CATALYST COATINGS FOR POLLUTION CONTROL
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 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.
2 . The catalysis composition of claim 1 , wherein the metal oxide catalyst is at least partially derived from a manganese acetate precursor.
3 . The catalysis composition of claim 1 , wherein the initial ozone concentration ranges from about 0.1 ppm to about 1.2 ppm.
4 . The catalysis composition of claim 1 , wherein a space velocity of the airstream ranges from about 200,000 hr −1 to about 800,000 hr −1 .
5 . The catalysis composition of claim 1 , wherein a temperature of the airstream is maintained within a range of about 70° C. to about 80° C.
6 . 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.
7 . The catalysis composition of claim 1 , wherein the substrate is 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.
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 is impregnated in the support material such that at least about 30% of a total number of metal atoms in the metal oxide catalyst are detectable by surface XPS.
10 . The catalysis composition of claim 1 , wherein the metal oxide catalyst is impregnated in the support material such that at least about 50% of a total number of metal atoms in the metal oxide catalyst are detectable by surface XPS.
11 . 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.
12 . The catalysis composition of claim 1 , wherein a cumulative pore volume of the catalysis composition is at least about 0.70 mL/g.
13 . The catalysis composition of claim 1 , wherein a cumulative pore volume of the catalysis composition is at least about 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 a surface area of the catalysis composition is at least about 160 m 2 /g.
16 . The catalysis composition of claim 1 , further comprising:
a first binder; and
a second binder.
17 . The catalysis composition of claim 16 , 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.
18 . 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%.
19 . The catalysis composition of claim 1 , wherein the catalysis composition, when coated onto the 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 91 , wherein the catalysis composition is coated onto the automobile component.
23 . A method comprising:
contacting a catalyst layer with an airstream, wherein:
the catalyst layer comprises a support material impregnated with a manganese oxide catalyst,
the airstream has an initial ozone concentration prior to contacting the catalyst layer, and
the airstream has a final ozone concentration after contact the catalyst layer, the final ozone concentration being reduced by greater than 30% of the initial ozone concentration.
24 . The method of claim 23 , wherein the catalyst layer comprises a metal oxide catalyst that is at least partially derived from a manganese acetate precursor.
25 . The method of claim 23 , wherein the catalyst layer is coated onto 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.
26 . The method of claim 25 , wherein the contacting of the catalyst layer with the airstream is performed by operating the automobile.
27 . The method of claim 23 , wherein the manganese 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.
28 . The method of claim 23 , wherein the catalyst layer has a deactivation factor of at least about 0.5.
29 . A catalysis composition comprising:
a catalyst; and
a support material impregnated with the catalyst, 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, and wherein the catalysis composition has a deactivation factor of at least about 0.5.
30 . A catalysis composition comprising:
a catalyst; and
a support material impregnated with the catalyst, 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, and wherein:
the initial ozone concentration ranges from about 0.1 ppm to about 1.2 ppm,
a space velocity of the airstream ranges from about 200,000 hr −1 to about 800,000 hr −1 , and
a temperature of the airstream is maintained within a range of about 70° C. to about 80° C.