Catalyst substrate having improved thermal durability

Abstract

A catalyst substrate comprises a substrate material having an inlet, an outlet, an opening therebetween to allow for the passage of exhaust gas therethrough, and further comprises a catalyst and a layer of zirconium phosphate. Catalyst substrates coated with zirconium phosphate exhibit improved thermal durability, improved thermal shock resistance, and improved alkali and acidic corrosion resistance.

1 . A catalyst substrate for use with a catalytic converter, comprising: 
 a catalyst substrate material comprising an inlet, an outlet, an opening for the passage of exhaust gas therethrough, and comprising a catalyst and zirconium phosphate.    
     
     
         2 . The catalyst substrate of  claim 1 , wherein said zirconium phosphate is a layer disposed on at least part of said catalyst substrate material.  
     
     
         3 . A catalytic converter, comprising: 
 a catalyst substrate comprising a catalyst and zirconium phosphate;    a shell having an opening for the passage of exhaust gas therethrough, wherein said shell is concentrically disposed around said catalyst substrate; and    a mat support material disposed between said catalyst substrate and said shell, and concentrically around said catalyst substrate.    
     
     
         4 . The catalytic converter of  claim 3 , wherein said zirconium phosphate is a layer on at least part of the catalyst substrate.  
     
     
         5 . The catalytic converter of  claim 3 , further comprising an exhaust system component secured to at least one end of said shell.  
     
     
         6 . The catalytic converter of  claim 5 , wherein said exhaust system component is selected from the group consisting of an endcone, an endplate, an exhaust manifold assembly, an exhaust pipe, a connecting pipe, a mounting flange, and combinations comprising at least one of the foregoing components.  
     
     
         7 . A method for manufacturing a catalytic converter, comprising: 
 forming a catalyst substrate comprising a catalyst and zirconium phosphate;    disposing concentrically said catalyst substrate in a shell having an opening;    disposing concentrically a mat support material between said catalyst substrate and said shell, and around said catalyst substrate; and    securing an exhaust system component to at least one end of said shell.    
     
     
         8 . The method of  claim 7 , wherein said forming a catalyst substrate further comprises applying a layer of zirconium phosphate to said catalyst substrate.  
     
     
         9 . The method of  claim 8 , wherein said applying further comprises a method selected from the group consisting of wash coating, imbibing, impregnating, physisorbing, chemisorbing, precipitation, dipping, and combinations comprising at least one of the foregoing methods.  
     
     
         10 . The method of  claim 8 , wherein said applying further comprises reacting zirconium metal with phosphoric acid to form a solution, and dipping said catalyst substrate into said solution.  
     
     
         11 . A method for manufacturing a catalyst substrate for use with a catalytic converter, comprising: 
 forming a catalyst substrate comprising a catalyst; and    applying zirconium phosphate to said catalyst substrate.    
     
     
         12 . The method of  claim 11 , wherein said applying further comprises applying a layer of zirconium phosphate to said catalyst substrate.  
     
     
         13 . The method of  claim 12 , wherein said applying further comprises a method selected from the group consisting of wash coating, imbibing, impregnating, physisorbing, chemisorbing, precipitation, dipping, and combinations comprising at least one of the foregoing.  
     
     
         14 . The method of  claim 12 , wherein said applying further comprises reacting zirconium metal with phosphoric acid to form a solution, and dipping said catalyst substrate into said solution.