Catalyst substrate having improved thermal durability
View Patent ↗A catalyst substrate comprises a substrate material having an inlet, an outlet, an opening therebetween to allow for the passage of exhaust gas therethrough, and further comprises a catalyst and a layer of zirconium phosphate. Catalyst substrates coated with zirconium phosphate exhibit improved thermal durability, improved thermal shock resistance, and improved alkali and acidic corrosion resistance.
1. A method for manufacturing a catalytic converter, comprising:
forming a catalyst substrate comprising a catalyst by applying a layer of zirconium phosphate to said catalyst;
disposing concentrically said catalyst substrate in a shell having an opening;
disposing concentrically a mat support material between said catalyst substrate and said shell, and around said catalyst substrate; and
securing an exhaust system component to at least one end of said shell;
wherein said applying further comprises reacting zirconium metal with phosphoric acid to form a solution, and dipping said catalyst into said solution.
2. The method according to claim 1 further comprising disposing on and/or throughout the catalyst a member selected from the group consisting of platinum, palladium, rhodium, iridium, osmium, ruthenium, oxides, mixtures and alloys thereof.
3. A method for manufacturing a catalyst substrate for use with a catalytic converter, comprising:
forming a catalyst substrate comprising a catalyst; and
applying a layer of zirconium phosphate to said catalyst, wherein said applying further comprises reacting zirconium metal with phosphoric acid to form a solution, and dipping said catalyst into said solution.
4. The method according to claim 3 further comprising disposing on and/or throughout the catalyst a member selected from the group consisting of platinum, palladium, rhodium, iridium, osmium, ruthenium, oxides, mixtures and alloys thereof.