Open mesh, random fiber, ceramic structure, monolithic catalyst support

摘要

The present invention provides a novel cellular ceramic catalyst support. The support consists of a random-fiber ceramic framework having a high surface area. The support is fabricated by flocking an organic sponge with wood or textile fibers, and impregnating the flocked sponge with a high alumina slurry containing a silicone resin and a flux. The impregnated organic sponge is sintered at a high temperature to burn out the organic sponge material. A fired high-silica glaze can be applied to the sintered article, followed by a second sintering step. A second glaze containing from 10-25 parts by weight CuO and from 10-25 parts by weight ZrO2, can be applied, followed by a 2000 DEG F. sintering step. The high temperature causes recrystallization of the CuO onto the surface of the catalyst support thereby increasing the surface area. The glazed surface can be plated with copper or nickel and combinations thereof to function as a reducing unit in a catalytic converter. In addition, other reduction catalysts and oxidation catalysts, e.g., platinum are compatible with the support.