Sdcmaterials, Inc.

Umicore Ag & Co Kg

David Leamon

Maximilian A Biberger

Qinghua Yin

Xiwang Qi

Frederick P Layman

Bryant Kearl

Eliseo Ruiz

The present disclosure relates to micron-sized particle used for catalyzing and storing NOgases, such as those found in vehicle exhaust emissions, washcoats employing micron-sized particle used for catalyzing and storing NOgases, washcoat coated substrates, lean NOtrap (LNT) systems, and vehicles using such systems. Also provided are methods of preparing micron-sized particle used for catalyzing and storing NOgases, as well as preparation of washcoats and coated substrates. More specifically, the present disclosure relates to a lean NOtrapping materials, wherein the materials include a NOcatalytic component attached to a micron-sized carrier particle and a NOstorage component, as well as washcoats and coated substrates useful in the treatment of exhaust gases. In some embodiments, a portion of the NOstorage component is attached to the micron-sized carrier particle.

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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, which in some cases use iron-exchanged zeolite particles that provide enhanced performance such as lower light-off temperatures and lower pollutant levels in exhaust gases. 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.

Washcoats and coated substrates for catalytic converters and methods of making and using same

The present disclosure relates to a substrate comprising nanoparticle catalysts and NOstorage materials for treatment of gases, and washcoats for use in preparing such a substrate. Also provided are methods of preparation of the nanoparticle catalysts and NOstorage materials, as well as methods of preparation of the substrate comprising the nanoparticle catalysts and NOstorage materials. More specifically, the present disclosure relates to a coated substrate comprising nanoparticle catalysts and NOstorage materials for lean NOtrap (LNT) systems, useful in the treatment of exhaust gases.

A method of producing a catalyst comprising: mixing catalytic particles and a solvent, thereby forming a mixture; performing a size distribution analysis on the mixture to determine a size distribution profile; repeating the mixing of the catalytic particles and the solvent in the mixture if the size distribution profile is below a threshold; centrifuging the mixture if the size distribution profile is at or above the threshold, thereby forming a supernate and a precipitate, wherein the supernate comprises a dispersion including the catalytic particles and the solvent; decanting the mixture, separating the supernate from the precipitate; determining the particle content of the separated supernate; determining a volume of the dispersion to be applied to a catalyst support based on one or more properties of the catalyst support; and impregnating the catalyst support with the catalytic particles in the dispersion by applying the volume of the dispersion to the catalyst support.

Catalyst production method and system

A method of making ceramics is provided. The method comprises preparing a dispersion of a nano-material. A slurry of a ceramic matrix material is prepared. The nano-dispersion is mixed with the matrix slurry to form a nano-dispersion/slurry mixture. The nano-dispersion/slurry mixture is dried. The nano-dispersion/slurry mixture is pressed into a final manufacture comprising a granular structure including the nano-material bonded within and uniformly distributed throughout the granular structure. The manufacture comprises an increased fracture toughness compared with a conventional manufacture produced without bonding the nano-material within the granular structure. The nano-material has a size on the order of tens of nanometers. The matrix material has a size on the order of several micrometers. Five percent of the nano-dispersion/slurry mixture comprises the nano-material dispersion. Sintering is performed on the final form using a sintering process following the pressing step. The sintering process includes a hot isostatic pressing process.

Fracture toughness of ceramics

A method of making glass is provided. The method comprises preparing a dispersion of a nano-material. A slurry of a glass matrix material is prepared. The nano-dispersion is mixed with the matrix slurry to form a nano-dispersion/slurry mixture. The nano-dispersion/slurry mixture is dried. The nano-dispersion/slurry mixture is pressed into a final manufacture comprising a molecular structure including the nano-material bonded within and uniformly distributed throughout the molecular structure. The manufacture comprises an increased fracture toughness compared with a conventional manufacture produced without bonding the nano-material within the molecular structure. The nano-material has a size on the order of tens of nanometers. The matrix material has a size on the order of several micrometers. Five percent of the nano-dispersion/slurry mixture comprises the nano-material dispersion. Sintering is performed on the final form using a sintering process following the pressing step. The sintering process includes a hot isostatic pressing process.

Fracture toughness of glass

A method of enhancing the flowability of a powder. The powder is defined by a plurality of particles having an initial level of inter-particle forces between each particle. The method comprises: treating the powder, wherein the level of inter-particle forces between each particle is substantially decreased from the initial level; fluidizing the treated powder; flowing the treated powder into a plasma arc chamber; the plasma arc chamber generating a plasma arc; and the plasma arc chamber operating on the treated powder using the generated plasma arc. Preferably, the inter-particle forces are decreased by coating the particles with an organic surfactant.

Powder treatment for enhanced flowability

Apparatuses for and methods of nano-material powder preservation and dispersion in liquid, capture, and treatments are disclosed. The applications of the present disclosure ensure powder accountability of the nano-materials preventing the nano material from dispersing into the air. The method of treating a nano-material comprises receiving a nano-material and mixing/dispersing the nano-material with a fluid in a vessel until the nano-material is sealed by the fluid. The apparatus for treating a nano-material comprises a hermetically sealable vessel containing a nano-material and a fluid, wherein the fluid is configured to increase the isolation between particles of the nano-material.

Methods and apparatuses for nano-materials powder treatment and preservation

A plasma gun system comprising: a plasma gun comprising an outlet, wherein the plasma gun is configured to generate a plasma stream and provide the plasma stream to the outlet; and a plasma gun extension assembly configured to be coupled to the plasma gun, wherein the plasma gun extension assembly comprises an extension chamber and a port, the extension chamber having an interior diameter defined by a chamber wall and being configured to receive the plasma stream from the outlet of the plasma gun and to enable the plasma stream to expand upon entering the extension chamber, and the port being configured to introduce a powder to the expanded plasma stream at a location outside of the plasma gun.

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Gilbert, AZ, United States of America

David Leamon