Multilayer Catalyst Washcoat for Substrate Adhesion
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Solution Overview
Problem
Current methods for applying catalysts to substrates often result in incompatibilities between the catalyst material and the substrate, leading to loss of catalyst dispersion and catalytic activity due to inadequate bonding, which limits the effectiveness of supported catalyst systems in industrial applications.
Innovation Solution
The use of multilayered catalyst supports, where a first washcoat with a soluble salt species and insoluble particulate material is applied to the substrate, followed by a second washcoat containing an oxide or oxide-supported catalyst, allowing for physisorption, chemisorption, or bonding to enhance catalyst adhesion and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single washcoat method is used to apply catalyst to substrate, then the manufacturing process is simple, but the bonding capability between catalyst and substrate is insufficient leading to loss of catalyst dispersion and activity
Solution Approach 1:
The single washcoat application is segmented into two distinct washcoat steps: a first washcoat that provides bonding capability to the substrate, and a second washcoat that provides catalytic activity. This segmentation allows each washcoat to be optimized for its specific function, resolving the contradiction between manufacturing simplicity and bonding reliability.
Solution Approach 2:
The first washcoat acts as an intermediary layer between the substrate and the second washcoat containing the catalyst. This intermediate layer enhances the bonding capability between the catalyst and substrate, preventing catalyst loss while maintaining a relatively simple two-step manufacturing process.
2Device complexity
If catalyst is applied directly to substrate without washcoat, then the manufacturing process is simpler, but there is incompatibility between catalyst material and substrate leading to poor adhesion
Solution Approach 1:
The first washcoat serves as an intermediary layer that is compatible with both the substrate and the second washcoat. This intermediate layer resolves the incompatibility between catalyst material and substrate, providing strong adhesion without significantly increasing manufacturing complexity.
Solution Approach 2:
The catalyst system uses a composite structure with two different washcoat materials: the first washcoat optimized for substrate bonding and the second washcoat optimized for catalytic function. This composite approach ensures strong adhesion while maintaining reasonable manufacturing complexity.
3Device complexity
If traditional single-layer catalyst support is used, then the structure is simple, but the catalyst dispersion is lost over time reducing catalytic activity
Solution Approach 1:
The single-layer support structure is segmented into two functional layers: the first washcoat layer that anchors the catalyst and prevents dispersion loss, and the second washcoat layer that maintains catalytic activity. This segmented structure preserves catalytic activity over time while keeping the overall support structure relatively simple.
Solution Approach 2:
The first washcoat is applied in advance to create a bonding layer on the substrate before applying the catalyst-containing second washcoat. This preliminary action ensures strong anchoring of the catalyst, preventing dispersion loss and maintaining catalytic activity duration.
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
This approach improves catalyst dispersion and maintains catalytic activity by enabling separate processing of the substrate and catalyst, overcoming previous limitations in bonding and substrate compatibility, thereby enhancing the performance of supported catalyst systems in industrial applications.
Implementation Method 1
contacting the first washcoat with a substrate to form a coated substrate
Implementation Method 2
contacting the coated substrate with a second washcoat comprising an oxide or an oxide-supported catalyst to physisorb, chemisorb, bond, or otherwise adhere the oxide or the oxide-supported catalyst to the coated substrate
Implementation Method 3
contacting the coated substrate with a second washcoat comprising an oxide or an oxide-supported catalyst to physisorb, chemisorb, bond, or otherwise adhere the oxide or the oxide-supported catalyst to the coated substrate
Data Source
AI summary
A method for providing a catalyst on a substrate is disclosed comprising providing a first washcoat comprising a soluble washcoat salt species, a polar organic solvent, and an insoluble particulate material, contacting the first washcoat with a substrate to form a coated substrate, and then contacting the coated substrate with a second washcoat comprising an oxide or an oxide-supported catalyst to physisorb, chemisorb, bond, or otherwise adhere the oxide or the oxide-supported catalyst to the coated substrate. Also disclosed is a catalyst on a substrate comprising: a substrate; an anchor layer comprising a soluble washcoat salt species, a polar organic solvent, and an insoluble particulate material; and a second layer comprising an oxide. The catalyst on a substrate can be in either green or fired form.