HIGHLY DISPERSED METAL OXIDE CATALYST COATINGS
Disclosed in certain implementations is a catalysis composition that includes a metal catalyst and a support material impregnated with the metal catalyst.
1 . A catalysis composition comprising:
a metal oxide catalyst; and
a support material impregnated with the metal oxide catalyst, wherein the metal oxide catalyst is impregnated in the support material such that at least about 15% of a total number of metal atoms in the metal oxide catalyst are detectable by surface X-ray photoelectron spectroscopy (XPS).
2 . The catalysis composition of claim 1 , wherein the metal oxide catalyst is impregnated in the support material such that at least about 30% of the total number of the metal atoms in the metal oxide catalyst are detectable by surface XPS.
3 . The catalysis composition of claim 1 , wherein the metal oxide catalyst is impregnated in the support material such that at least about 50% of the total number of the metal atoms in the metal oxide catalyst are detectable by surface XPS.
4 . The catalysis composition of claim 1 , wherein all atoms detectable by surface XPS are within about 10 nanometers from a surface of the catalysis composition at which the surface XPS is performed.
5 . The catalysis composition of claim 1 , wherein the metal oxide catalyst is impregnated in the support material in an amount ranging from about 5% to about 30% by mass, about 10% to about 25% by mass, or about 12% to about 18% by mass.
6 . The catalysis composition of claim 1 , wherein a cumulative pore volume of the catalysis composition is at least about 0.70 mL/g.
7 . The catalysis composition of claim 1 , wherein a cumulative pore volume of the catalysis composition is at least about 0.80 mL/g.
8 . The catalysis composition of claim 1 , wherein the metal atoms are manganese atoms.
9 . The catalysis composition of claim 1 , wherein the metal oxide catalyst comprises at least one of Mn 3 O 4 crystallites or MnO crystallites.
10 . The catalysis composition of claim 1 , wherein the catalysis composition, when coated onto a substrate and contacted with an airstream having an initial ozone concentration, is adapted to convert ozone within the airstream such that a final ozone concentration of the airstream is reduced by greater than 30% of the initial ozone concentration after the catalysis composition is contacted with the airstream.
11 . The catalysis composition of claim 1 , wherein the metal oxide catalyst is at least partially derived from a manganese acetate precursor.
12 . The catalysis composition of claim 1 , wherein the catalysis composition is coated onto an automobile component selected from a group consisting of vehicle paint, a wheel well, a bumper, an air conditioning component, a grille, a fan, a fan blade, a shroud, a shutter, a turbo intercooler, a gear box cooler, a battery cooler, a front end component, a radiator, and a hood liner.
13 . The catalysis composition of claim 1 , wherein an x-ray diffraction spectrum of the catalysis composition comprises at least one characteristic peak comprising at least one of a manganosite peak, pyrolusite peak, a bixbyite peak, or a hausmannite peak.
14 . The catalysis composition of claim 1 , further comprising:
a first binder; and
a second binder.
15 . The catalysis composition of claim 14 , wherein the first binder is a styrene acrylic binder having a first glass transition temperature ranging from about 5° C. to about 20° C., and wherein the second binder is a styrene acrylic binder having a second glass transition temperature ranging from about 70° C. to about 90° C.
16 . The catalysis composition of claim 1 , wherein, after coating the catalysis composition onto a substrate, an ultrasonic washcoat adhesion weight loss of the substrate is less than 1.60%.
17 . The catalysis composition of claim 1 , wherein a surface area of the catalysis composition is at least about 160 m 2 /g.
18 . The catalysis composition of claim 1 , wherein the catalysis composition, when coated onto a substrate, has a deactivation factor of at least about 0.5.
19 . The catalysis composition of claim 1 , wherein the metal oxide catalyst comprises a base metal oxide selected from a group consisting of iron, copper, chromium, zinc, manganese, cobalt, nickel, compounds containing the same, and combinations thereof.
20 . The catalysis composition of claim 1 , 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.
21 . A catalysis device comprising:
an automobile component; and
the catalysis composition of claim 1 , wherein the catalysis composition is coated onto the automobile component.
22 . A method comprising:
providing a slurry of a catalysis composition, wherein the catalysis composition comprises:
a metal oxide catalyst;
a support material impregnated with the metal oxide catalyst, wherein the metal oxide catalyst is impregnated in the support material such that at least about 15% of a total number of metal atoms in the metal oxide catalyst are detectable by surface XPS; and
coating the slurry onto a substrate to produce a catalyst layer.
23 . The method of claim 22 , wherein the metal oxide catalyst is impregnated in the support material such that at least about 30% of the total number of the metal atoms in the metal oxide catalyst are detectable by surface XPS.
24 . The method of claim 22 , wherein the metal oxide catalyst is impregnated in the support material such that at least about 50% of the total number of the metal atoms in the metal oxide catalyst are detectable by surface XPS.
25 . The method of claim 22 , wherein all atoms detectable by surface XPS are within about 10 nanometers from a surface of the catalysis composition at which the surface XPS is performed.
26 . The method of claim 22 , wherein a cumulative pore volume of the catalysis composition is at least about 0.70 mL/g.
27 . The method of claim 22 , wherein a cumulative pore volume of the catalysis composition is at least about 0.80 mL/g.
28 . The method of claim 22 , wherein a surface area of the catalysis composition is at least about 160 m 2 /g.
29 . The method of claim 22 , wherein coating the slurry onto the substrate comprises drying the slurry at a temperature ranging from about 80° C. to about 120° C. to produce the catalyst layer.
30 . The method of claim 22 , wherein the substrate is a component of an automobile, and wherein the component is selected from a group consisting of vehicle paint, a wheel well, a bumper, an air conditioning component, a grille, a fan, a fan blade, a shroud, a shutter, a turbo intercooler, a gear box cooler, a battery cooler, a front end component, a radiator, and a hood liner.