature.

8. The catalysis composition of claim 1 , wherein the first binder has a first glass transition temperature ranging from about 70° C. to about 90° C., and wherein the second binder has a second glass transition temperature that is less than the first glass transition temperature.

9. The catalysis composition of claim 1 , wherein the first binder has a first glass transition temperature ranging from about 75° C. to about 85° C., and wherein the second binder has a second glass transition temperature that is less than the first glass transition temperature.

10. The catalysis composition of claim 1 , wherein the first binder has a first glass transition temperature ranging from about 5° C. to about 20° C., and wherein the second binder has a second glass transition temperature ranging from about 70° C. to about 90° C.

11. The catalysis composition of claim 1 , wherein the first binder has a first glass transition temperature ranging from about 8° C. to about 15° C., and wherein the second binder has a second glass transition temperature ranging from about 75° C. to about 85° C.

12. The catalysis composition of claim 1 , wherein a first mass percent of the first binder within the catalysis composition is between about 4% and about 8%, and wherein a second mass percent of the second binder within the catalysis composition is between about 4% and about 8%.

13. The catalysis composition of claim 1 , wherein the support material comprises alumina.

14. The catalysis composition of claim 1 , wherein a surface area of the catalysis composition is from about 160 m 2 /g to about 200 m 2 /g.

15. The catalysis composition of claim 1 , wherein the manganese oxide catalyst is impregnated in the support material such that at least about 15% of a total number of metal atoms in the catalysis composition are detectable by surface x-ray photoelectron spectroscopy (XPS).

16. The catalysis composition of claim 1 , wherein a cumulative pore volume of the catalysis composition is from about 0.85 mL/g to about 2.0 mL/g.

17. The catalysis composition of claim 1 , wherein the manganese oxide catalyst comprises manganese oxide crystallites.

18. The catalysis composition of claim 1 , wherein the catalysis composition, when coated onto an automobile radiator, has a deactivation factor of at least 0.7, wherein the deactivation factor is the ratio of aged catalyst % ozone conversion to fresh catalyst % ozone conversion, wherein the aged % conversion is after exposure of the coated radiator to the equivalent of 150,000 miles driving time.

19. The catalysis composition of claim 1 , wherein the support material is selected from a group consisting of alumina, silica, and combinations thereof.

20. The catalyst composition of claim 1 , wherein at least 60% of the manganese oxide catalyst is in amorphous form.

21. The catalyst composition of claim 1 , wherein at least 75% of the manganese oxide catalyst is in amorphous form.

22. The catalyst composition of claim 1 , wherein at least 85% of the manganese oxide catalyst is in amorphous form.

23. A catalysis device comprising:
an automobile component; and
the catalysis composition of claim 1 , wherein the catalysis composition is coated onto the automobile component.

24. A method of preparing a catalysis device of claim 23 , comprising:
providing a slurry of the catalysis composition, and
coating the slurry onto the automobile component to produce a catalyst layer, wherein, after coating the slurry onto the component, an ultrasonic washcoat adhesion weight loss of the substrate is less than 1.60%, wherein
the weight loss is weight difference of the coated component after being immersed in deionized water and exposed to ultrasonic waves at 25 kHz and 500 Watts for 5 minutes and dried at 90° C.

25. The method of claim 24 , wherein coating the slurry onto the component comprises drying the slurry at a temperature ranging from about 80° C. to about 120° C. to produce the catalyst layer.

26. The method of claim 24 , wherein at least one of the first binder or the second binder is a styrene acrylic binder.

Assignees

• Basf Corp

Inventors

• Buelow Mark Thomas
• Chin Steven W
• Hoke Jeffrey Barmont
• Leclerc Nicholas R
• Robinson David M

Classifications

• B01J35/1061

  Operations & Transport · mapped topic

• B01D53/88

  Handling or mounting catalysts · CPC title

• B01J37/0201

  Impregnation · CPC title

• B01D2257/702

  Hydrocarbons · CPC title

• B01D2257/708

  Volatile organic compounds V.O.C.'s · CPC title