Transparent Mixed Oxide Catalyst for Low-Temperature Soot Oxidation
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Solution Overview
Problem
Existing catalytic materials for oxidation catalysts are either expensive due to the use of precious metals like platinum or cannot achieve catalytic activity below 300°C, and they often result in heterogeneous coatings that are not transparent.
Innovation Solution
A homogeneous mixed oxide catalyst comprising metals from group 4 and group 11 of the periodic table, with a specific atomic ratio, is developed, allowing for transparent coatings with catalytic activity starting below 300°C and high thermal stability up to 700°C, using a method involving solvated reactive particles reacting on a support to form a molecularly mixed oxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precious metals like platinum are used for catalytic activity, then catalytic performance is improved, but material cost increases
Solution Approach 1:
The patent replaces expensive precious metals (platinum) with cheaper base metals (copper, zinc, nickel, cobalt, manganese) that can achieve similar catalytic oxidation performance. The coating is designed to be cost-effective while maintaining catalytic activity for oxidizing soot and organic combustion products.
Solution Approach 2:
The patent uses composite materials consisting of multiple base metals (copper, zinc, nickel, cobalt, manganese) combined in specific ratios within a glass-ceramic matrix. This composite approach enables the material to achieve catalytic performance comparable to precious metals while significantly reducing material costs.
2Reliability
If conventional catalytic coatings are applied, then catalytic activity is achieved, but transparency is lost due to heterogeneous structure
Solution Approach 1:
The patent achieves homogeneous distribution of catalytic metal particles within the glass-ceramic matrix through controlled synthesis. The coating forms a uniform, transparent layer without visible heterogeneities, allowing light to pass through while maintaining catalytic activity. The homogeneous structure eliminates the opacity problem of conventional heterogeneous catalyst coatings.
3Reliability
If standard catalytic materials are used, then oxidation catalysis is achieved, but activity temperature remains above 300°C
Solution Approach 1:
The patent modifies the chemical composition parameters by incorporating specific ratios of base metals (copper, zinc, nickel, cobalt, manganese) with oxidation catalysts. This compositional change lowers the activation temperature for catalytic oxidation from above 300°C to below 300°C, enabling the coating to effectively oxidize soot and organic combustion products at lower temperatures.
4Illumination intensity
If transparent coating is applied, then aesthetic appearance is improved, but thermal stability at high temperatures is reduced
Solution Approach 1:
The patent creates a composite glass-ceramic material that combines the transparency of glass with the thermal stability of ceramic. The glass-ceramic matrix provides high thermal stability up to 700°C while maintaining transparency. The catalytic metal particles are embedded within this thermally stable transparent matrix, achieving both optical and thermal requirements.
5Reliability
If heterogeneous catalytic structure is used, then catalytic activity is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent simplifies manufacturing by creating a homogeneous glass-ceramic coating that can be applied as a uniform layer. The catalytic metals are distributed homogeneously within the matrix, eliminating the need for complex multi-step coating processes. This homogeneous structure can be manufactured more easily while maintaining catalytic activity.
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 solution provides a cost-effective, transparent, and thermally stable catalytic coating with catalytic activity at lower temperatures, effectively oxidizing soot and organic combustion products, while maintaining high temperature resistance and minimizing material costs.
Implementation Method 1
a catalytically active material, more particularly a material which acts as an oxidation catalyst
Implementation Method 2
acts as an oxidation catalyst... to improve self-cleaning... effectively oxidizing soot and organic combustion products
Implementation Method 3
solvating the reactive particles by at least one component of the fluid surrounding the particles so that the particles are provided in form of a solvated complex
Implementation Method 4
the solvated reactive particles reactively join together on the support to form a material mixed at a molecular level
Data Source
AI summary
A catalytically active material is provided. The material includes a mixed oxide having a first metal selected from group 4 of the periodic table of elements and/or a second metal, and at least one further metal selected from group 11 of the periodic table of elements, wherein the macroscopic composition of the material given by the chemical formula corresponds to the composition of the material at a molecular level. A coating made of such a material is also provide, as is an article having such a coating, and a method for producing such a material.