Substrate and a method of manufacturing a substrate
A catalytic convertor comprising a substrate body ( 100 ) arranged within the catalytic convertor such that a principal flow of fluid through the catalytic convertor flows along a surface ( 101 ) of the substrate body, wherein said surface ( 101 ) has a plurality of openings ( 210 ) to micro-channels that extend away from said surface ( 101 ); and at least a portion of the surface ( 101 ) of the substrate body ( 100 ) comprises a catalytically active material, wherein the substrate body ( 100 ) is in the form of: a pellet; a sheet; solid elongate bodies; solid rods; a solid body having a plurality of bores; a non-tubular elongate body; a non-hollow body; a sheet curved in the form or a spiral; or a combination thereof.
1. A method of manufacturing a substrate having a plurality of micro-channels formed therein, the method comprising:
providing a suspension containing a substrate material in particulate form and a polymer in a first solvent;
introducing the suspension into a mould or extruding the suspension;
contacting the suspension with a second solvent to remove at least some of the first solvent from the suspension and thereby form a green body having micro-channels from said substrate material and said polymer; and
removing at least a portion of a surface layer of said green body to uncover a plurality of micro-channel openings in the outer surface of the green body, the openings having diameters falling in the range 5 μm to 200 μm; and
sintering the green body at a temperature from 1200 to 1600° C.
2. The method of claim 1 , wherein the step of removing at least a portion of a surface layer of material is carried out using a blade.
3. The method of claim 1 , wherein the step of removing at least a portion of a surface layer of material is carried out using an abrasive.
4. The method of claim 1 , wherein the step of removing at least a portion of a surface layer of material is carried out by sanding.
5. The method of claim 1 , wherein the mould is shaped such that the green body forms a sheet material.
6. The method of claim 1 , wherein the mould is shaped to form a sheet of material having at least one protrusion extending from a major surface thereof.
7. The method of claim 1 , wherein the suspension comprises a catalytically active material.
8. The method of claim 1 , further comprising coating at least a portion of the substrate with a catalytically active coating.
9. The method of claim 1 , wherein the substrate material includes at least one member selected from the group consisting of: a ceramic, cordierite, zirconia, yttrium-stabilized zirconia, titania, silicon carbide, clay, alumina, stainless steel, FeCr alloys, alloys of iron, alloys of aluminum, aluminum titanate, or sintered metals.
10. The method of claim 1 , wherein selecting the polymer from the group consisting of polyether sulfone, polysulphone, cellulose and derivatives thereof, polyethermide, polyimide and derivatives thereof.
11. A method of manufacturing a substrate having a plurality of micro-channels formed therein, the method comprising:
providing a suspension containing a substrate material in particulate form and a polymer in a first solvent;
introducing the suspension into a mould or extruding the suspension;
contacting the suspension with a second solvent to remove at least some of the first solvent from the suspension and thereby form a green body having micro-channels from said substrate material and said polymer;
sintering the green body at a temperature from 1200 to 1600° C. to form a sintered body; and
removing at least a portion of a surface layer of said sintered body to uncover a plurality of micro-channel openings in the outer surface of the sintered body, the openings having diameters falling in the range 5 μm to 200 μm.
12. The method of claim 11 , further comprising removing at least a portion of a surface layer of said green body.
13. The method of claim 11 , wherein the step of removing at least a portion of a surface layer of material is carried out using an abrasive.
14. The method of claim 11 , wherein the step of removing at least a portion of a surface layer of material is carried out by sanding.
15. The method of claim 11 , wherein the step of removing at least a portion of a surface layer of material is carried out by contacting the surface of the sintered body with acidic solution or alkaline solution.
16. The method of claim 11 , wherein the mould is shaped such that the green body forms a sheet material.
17. The method of claim 11 , wherein the mould is shaped to form a sheet of material having at least one protrusion extending from a major surface thereof.
18. The method of claim 11 , wherein the suspension comprises a catalytically active material.
19. The method of claim 11 , further comprising coating at least a portion of the substrate with a catalytically active coating.
20. The method of claim 11 , wherein the substrate material includes at least one member selected from the group consisting of: a ceramic, cordierite, zirconia, yttrium-stabilized zirconia, titania, silicon carbide, clay, alumina, stainless steel, FeCr alloys, alloys of iron, alloys of aluminum, aluminum titanate, or sintered metals.
21. The method of claim 11 , wherein selecting the polymer from the group consisting of polyether sulfone, polysulphone, cellulose and derivatives thereof, polyethermide, polyimide and derivatives thereof.
22. The method of claim 19 , wherein the substrate material includes at least one member selected from the group consisting of: a ceramic, cordierite, zirconia, yttrium-stabilized zirconia, titania, silicon carbide, clay, alumina, stainless steel, FeCr alloys, alloys of iron, alloys of aluminum, aluminum titanate, or sintered metals.
23. The method of claim 19 , wherein selecting the polymer from the group consisting of polyether sulfone, polysulphone, cellulose and derivatives thereof, polyethermide, polyimide and derivatives thereof.
24. A method of manufacturing a catalytic convertor substrate having a plurality of micro-channels formed therein, the method comprising:
providing a suspension containing a substrate material in particulate form and a polymer in a first solvent;
introducing the suspension into a mould or extruding the suspension;
contacting the suspension with a second solvent to remove at least some of the first solvent from the suspension and thereby form a green body having micro-channels from said substrate material and said polymer;
removing at least a portion of a surface layer of said green body to uncover a plurality of micro-channel openings in the outer surface of the green body, the openings having diameters falling in the range 5 μm to 200 μm; and
sintering the green body at a temperature from 1200 to 1600° C.
25. The method of claim 24 , wherein the substrate material includes at least one member selected from the group consisting of: a ceramic, cordierite, zirconia, yttrium-stabilized zirconia, titania, silicon carbide, clay, alumina, stainless steel, FeCr alloys, alloys of iron, alloys of aluminum, aluminum titanate, or sintered metals.
26. The method of claim 24 , wherein selecting the polymer from the group consisting of polyether sulfone, polysulphone, cellulose and derivatives thereof, polyethermide, polyimide and derivatives thereof.
27. A method of manufacturing a catalytic convertor substrate having a plurality of micro-channels formed therein, the method comprising:
providing a suspension containing a substrate material in particulate form and a polymer in a first solvent;
introducing the suspension into a mould or extruding the suspension;
contacting the suspension with a second solvent to remove at least some of the first solvent from the suspension and thereby form a green body having micro-channels from said substrate material and said polymer;
sintering the green body at a temperature from 1200 to 1600° C. to form a sintered body; and
removing at least a portion of a surface layer of said sintered body to uncover a plurality of micro-channel openings in the outer surface of the sintered body, the openings having diameters falling in the range 5 μm to 200 μm.