CATALYST COATINGS HAVING METAL OXIDE CRYSTALLITES
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 comprising manganese oxide, 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; and
a support material impregnated with the metal oxide catalyst.
2 . 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.
3 . The catalysis composition of claim 1 , wherein the at least one characteristic peak of the x-ray diffraction spectrum corresponds to crystallite domains having average diameters of less than about 20 nanometers.
4 . The catalysis composition of claim 1 , wherein the at least one characteristic peak comprises a pyrolusite peak and a bixbyite peak.
5 . The catalysis composition of claim 1 , wherein the at least one characteristic peak comprises a pyrolusite peak and a hausmannite peak.
6 . The catalysis composition of claim 1 , wherein the at least one characteristic peak comprises a bixbyite peak and a hausmannite peak.
7 . The catalysis composition of claim 1 , wherein the at least one characteristic peak comprises a bixbyite peak, a pyrolusite peak, and a hausmannite peak.
8 . The catalysis composition of claim 1 , 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).
9 . The catalysis composition of claim 1 , wherein the metal oxide catalyst was at least partially derived from a manganese acetate precursor.
10 . 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.
11 . The catalysis composition of claim 1 , wherein a surface area of the catalysis composition is at least about 160 m 2 /g.
12 . The catalysis composition of claim 1 , wherein a cumulative pore volume of the catalysis composition is greater than 0.70 mL/g.
13 . The catalysis composition of claim 1 , wherein a cumulative pore volume of the catalysis composition is greater than 0.80 mL/g.
14 . The catalysis composition of claim 1 , wherein an average pore radius of the catalysis composition ranges from about 6 nanometers to about 15 nanometers.
15 . 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.
16 . The catalysis composition of claim 1 , wherein 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.
17 . The catalysis composition of claim 1 , further comprising:
a first binder; and
a second binder.
18 . The catalysis composition of claim 17 , 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.
19 . 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.
20 . 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.
21 . 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.
22 . A catalysis device comprising:
an automobile component; and
the catalysis composition of claim 1 , wherein the catalysis composition is coated onto the automobile component.
23 . A method comprising:
providing a slurry of a catalysis composition, wherein the catalysis composition comprises:
a metal oxide catalyst; and
a support material impregnated with the metal oxide catalyst, 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; and
coating the slurry onto a substrate to produce a catalyst layer.
24 . The method of claim 23 , wherein the at least one characteristic peak comprises a pyrolusite peak and a bixbyite peak.
25 . The method of claim 23 , wherein the at least one characteristic peak comprises a pyrolusite peak and a hausmannite peak.
26 . The method of claim 23 , wherein the at least one characteristic peak comprises a bixbyite peak and a hausmannite peak.
27 . The method of claim 23 , wherein the at least one characteristic peak comprises a bixbyite peak, a pyrolusite peak, and a hausmannite peak.
28 . The method of claim 23 , wherein a surface area of the catalysis composition is at least about 160 m 2 /g.
29 . The method of claim 23 , 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 23 , 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.