Direct application of catalysts to substrates via a thermal spray process for treatment of the atmosphere
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B01J-023/00
B01J-023/72
B01J-023/48
B05D-001/08
C23C-004/10
출원번호
US-0263269
(2002-10-02)
§371/§102 date
20030606
(20030606)
발명자
/ 주소
Smith, John R.
Sultan, Michel Farid
Wu, Ming-Cheng
Zhao, Zhibo
Gillispie, Bryan A.
출원인 / 주소
Delphi Technologies, Inc.
인용정보
피인용 횟수 :
1인용 특허 :
56
초록▼
Disclosed is a method for direct application of a catalyst to a substrate for treatment of atmospheric pollution including ozone. The method includes applying a catalytic metal to a substrate utilizing a thermal spray process. The process can be utilized to apply a base metal such as copper to a sub
Disclosed is a method for direct application of a catalyst to a substrate for treatment of atmospheric pollution including ozone. The method includes applying a catalytic metal to a substrate utilizing a thermal spray process. The process can be utilized to apply a base metal such as copper to a substrate and the base metal becomes the catalytically active oxide during and following application to the substrate. This system replaces a multi-step process within a single step process to provide a catalytically active surface that can be utilized to reduce ground level ozone and other atmospheric pollutants.
대표청구항▼
1. A method of forming a catalytically active surface on a substrate for treatment of atmospheric pollution comprising the steps of:a) providing a feedstock of at least one catalytic metal to a thermal spray system, said thermal spray system forming a molten catalytic metal; b) applying said molten
1. A method of forming a catalytically active surface on a substrate for treatment of atmospheric pollution comprising the steps of:a) providing a feedstock of at least one catalytic metal to a thermal spray system, said thermal spray system forming a molten catalytic metal; b) applying said molten catalytic metal from said thermal spray system directly onto a substrate material surface, said molten catalytic metal forming a direct bond to said substrate and forming a catalytically active layer on said substrate material surface, wherein said catalytically active layer is capable of catalyzing the conversion of at least one of ozone, hydrocarbons, or carbon monoxide to oxygen, water, and carbon dioxide, respectively, and wherein said surface and said substrate material are free from binders of said molten catalytic metal. 2. The method of claim 1, wherein step a) comprises providing a catalytic metal comprising copper, manganese, nickel, iron, chromium, zinc, palladium, platinum, rhodium, ruthenium, silver, gold, or mixtures thereof.3. The method of claim 1, wherein step a) comprises providing a catalytic metal comprising an oxide of copper, an oxide of manganese, an oxide of nickel, an oxide of iron, an oxide of chromium, an oxide of zinc, an oxide of palladium, an oxide of platinum, an oxide of rhodium, an oxide of ruthenium, an oxide of silver, an oxide of gold, or mixtures thereof.4. The method of claim 1, wherein step a) comprises providing said feedstock as a powder having a nominal diameter of from 5.0 to 250.0 microns.5. The method of claim 1, wherein step a) comprises providing said feedstock as a powder having a nominal diameter of from 15.0 to 120.0 microns.6. The method of claim 1, wherein step a) comprises providing said feedstock as a powder having a nominal diameter of from 25.0 to 75.0 microns.7. The method of claim 1, wherein step a) comprises providing said feedstock as a plurality of wires each having a diameter of from 1/16 to 4/16 of an inch and wherein said thermal spray system is a twin wire arc thermal spray system.8. The method of claim 1, wherein step b) comprises applying said molten catalytic metal to a thickness of from 10.0 to 50.0 microns onto said substrate material surface.9. The method of claim 1, where in step a) said thermal spray system heats said feedstock to a temperature of from 0.0 to 400.0 degrees Celsius above the melting point of the feedstock to form said molten catalytic metal.10. The method of claim 1, where in step a) said thermal spray system heats said feedstock to a temperature of from 0.0 to 250.0 degrees Celsius above the melting point of the feedstock to form said molten catalytic metal.11. The method of claim 1, where in step a) said thermal spray system heats said feedstock to a temperature of from 0.0 to 100.0 degrees Celsius above the melting point of the feedstock to form said molten catalytic metal.12. The method of claim 1, further comprising after step b) a step of maintaining said substrate with said catalytically active layer at a temperature of from 300 to 1100 degrees Celsius for a period of from 20 minutes to 2 hours in an atmosphere comprising air.13. The method of claim 1, wherein step b) comprises applying said molten catalytic metal to said substrate material surface at an angle of from 0.0 to 80.0 degrees, said angle measured relative to a line drawn normal to said substrate material surface.14. The method of claim 1, wherein step b) comprises applying said molten catalytic metal to said substrate material surface at an angle of from 0.0 to 50.0 degrees, said angle measured relative to a line drawn normal to said substrate material surface.15. The method of claim 1, wherein step b) comprises applying said molten catalytic metal to said substrate material surface at an angle of from 0.0 to 30.0 degrees, said angle measured relative to a line drawn normal to said substrate material surface.16. The method of claim 1, wherein step b) comprises applying said molten catalytic metal to said substrate material surface from a stand off distance of from 10.0 to 500.0 millimeters.17. The method of claim 1, wherein step b) comprises applying said molten catalytic metal to said substrate material surface from a stand-off distance of from 30.0 to 100.0 millimeters.18. The method of claim 1, wherein step b) comprises applying said molten catalytic metal to said substrate material surface from a stand-off distance of from 30.0 to 80.0 millimeters.19. The method of claim 1, wherein step b) comprises accelerating said molten catalytic metal to a velocity of from 50.0 to 900.0 meters per second to apply said molten catalytic metal to said substrate material surface.20. The method of claim 1, wherein step b) comprises accelerating said molten catalytic metal to a velocity of from 200.0 to 900.0 meters per second to apply said molten catalytic metal to said substrate material surface.21. The method of claim 1, wherein step b) comprises accelerating said molten catalytic metal to a velocity of from 400.0 to 600.0 meters per second to apply said molten catalytic metal to said substrate material surface.22. The method of claim 1, wherein step a) comprises providing said feedstock to said thermal spray system at a rate of from 0.1 to 4.0 grams per second.23. The method of claim 1, wherein step a) comprises providing said feedstock to said thermal spray system at a rate of from 0.4 to 2.0 grams per second.24. The method of claim 1, wherein step a) comprises providing said feedstock to said thermal spray system at a rate of from 0.5 to 1.0 grams per second.25. The method of claim 1, wherein step a) comprises providing a high-velocity oxyfuel thermal spray system as said thermal spray system.26. The method of claim 1, wherein step a) comprises providing a plasma thermal spray system as said thermal spray system.27. The method of claim 26, wherein step b) comprises applying said molten catalytic metal to said substrate material surface using argon as the primary gas.28. The method of claim 26, wherein step b) comprises providing helium as the secondary gas at a level of from 0.0 to 80.0 percent by volume.29. The method of claim 26, wherein step b) comprises providing helium as the secondary gas at a level of from 0.0 to 70.0 percent by volume.30. The method of claim 26, wherein step b) comprises providing helium as the secondary gas at a level of from 0.0 to 50.0 percent by volume.31. The method of claim 1, wherein step b) comprises applying the molten catalytic metal to one of a radiator fin stock or a radiator core as said substrate material surface.32. The method of claim 31, further comprising after step b) a step of maintaining said substrate with said catalytically active layer at a temperature of from 300 to 1100 degrees Celsius for a period of from 20 minutes to 2 hours in an atmosphere comprising air.33. The method of claim 1, wherein step a) comprises providing a catalytic metal comprising copper, manganese, nickel, iron, chromium, zinc, palladium, platinum, rhodium, ruthenium, silver, gold, an oxide of copper, an oxide of manganese, an oxide of nickel, an oxide of iron, an oxide of chromium, an oxide of zinc, an oxide of palladium, an oxide of platinum, an oxide of rhodium, an oxide of ruthenium, an oxide of silver, an oxide of gold, or mixtures thereof.
Ballinger, Robert S.; Disser, Robert J.; Drennen, David B.; Hewer, Thomas D.; Hickey, Gregory M.; Klode, Harald; Mescher, Patrick A., Disk brake mounting bracket and high gain torque sensor.
Marantz Daniel R. (Sands Point NY) Marantz David R. (Sands Point NY) Kowalsky Keith A. (Merrick NY), High velocity electric-arc spray apparatus and method of forming materials.
Carl Elmer Miller ; Bruno Depreter ; Haskell Simpkins ; Jean Joseph Botti, Integrated fuel reformation and thermal management system for solid oxide fuel cell systems.
Pinkerton Frederick Eugene ; Herbst Jan Francis ; Capehart Tenneille Weston ; Murphy Charles Bernard ; Brewer Earl George, Magnetostrictive composites.
Pinkerton Frederick Eugene ; Herbst Jan Francis ; Capehart Tenneille Weston ; Perry Thomas Arthur ; Meyer Martin Stephen, Magnetostrictive torque sensor utilizing RFe.sub.2 -based composite materials.
Lenling William J. (Madison WI) Henfling Joseph A. (Bosque Farms NM) Smith Mark F. (Albuquerque NM), Method for minimizing decarburization and other high temperature oxygen reactions in a plasma sprayed material.
Korotkikh, Olga; Farrauto, Robert J.; McFarland, Andrew, Method for preparation of catalytic material for selective oxidation and catalyst members thereof.
Gorynin Igor V. (Leningrad SUX) Farmakovsky Boris V. (Leningrad SUX) Khinsky Alexander P. (Leningrad SUX) Kalogina Karina V. (Leningrad SUX) Riviere Alfredo V. (Caracas MA VEX) Szekely Julian (Weston, Method for the production of compositionally graded coatings by plasma spraying powders.
Frederick Eugene Pinkerton ; Thomas Hubert Van Steenkiste ; Jerome Joseph Moleski ; Martin Stephen Meyer, Method of forming a magnetostrictive composite coating.
Nelson, David Emil; Li, Bob Xiaobin; Hemingway, Mark David; Herling, Darrell R.; Baskaran, Suresh, Non-thermal plasma reactor design and single structural dielectric barrier.
Alasafi Kaldoun (Schwaebisch Gmuend DEX) Buehl Horst (Weinstadt DEX) Gutoehrlein Ralf (Fellbach DEX) Schiessle Edmund (Schorndorf DEX), Sensor for non-contact torque measurement on a shaft as well as a measurement layer for such a sensor.
Sugihara Tadashi (Saitama-ken JPX) Yoshida Kazushi (Saitama-ken JPX) Inoue Kazutoshi (Tiba-ken JPX) Yang Ji-bin (Niigata-ken JPX) Suzuki Isao (Saitama-ken JPX), Shaft having a magnetostrictive torque sensor and a method for making same.
Simpkins, Haskell; Thomas, Stephen M.; Labarge, William J., Solid oxide fuel cell having a monolithic heat exchanger and method for managing thermal energy flow of the fuel cell.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.