Advanced catalysts for automotive applications
Embodiments of present inventions are directed to an advanced catalyst. The advanced catalyst includes a honeycomb structure with an at least one nano-particle on the honeycomb structure. The advanced catalyst used in diesel engines is a two-way catalyst. The advanced catalyst used in gas engines is a three-way catalyst. In both the two-way catalyst and the three-way catalyst, the at least one nano-particle includes nano-active material and nano-support. The nano-support is typically alumina. In the two-way catalyst, the nano-active material is platinum. In the three-way catalyst, the nano-active material is platinum, palladium, rhodium, or an alloy. The alloy is of platinum, palladium, and rhodium.
1. A catalytic converter comprising:
a honeycomb structure; and
a washcoat layer on the honeycomb structure comprising nano-particles and micron sized oxide particles, wherein the nano-particles are plasma-generated;
wherein the nano-particles consist of a single nano-active material component and a single nano-support component.
2. The catalytic converter of claim 1 , wherein the nano-active material comprises platinum.
3. The catalytic converter of claim 1 , wherein the nano-active material comprises palladium.
4. The catalytic converter of claim 1 , wherein the nano-active material comprises rhodium.
5. The catalytic converter of claim 1 , wherein the nano-active material comprises an alloy.
6. The catalytic converter of claim 1 , wherein the nano-support comprises alumina.
7. The catalytic converter of claim 1 , wherein the nano-support comprises a partially reduced alumina surface.
8. The catalytic converter of claim 1 , wherein the micron sized oxide particles comprise alumina.
9. The catalytic converter of claim 1 , wherein the nano-active material comprises an alloy comprising platinum and palladium.
10. A cordierite substrate in a catalytic converter comprising:
a. a first type of plasma-generated nano-particles consisting of a single first nano-active material component and a single first nano-support component; and
b. a second type of plasma-generated nano-particles consisting of a single second nano-active material component and a single second nano-support component.
11. The cordierite substrate of claim 10 , wherein the first nano-active material comprises platinum.
12. The cordierite substrate of claim 10 , wherein the first nano-support comprises alumina.
13. The cordierite substrate of claim 10 , wherein the first nano-support comprises a partially reduced alumina surface.
14. The cordierite substrate of claim 10 , wherein the first type of nano-active material comprises palladium.
15. The cordierite substrate of claim 14 , wherein the first nano-support comprises alumina.
16. The cordierite substrate of claim 10 , wherein the second nano-support comprises a partially reduced alumina surface.
17. The cordierite substrate of claim 10 , wherein the second nano-active material comprises rhodium.
18. The cordierite substrate of claim 10 , wherein the second nano-support comprises alumina.
19. The cordierite substrate of claim 10 , wherein the third nano-support comprises a partially reduced alumina surface.
20. The cordierite substrate of claim 10 , wherein the first nano-active material comprises palladium, and the second nano-active material comprises rhodium.
21. The cordierite substrate of claim 10 , further comprising a third type of plasma-generated nano-particles comprising a third nano-active material and a third nano-support.
22. The cordierite substrate of claim 21 , wherein the first nano-active material comprises palladium, the second nano-active material comprises rhodium, and the third nano-active material comprises platinum.
23. The cordierite substrate of claim 21 , wherein the first nano-support and the second nano support comprise alumina.
24. A catalytic converter comprising:
a honeycomb structure;
oxidation nano-particles on the honeycomb structure, wherein the oxidation nano-particles comprise particles having a single oxidation nano-active material component and a single nano-support component; and
reduction nano-particles on the honeycomb structure, wherein the reduction nano-particles comprise particles having a single reduction nano-active material and a single nano-support component;
wherein the oxidation nano-particles and reduction nano-particles are plasma-generated.
25. The catalytic converter of claim 24 , wherein the oxidation nano-particles and reduction nano-particles are part of a washcoat layer formed on the honeycomb structure.
26. The catalytic converter of claim 24 , wherein the oxidation nano-particles are part of a first washcoat layer on the honeycomb structure and reduction nano-particles are part of a second washcoat layer formed on the honeycomb structure.
27. The catalytic converter of claim 24 , wherein the oxidation nano-active material comprises palladium.
28. The catalytic converter of claim 24 , wherein the oxidation nano-active material comprises platinum.
29. The catalytic converter of claim 24 , wherein the reduction nano-active material comprises rhodium.
30. The catalytic converter of claim 24 , wherein the nano support of the oxidation nano-particles comprises alumina.
31. The catalytic converter of claim 24 , further comprising micron sized oxide particles on the honeycomb structure.