Nanoporous Metal Oxide Catalyst Support Adhesion
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Solution Overview
Problem
Conventional metal oxide powders used in catalysts face challenges with adhesion to substrates, particularly metallic honeycomb filters and high-density honeycombs, and limitations in reforming performance, especially in hydrogen production reactions.
Innovation Solution
A catalyst support is developed with a nanoporous metal oxide matrix, created by mixing metal oxide powders with colloidal or salt solutions at high shear rates and rapid drying, resulting in improved adhesion and reforming performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional metal oxide powder obtained by wet grinding method is used, then the powder can be easily manufactured, but adhesion to substrates (especially metal substrates) is insufficient
Solution Approach 1:
The patent changes the particle size parameter of metal oxide powder to nanometer scale (1-100 nm), which fundamentally alters the surface properties and adhesion characteristics. This parameter change enables both easy manufacture through colloidal processing and high adhesion to substrates, resolving the technical contradiction between ease of manufacture and adhesion reliability.
Solution Approach 2:
The patent introduces nanoporous metal oxide materials with controlled pore structures (pore size 0.1-10 nm) as the support medium. These porous materials provide high surface area and enhanced adhesion properties while maintaining ease of manufacture through colloidal deposition methods, thus resolving the contradiction between manufacturing simplicity and adhesion performance.
2Device complexity
If conventional metal oxide powder is used, then the manufacturing process is simple, but formation of thin film coating on substrate is limited
Solution Approach 1:
By changing the particle size parameter to nanometer scale and controlling the colloidal concentration, the patent enables precise control of coating thickness while maintaining process simplicity. The nanoscale particles can form uniform thin films through controlled deposition, resolving the contradiction between process complexity and coating precision.
Solution Approach 2:
The patent applies colloidal metal oxide solutions that can be locally controlled in concentration and deposition conditions, enabling precise control of coating thickness and uniformity. This local quality control allows formation of thin film coatings with precise thickness control while keeping the overall process simple.
3Quantity of substance
If conventional metal oxide powder is used, then the coating can be formed, but high density honeycombs with microchannels equal to or greater than 1200 cell/inch2 cannot be effectively supported
Solution Approach 1:
The patent changes the particle size parameter to nanometer scale, which enables the metal oxide powder to effectively coat high density honeycombs with microchannels (≥1200 cell/inch2). The nanoscale particles can access and uniformly coat the narrow channels of high density substrates, resolving the contradiction between coating coverage and coating uniformity on high density structures.
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 catalyst supports exhibit high adhesion to various substrates and significantly enhance reforming performances in hydrogen production reactions, overcoming previous limitations.
Implementation Method 1
when colloidal solutions of metal oxides or metal salt solutions are mixed at a high shear rate and used preferably after rapid drying, obtained metal oxides are surprisingly novel having nanopores with diameters of 10 nm or less
Implementation Method 2
when colloidal solutions of metal oxides or metal salt solutions are mixed at a high shear rate and used preferably after rapid drying, obtained metal oxides are surprisingly novel having nanopores with diameters of 10 nm or less
Implementation Method 3
obtained metal oxides are surprisingly novel having nanopores with diameters of 10 nm or less
Implementation Method 4
By making substrates support metal oxide powder by the use of such a metal oxide as matrix, high adhesion to various substrates is achieved
Data Source
AI summary
A method of producing a catalyst support comprising a substrate, and coating formed on the surface of the substrate and including powder of a first metal oxide of at least one member selected from the group consisting of alumina, zirconia, titania, iron oxides, oxides of rare earth elements, alkali metal oxides and alkali earth metal oxides, wherein the coating is obtained by heat treating the substrate after applied with a coating composition obtained by mixing the first metal oxide powder together with a fluid raw material composition containing raw material of a second metal oxide of at least one member selected from the group consisting of alumina, zirconia, titania, iron oxides, oxides of rare earth elements, alkali metal oxides and alkali earth metal oxides, at a shear rate of 1000 sec−1 or higher.