Composite Catalyst Substrate Metallic Core Ceramic Coating

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing catalyst substrates face challenges in balancing structural support with efficiency, as ceramic substrates provide superior efficiency but inferior structural support, while metallic substrates lack surface properties, and current solutions risk catastrophic failure due to brittleness.

Innovation Solution

A composite catalyst substrate with a metallic core and a porous ceramic coating, along with a washcoat containing catalyst material, which is dispersed or coated on the ceramic coating, providing structural reinforcement and maintaining efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a ceramic substrate is used for catalyst support, then catalytic efficiency is improved, but structural strength deteriorates

Engineering Contradiction:

Improvecatalytic efficiencyVSAvoidstructural strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent employs a composite substrate structure consisting of a metallic core (stainless steel or Inconel) bonded to a ceramic coating (cordierite or silicon nitride). This composite construction combines the high structural strength and thermal stability of metals with the superior catalytic efficiency and porosity of ceramics, resolving the contradiction between strength and efficiency.

Inventive Principle:

Principle #40Composite materials

2Productivity

If a ceramic substrate is used for catalyst support, then catalytic efficiency is improved, but reliability deteriorates due to brittleness

Engineering Contradiction:

Improvecatalytic efficiencyVSAvoidresistance to catastrophic failure

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The metallic core-ceramic coating composite structure provides both the catalytic efficiency of ceramic and the reliability of metal. The ductile metallic core prevents catastrophic failure by absorbing thermal shocks and mechanical stresses that would cause brittle ceramic to crack or shatter, while the ceramic coating maintains high catalytic efficiency.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The metallic core acts as a cushioning layer that absorbs thermal and mechanical shocks before they can propagate through the ceramic structure. This pre-cushioning effect prevents the propagation of cracks and catastrophic failures in the ceramic coating during thermal cycling and engine operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Strength

If a metallic substrate is used for catalyst support, then structural strength is improved, but catalytic efficiency deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidcatalytic efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The composite substrate combines a metallic core that provides structural strength with a ceramic coating layer that provides the porous surface properties necessary for high catalytic efficiency. The metal-ceramic interface ensures both mechanical integrity and catalytic performance.

Inventive Principle:

Principle #40Composite materials

4Strength

If a ceramic coating is applied on metallic core, then strength is improved, but device complexity increases

Engineering Contradiction:

Improvestructural strengthVSAvoidsubstrate structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The substrate is constructed as a composite material system with a metallic core and a ceramic coating layer bonded together. This composite structure enhances strength while managing complexity through standardized manufacturing processes for creating metal-ceramic bonded substrates.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composite substrate offers enhanced structural support, preventing catastrophic failure and maintaining performance even if the ceramic coating cracks, while ensuring effective interaction with exhaust constituents.

Implementation Method 1

a porous ceramic coating on the metallic core

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 2

a washcoat substantially covering the ceramic coating and including a catalyst material configured to react with constituents in an exhaust flow

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS9009967B2Composite catalyst substrate

Publication Date: 2015.04.21 CATERPILLAR INC

AI summary

A composite catalyst substrate is provided, which may include a metallic core and a porous ceramic coating on the metallic core. The substrate may also include a washcoat substantially covering the ceramic coating and including a catalyst material configured to react with constituents in an exhaust flow of an exhaust producing engine. The catalyst material may be dispersed in, or coated on, the washcoat.