US2011113762A1PendingUtilityA1

Use Of Powder Coated Nickel Foam As A Resistor To Increase The Temperature of Catalytic Converter Devices With The Use Of Electricity

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Assignee: AIRFLOW CATALYST SYSTEMSPriority: Nov 16, 2009Filed: Nov 16, 2009Published: May 19, 2011
Est. expiryNov 16, 2029(~3.3 yrs left)· nominal 20-yr term from priority
Inventors:Thomas R. Roberts
F01N 3/035F01N 3/2026Y02T10/40F01N 2330/22F01N 3/027F01N 9/00Y02T10/12F01N 13/0097F01N 13/0093
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Claims

Abstract

The disclosed invention relates to the optimization of catalytic reactions in diesel engines. A powder-coated nickel or other metallic foam is used as both the substrate and a resistor in a catalytic converter. The disclosed method uses a closed-loop system to heat the metallic foam with electric current to heat the diesel exhaust and thereby optimize the temperature at which the catalytic reaction occurs. The disclosed apparatus comprises a metallic foam substrate with a catalytic coating. The substrate is heated with electrical current to optimize the catalytic reaction. A variety of washcoats and/or catalysts may be used to coat the metallic foam substrate and the optimal temperature will depend on the catalyst used.

Claims

exact text as granted — not AI-modified
1 . A method of optimizing the temperature of diesel engine exhaust comprising:
 providing a substrate consisting of a metal foam coated with a catalytic material;   heating the substrate to a temperature range designed to optimize the catalytic reaction by passing an electric current through the substrate; and   causing the diesel engine exhaust to flow over the substrate so that the catalytic material interacts with said exhaust.   
     
     
         2 . A method according to  claim 1  wherein said substrate is in the form of nickel foam. 
     
     
         3 . A method according to  claim 1  wherein a wash coat is combined with a catalyst to form the catalytic material. 
     
     
         4 . A method according to  claim 1  wherein said catalytic material comprises an iron manganese catalyst. 
     
     
         5 . A method according to  claim 1  wherein said catalytic material comprises a catalyst consisting of titanium dioxide. 
     
     
         6 . A method according to  claim 1  wherein said catalytic material comprises an SCR catalyst. 
     
     
         7 . A method according to  claim 2  wherein a wash coat is combined with a catalyst to form the catalytic material. 
     
     
         8 . A method according to  claim 2  wherein said catalytic material comprises an iron manganese catalyst. 
     
     
         9 . A method according to  claim 2  wherein said catalytic material comprises a catalyst consisting of titanium dioxide. 
     
     
         10 . A method according to  claim 2  wherein said catalytic material comprises a catalyst consisting of an SCR catalyst. 
     
     
         11 . A method according to  claim 3  wherein said catalytic material comprises an iron manganese catalyst. 
     
     
         12 . A method according to  claim 3  wherein said catalytic material comprises a catalyst consisting of titanium dioxide. 
     
     
         13 . A method according to  claim 3  wherein said catalytic material comprises a catalyst consisting of a an SCR catalyst. 
     
     
         14 . A method according to  claim 3  wherein said catalytic material comprises a catalyst consisting of platinum. 
     
     
         15 . A method according to  claim 7  wherein said catalytic material comprises an iron manganese catalyst. 
     
     
         16 . A method according to  claim 7  wherein said catalytic material comprises a catalyst consisting of titanium dioxide. 
     
     
         17 . A method according to  claim 7  wherein said catalytic material comprises a catalyst consisting of an SCR catalyst. 
     
     
         18 . A method according to  claim 7  wherein said catalytic material comprises a catalyst consisting of platinum. 
     
     
         19 . A diesel engine exhaust system comprising; a housing having an inlet for receiving diesel exhaust; a metallic foam substrate within the housing, the substrate having a catalytic coating; an electrical system for heating said substrate; and an outlet for emitting diesel exhaust. 
     
     
         20 . A system according to  claim 19  wherein said substrate is in the form of nickel foam. 
     
     
         21 . A system according to  claim 19  wherein said catalytic coating also comprises a washcoat. 
     
     
         22 . A system according to  claim 19  wherein said catalytic coating comprises an iron manganese catalyst. 
     
     
         23 . A system according to  claim 19  wherein said catalytic coating comprises a catalyst consisting of titanium dioxide. 
     
     
         24 . A system according to  claim 19  wherein said catalytic coating comprises a catalyst consisting of an SCR catalyst. 
     
     
         25 . A system according to  claim 20  wherein said catalytic coating also comprises a washcoat. 
     
     
         26 . A system according to  claim 20  wherein said catalytic coating comprises an iron manganese catalyst. 
     
     
         27 . A system according to  claim 20  wherein said catalytic coating comprises a catalyst consisting of titanium dioxide. 
     
     
         28 . A method according to  claim 20  wherein said catalytic coating comprises a catalyst consisting of a an SCR catalyst. 
     
     
         29 . A system according to  claim 21  wherein said catalytic coating comprises an iron manganese catalyst. 
     
     
         30 . A system according to  claim 21  wherein said catalytic coating comprises a catalyst consisting of titanium dioxide. 
     
     
         31 . A system according to  claim 21  wherein said catalytic coating comprises a catalyst consisting of a an SCR catalyst. 
     
     
         32 . A system according to  claim 21  wherein said catalytic material comprises a catalyst consisting of platinum. 
     
     
         33 . A system according to  claim 25  wherein said catalytic material comprises an iron manganese catalyst. 
     
     
         34 . A system according to  claim 25  wherein said catalytic material comprises a catalyst consisting of titanium dioxide. 
     
     
         35 . A system according to  claim 25  wherein said catalytic material comprises a catalyst consisting of a an SCR catalyst. 
     
     
         36 . A system according to  claim 25  wherein said catalytic material comprises a catalyst consisting of platinum.

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