COATED SUBSTRATES FOR USE IN CATALYSIS AND CATALYTIC CONVERTERS AND METHODS OF COATING SUBSTRATES WITH WASHCOAT COMPOSITIONS

摘要

Disclosed are, inter alia, methods of forming coated substrates for use in catalytic converters, as well as washcoat compositions and methods suitable for using in preparation of the coated substrates, and the coated substrates formed thereby. The catalytic material is prepared by a plasma-based method, yielding catalytic material with a lower tendency to migrate on support at high temperatures, and thus less prone to catalyst aging after prolonged use. Also disclosed are catalytic converters using the coated substrates, which have favorable properties as compared to catalytic converters using catalysts deposited on substrates using solution chemistry. Also disclosed are exhaust treatment systems, and vehicles, such as diesel vehicles, particularly light-duty diesel vehicles, using catalytic converters and exhaust treatment systems using the coated substrates.

主权项

1. A coated substrate comprising:
a substrate; a washcoat layer comprising zeolite particles; and a washcoat layer comprising catalytically active particles; wherein the catalytically active particles comprise plasma synthesized composite nano-particles bonded to micron-sized carrier particles, and the composite nano-particles comprise a support nano-particle and a catalytic nano-particle, the catalytic nano-particle comprising at least one platinum group metal.