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 micron-sized oxide particles and plasma-generated nano-particles, the nano-particles comprising nano-active material and a nano-support; and
wherein the nano-support comprises a partially reduced alumina surface configured to limit movement of the nano-active material and limit conglomeration of the nano-active material.
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. A cordierite substrate in a catalytic converter comprising:
a. a first type of nano-particles comprising a first nano-active material and a first nano-support, wherein the first nano-support comprises a partially reduced alumina surface configured to limit movement of the first nano-active material and limit conglomeration of the first nano-active material; and
b. a second type of nano-particles comprising a second nano-active material and a second nano-support.
7. The cordierite substrate of claim 6 , wherein the first nano-active material comprises platinum.
8. The cordierite substrate of claim 6 , wherein the second nano-active material comprises palladium.
9. The cordierite substrate of claim 6 , wherein the second nano-active material comprises rhodium.
10. The cordierite substrate of claim 6 , wherein the second nano-support is configured to limit movement of the second nano-active material and limit conglomeration of the second nano-active material.
11. The cordierite substrate of claim 10 , wherein the second nano-support comprises alumina.
12. The cordierite substrate of claim 10 , wherein second nano-support comprises a partially reduced alumina surface.
13. The cordierite substrate of claim 6 , further comprising a third type of nano-particles comprising a third nano-active material and a third nano-support.
14. The cordierite substrate of claim 13 , wherein the third nano-support is configured to limit movement of the third nano-active material and limit conglomeration of the third nano-active material.
15. The cordierite substrate of claim 13 , wherein the third nano-support comprises alumina.
16. The cordierite substrate of claim 13 , wherein the third nano-support comprises a partially reduced alumina surface.