U.S. patent application number 10/002272 was filed with the patent office on 2002-06-13 for method and device for cleaning the atmosphere.
This patent application is currently assigned to ENGELHARD CORPORATION. Invention is credited to Allen, Fred M., Heck, Ronald M., Hoke, Jeffrey B..
Application Number | 20020071800 10/002272 |
Document ID | / |
Family ID | 23811104 |
Filed Date | 2002-06-13 |
United States Patent
Application |
20020071800 |
Kind Code |
A1 |
Hoke, Jeffrey B. ; et
al. |
June 13, 2002 |
Method and device for cleaning the atmosphere
Abstract
Method for treating atmospheric pollutants by contacting the
atmosphere with a catalyst composition or adsorptive material
coated on the surface of a substrate in which the catalyst
composition or adsorptive material is protected from degradation by
harmful contaminants contained in the atmosphere by a coating of at
least one porous protective material and a device useful
therefor.
Inventors: |
Hoke, Jeffrey B.; (North
Brunswick, NJ) ; Heck, Ronald M.; (Frenchtown,
NJ) ; Allen, Fred M.; (Princeton Junction,
NJ) |
Correspondence
Address: |
Chief Patent Counsel
Engelhard Corporation
101 Wood Avenue
P.O. Box 770
Iselin
NJ
08830-0770
US
|
Assignee: |
ENGELHARD CORPORATION
|
Family ID: |
23811104 |
Appl. No.: |
10/002272 |
Filed: |
November 15, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10002272 |
Nov 15, 2001 |
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09689217 |
Oct 12, 2000 |
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09689217 |
Oct 12, 2000 |
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09456016 |
Nov 30, 1999 |
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6190627 |
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Current U.S.
Class: |
423/210 ;
423/219; 423/245.1; 423/247; 502/182; 502/185; 502/324; 502/527.24;
502/73; 502/74 |
Current CPC
Class: |
B01D 53/8675 20130101;
B01J 37/0225 20130101; B01J 37/0244 20130101; B64D 2013/0651
20130101; B01J 33/00 20130101; B01D 53/864 20130101; B01D 2259/4558
20130101; B01D 53/885 20130101; B01J 23/34 20130101; F01N 2550/20
20130101 |
Class at
Publication: |
423/210 ;
502/324; 502/527.24; 423/219; 423/245.1; 423/247; 502/73; 502/74;
502/185; 502/182 |
International
Class: |
B01J 023/10; B01D
053/38 |
Claims
What is claimed:
1. A method of cleaning the atmosphere either by catalytically
treating the atmosphere to convert atmospheric pollutants to less
harmful materials or by adsorbing pollutants contained in the
atmosphere comprising contacting the pollutant containing
atmosphere with an outer surface of a substrate which has been
coated with either a catalyst composition to render said surface
capable of catalytically converting said atmospheric pollutants
into less harmful materials or an adsorptive composition in order
to render said surface capable of adsorbing said atmosphere
components and protecting the catalyst and/or adsorbent coated
surface with an overcoat of at least one porous protective material
which is sufficiently porous to enable said atmospheric containing
said pollutants to pass therethrough into operative contact with
the catalyst and/or adsorbent composition and which is sufficiently
protective to prevent harmful contaminants from contacting the
catalyst and/or adsorbent composition.
2. A method of cleaning the atmosphere by catalytically treating
the atmosphere to convert atmospheric pollutants to less harmful
materials comprising contacting the pollutant containing atmosphere
with an outer surface of a substrate which has been coated with a
catalyst composition to render said surface capable of
catalytically converting said atmospheric pollutants into less
harmful materials and protecting the catalyst coated surface with
an overcoat of at least one porous protective material which is
sufficiently porous to enable said atmospheric containing said
pollutants to pass therethrough into operative contact with the
catalyst composition and sufficiently protective to prevent harmful
contaminants from contacting the catalyst composition.
3. The method of claim 2 further comprising coating the porous
protective material overcoated catalytic surface with at least one
hydrophobic protective substance which is capable of substantially
preventing liquid water and/or water vapor from reaching the
catalyst composition.
4. The method of claim 2 comprising catalytically treating the
atmosphere at temperatures of from about 0.degree.-to about
150.degree. C.
5. The method of claim 2 wherein the catalyst composition comprises
base metals, precious metals as well as salts and oxides thereof
and combinations thereof.
6. The method of claim 2 wherein the catalyst composition comprises
manganese dioxide.
7. The method of claim 2 wherein the porous protective material is
selected from the group consisting of zeolites, clays, alumina,
silica, alkaline earth oxides, rare earth oxides, carbon and inert
metal oxides and mixtures thereof.
8. The method of claim 7 wherein the porous protective material is
silica containing high surface area alumina.
9. The method of claim 3 wherein the hydrophobic substance is
selected from the group comprising fluoropolymers and silicone
polymers.
10. A device for cleaning the atmosphere by catalytically treating
the atmosphere to convert atmospheric pollutants to harmless
byproducts comprising: a) a substrate having a surface; b) a
catalyst composition coated on said surface; and c) at least one
porous protective material coated over the catalyst composition,
said porous protective material being sufficiently porous to enable
said atmosphere containing pollutants to pass therethrough into
operative contact with the catalyst composition and sufficiently
adsorbent to prevent harmful contaminants from contacting the
catalyst composition.
11. The device of claim 10 further comprising at least one
hydrophobic protective material overcoating the porous protective
material which is capable of substantially preventing liquid water
and/or water vapor from reaching the catalyst composition.
12. The device of claim 10 comprising at least one layer of a
protective material over the catalyst composition.
13. The device of claim 11 comprising at least one layer of the
porous protective material and at least one layer of the
hydrophobic protective material coated over the catalyst
composition.
14. The device of claim 13 wherein at least one layer containing
the hydrophobic protective material is between the layer of porous
protective material and the catalyst composition.
15. The device of claim 10 wherein the catalyst composition
comprises base metals, precious metals as well as salts and oxides
thereof and combinations thereof.
16. The device of claim 10 wherein the catalyst composition
comprises manganese dioxide.
17. The device of claim 10 wherein the porous protective material
and the hydrophobic protective material are contained within at
least one single layer.
18. The device of claim 10 wherein the porous protective material
is selected from the group consisting of zeolites, clays, alumina,
silica, alkaline earth oxides, rare earth oxides, carbon and inert
metal oxides.
19. The device of claim 10 wherein the porous protective material
is chosen from alumina or a silica containing high surface area
alumina.
20. The device of claim 10 wherein the porous protective material
is alumina and the catalyst composition comprises manganese
dioxide.
21. The device of claim 10 wherein the pollutants to be treated are
selected from the group comprising ozone, hydrocarbons, carbon
monoxide and mixtures thereof.
22. The device of claim 11 wherein the hydrophobic protective
material is selected from the group consisting of fluoropolymers
and silicone.
23. A method of cleaning the atmosphere by adsorbing pollutants
contained in the atmosphere comprising contacting the pollutant
containing atmosphere with an outer surface of a substrate which
has been coated with an adsorptive material to render said surface
capable of adsorbing said atmospheric pollutants and protecting the
adsorptive material coated surface with an overcoat of at least one
porous protective material which is sufficiently porous to enable
said atmosphere containing said pollutants to pass therethrough
into operative contact with the adsorptive material and
sufficiently protective to prevent harmful contaminants from
contacting the adsorptive material.
24. The method of claim 23 further comprising coating the porous
protective material overcoated surface with at least one
hydrophobic protective substance which is capable of substantially
preventing liquid water and/or water vapor from reaching the
adsorptive material.
25. The method of claim 23 wherein the adsorptive material is
chosen from among zeolites, molecular sieves, carbon and Group IIA
metal oxides.
26. The method of claim 23 wherein the adsorptive material is a
zeolite.
27. The method of claim 26 wherein the zeolite is beta-zeolite.
28. The method of claim 23 wherein the porous protective material
is selected from the group consisting of zeolites, clays, alumina,
high surface area alumina silica, alkaline earth oxides, rare earth
oxides, carbon and inert metal oxides and mixtures thereof.
29. The method of claim 24 wherein the hydrophobic substance is
selected from the group comprising fluoropolymers and silicone
polymers.
30. A device for cleaning the atmosphere comprising: a) a substrate
having a surface; b) an adsorptive material coated on said surface;
and c) at least one porous protective material coated over the
adsorptive material, said porous protective material being
sufficiently porous to enable said atmosphere-containing pollutants
to pass therethrough into operative contact with the adsorptive
material and sufficiently protective to prevent harmful
contaminants from contacting the adsorptive material.
31. The device of claim 30 further comprising at least one
hydrophobic protective material overcoating the porous protective
material which is capable of substantially preventing liquid water
and/or water vapor from reaching the adsorptive material.
32. The device of claim 31 comprising at least one layer of the
porous protective material and at least one layer of the
hydrophobic protective material coated over the adsorptive
material.
33. The device of claim 30 wherein the adsorptive material is
selected from zeolites, molecular sieves, carbon and Group IIA
metal oxides and combinations thereof.
34. The device of claim 30 wherein the adsorptive material is a
zeolite.
35. The device of claim 30 wherein the porous protective material
is selected from the group consisting of zeolites, clays, alumina,
silica, alkaline earth oxides, rare earth oxides, carbon and inert
metal oxides.
36. The device of claim 30 wherein the porous protective material
is high surface area alumina.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a method for the low
temperature cleaning of the atmosphere and more particularly to the
rendering of the outer surface of a substrate, such as a radiator
of a motor vehicle, capable of either catalytically converting
atmospheric pollutants to less harmful materials or adsorbing such
pollutants without adversely affecting the functioning of the
substrate. The method is accomplished through the employment of a
pollutant treatment coating on the surface of such substrate said
coating being further provided with an overcoating of either a
protective material alone or in combination with a water repellant
material which improves durability and long term performance of the
catalytic or adsorptive coating.
BACKGROUND OF THE INVENTION
[0002] A review of literature relating to pollution control reveals
that the general approach is to reactively clean waste streams
entering the environment. If too much of one pollutant or another
is detected or being discharged, the tendency has been to focus on
the source of the pollutant. For the most part gaseous streams are
treated to reduce the pollutants prior to entering the
atmosphere.
[0003] It has been disclosed to treat atmospheric air directed into
a confined space to remove undesirable components therein. However,
there has been little effort to treat pollutants which are already
in the environment; the environment has been left to its own
self-cleansing systems.
[0004] References are known which disclose proactively cleaning the
environment. U.S. Pat. No. 3,738,088 discloses an air filtering
assembly for cleaning pollution from the ambient air by utilizing a
vehicle as a mobile cleaning device. A variety of elements are
disclosed to be used in combination with a vehicle to clean the
ambient air as the vehicle is driven through the environment. In
particular, there is disclosed ducting to control air stream
velocity and direct the air to various filter means. The filter
means can include filters and electronic precipitators. Catalyzed
postfilters are disclosed to be useful to treat non-particulate or
aerosol pollution such as carbon monoxide, unburned hydrocarbons,
nitrous oxide and/or sulfur oxides, and the like.
[0005] Another approach is disclosed in U.S. Pat. No. 5,147,429.
There is disclosed a mobile airborne air cleaning station. In
particular this patent features a dirigible for collecting air. The
dirigible has a plurality of different types of air cleaning
devices contained therein. The air cleaning devices disclosed
include wet scrubbers, filtration machines, and cyclonic spray
scrubbers.
[0006] The difficulty with devices disclosed to proactively clean
the atmospheric air is that they require new and additional
equipment. Even the modified vehicle disclosed in U.S. Pat. No.
3,738,088 requires ducting and filters which can include catalytic
filters.
[0007] DE 40 07 965 C2 to Klaus Hager discloses a catalyst
comprising copper oxides for converting ozone and a mixture of
copper oxides and manganese oxides for converting carbon monoxide.
The catalyst can be applied as a coating to a self-heating
radiator, oil coolers or charged-air coolers. The catalyst coating
comprises heat resistant binders which are also gas permeable. It
is indicated that the copper oxides and manganese oxides are widely
used in gas mask filters and have the disadvantage of being
poisoned by water vapor. However, the heating of the surfaces of
the automobile during operation evaporates the water. In this way,
continuous use of the catalyst is possible since no drying agent is
necessary.
[0008] Responsive to the difficulties associated with devices which
proactively treat the atmosphere, the Assignee herein in U.S.
patent application Ser. No. 08/410,445 filed on Mar. 24, 1995, U.S.
patent application Ser. No.08/589,182 filed Jan. 19, 1996, and U.S.
patent application Ser. No. 08/589,030 filed Jan. 19, 1996, each
incorporated herein by reference, disclosed apparatus in related
methods for treating the atmosphere by employing a moving vehicle.
In preferred embodiments a portion of the surface of the engine or
cabin cooling system (e.g. the radiator, air-conditioning
condenser, etc.) is coated with a catalytic or adsorption
composition. Additionally, the fan associated with the engine
cooling system can operate to draw or force air into operative
contact with the radiator. Pollutants contained within the air such
as ozone, hydrocarbons and/or carbon monoxide are then
catalytically converted to non-polluting compounds (e.g., oxygen,
water and carbon dioxide).
[0009] The Assignee herein also has pending U.S. patent application
Ser. No. 08/412,525 filed on Mar. 29, 1995, incorporated herein by
reference, which discloses devices and methods for proactively
treating the atmosphere catalytically by employing a stationary
object such as selected surfaces of an automobile at rest, a
billboard, an air conditioning unit and the like coated with a
catalytic composition.
[0010] In addition, International Publication No. WO 98/02235 of
the Assignee herein discloses a process of catalytically activating
the surface of a heat exchange device such as a motor vehicle
radiator while retaining the heat exchange properties of the
device. The method enables the catalytic treatment of the
atmosphere by converting pollutants contained therein to less
harmful materials while allowing the radiator to perform its
function normally. A polymeric protective coating which is stable
up to temperatures of about 100.degree. C. may be employed to
retard degradation and inactivation of the catalyst.
[0011] The application of a catalyst or absorbent composition to
the surface of a substrate such as a radiator of a motor vehicle
presents problems such as the exposure of the composition to
relatively high concentrations of contaminants which can
deleteriously affect the functioning of the composition. Such
contaminants include solid or vaporized particulates, corrosive
compounds such as salts and oxides of nitrogen, sulfur and the
like. Contact of the composition with such contaminants can result
in masking, fouling and/or poisoning. In addition, water (and
contaminants contained therein) can be a source of degradation and
can also decrease the activity and useful life of catalyst and
adsorbent compositions.
[0012] It would therefore be a significant advance in the art of
reducing atmospheric pollution to employ catalytic and adsorptive
composition coated devices for the treatment of the atmosphere to
remove pollutants contained therein wherein the composition is
protected against those contaminants commonly encountered in the
atmosphere which can adversely affect performance of the
composition. It would be a further advance in the art if the
composition could be protected from contaminants at from ambient
temperatures up to about several hundred degrees centigrade. It
would be still a further advance in the art if the composition
could be protected from water especially liquid water.
SUMMARY OF THE INVENTION
[0013] The present invention generally relates to a method and
device for cleaning the atmosphere by removing pollutants
therefrom. A surface which contacts the atmosphere such as a
surface of a radiator of a motor vehicle is treated with a catalyst
or absorbent composition so that the outer surface (i.e., air side)
thereof is capable of either adsorbing pollutants or catalytically
converting pollutants contained in the atmosphere into less harmful
substances. The composition is coated at least in part (preferably
completely) with a porous, protective coating as defined herein
which effectively protects the composition from atmospheric
contaminants at ambient temperatures up to several hundred degrees
centigrade or higher. Preferably, the porous protective coating is
itself overcoated with a hydrophobic material. The present
invention also encompasses devices treated in the manner described
herein.
[0014] The term "adsorption" is defined as including: (a) the
penetration of one substance into the inner structure of another
(commonly referred to as "absorption"); and (b) adherence of the
atoms, ions, or molecules of a gas or liquid to the surface of
another substance (commonly referred to as "adsorption"). See, for
example, Hawley's Condensed Chemical Dictionary, Thirteenth
Edition, Van Nostrand Reinhold, 1997, pp. 2, 3, 24.
[0015] Similarly, related terms such as, for example, adsorbents,
adsorbing, adsorptive, etc. shall be understood to include both
related meanings. The term "atmosphere" means the mass of air
surrounding the earth, and includes "ambient air" which is the
portion of the atmosphere that is drawn or forced towards the outer
surface of the coated substrate. Ambient air includes air, which
has been heated either incidentally or by a heating means. The term
"substrate" is used in its customary broad sense and includes any
surface which can be coated with a suitable catalyst or adsorbing
composition and thereafter have the composition protected in the
manner described herein. Such surfaces include those surfaces found
in motor vehicles such as automobiles, trucks, vans, buses, trains,
airplanes and the like and include but are not limited to
radiators, condensers, charge air coolers, transmission coolers,
inserted devices which may be separately heated, heat exchangers,
fluid transporting conduits and the like. Surfaces normally
described as stationary such as billboards, road signs, outdoor
HVAC equipment are also included. For convenience only, a motor
vehicle radiator will be discussed herein as typical of a suitable
substrate.
[0016] In accordance with the present invention, the surface of the
substrate (e.g., radiator) is provided with a substance which can
either effectively catalyze the conversion of pollutants contained
in the atmosphere to less harmful substances or adsorb such
pollutants for later treatment as appropriate. The surface of the
radiator is therefore capable of either catalytically converting
pollutants such as hydrocarbons, carbon monoxide and ozone into
less harmful materials such as oxygen, carbon dioxide and water, or
adsorbing pollutants such as NOx, SOx hydrocarbons and carbon
monoxide as the case may be.
[0017] In one aspect, the present invention is directed to a method
of catalytically treating the atmosphere to convert pollutants to
less harmful materials comprising treating an outer surface of a
substrate, particularly an auto radiator to render said surface
capable of catalytically converting said pollutants and then
providing the catalyst with an overcoating of at least one material
or mixtures of such materials which is porous and preferably also
adsorbent (hereinafter, "porous protective material"). The porous
protective material is preferably sufficiently porous to enable the
atmosphere including the contained pollutants to be treated to pass
therethrough into operative contact with the catalyst composition
to enable conversion thereof into less harmful materials. The
porous protective material preferably should also be adsorbent in
order to trap atmospheric catalyst degradating contaminants so that
they are at least substantially prevented from reaching the
catalyst composition. Still further, the catalyst and the porous
protective material are preferably stable at ambient temperatures
and up to about several hundred degrees centigrade.
[0018] In another aspect of the invention, the porous protective
material may include or be overcoated with at least one substance
which is capable of protecting the catalyst composition from
contact with liquid water and/or water vapor (hereinafter,
"hydrophobic protective material").
[0019] In another aspect of the invention, the outer surface of the
substrate (e.g. radiator) is made of or provided with a
catalytically active substance such as a base metal catalyst (e.g.
manganese dioxide), precious metal catalyst or combination thereof.
As used herein the terms "base metal catalyst" and "precious metal
catalyst" shall include the base metals and precious metals
themselves as well as compounds containing the same e.g., salts and
oxides and the like.
[0020] In another aspect, the present invention is directed to a
method for cleaning the atmosphere comprising treating an outer
surface of a substrate, particularly an auto radiator with an
adsorptive material to render said surface capable of adsorbing
pollutants present in the atmosphere such as NOx, SOx hydrocarbons
and carbon monoxide and then providing the adsorptive material with
an overcoating of at least one porous protective material.
[0021] In another aspect of the invention, the outer substrate
surface coated with either a catalyst composition or adsorbing
composition, is coated with the porous protective material which is
then overcoated with a hydrophobic protective material. The
protective material, whether porous, hydrophobic or a combination
of both still permits pollutants to pass into contact with either
the catalyst composition so they may be converted to less harmful
materials or into contact with the adsorbing composition so that
they may be absorbed and thereby removed from the atmosphere.
[0022] The coatings contemplated for use herein do not
substantially interfere with the normal desired operation of the
substrate (e.g., auto radiator) whose surface has been coated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The following drawings in which like reference characters
indicate like parts are illustrative of embodiments of the
invention and are not intended to limit the invention as
encompassed by the claims forming part of the application.
[0024] FIGS. 1A-1F are cross-sectional views showing various
arrangements of the catalyst or adsorbing composition and
protective material of the present invention.
[0025] FIG. 2 is a side view of a radiator assembly of a motor
vehicle; and
[0026] FIG. 3 is an enlarged cross-sectional view of a motor
vehicle radiator.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention is directed to a method of cleaning
the atmosphere by treating the surface of a substrate (e.g. a motor
vehicle radiator) so that pollutants contained in ambient air upon
contact with said surface may either be readily converted
catalytically to less harmful materials or removed by adsorption.
For example, (a) the surface of the substrate may be rendered
catalytic if the surface is provided with catalytically active
materials or a catalyst composition or the surface itself may be
made of a catalytically active material; or (b) an adsorptive
composition may be applied to the surface of the substrate. Thus,
the present invention is particularly adapted to either the
catalytic conversion of hydrocarbons, ozone and carbon monoxide
into less harmful materials such as oxygen, carbon dioxide and
water or the removal of e.g., NOx, SOx, hydrocarbons and carbon
monoxide by adsorption.
[0028] In accordance with the present invention, the surface coat
of the catalyst or adsorptive composition is overcoated with a
porous protective material which is porous and adsorbent. The term
"porous" means that the material allows the ambient air containing
pollutants such as hydrocarbons, ozone, carbon monoxide and the
like to pass through the porous protective material to effectively
contact the catalyst and adsorptive composition and thereby be
converted to less harmful materials. The term "adsorbent" when used
herein means that undesirable contaminants such as particulate
matter, high molecular weight hydrocarbons, water borne salts,
aerosols, gases (e.g. NOx, SOx), and the like which can mask, foul
and/or poison the catalyst composition or interfere with the
functioning of the adsorptive composition are adsorbed, trapped and
may be retained in the porous protective material so that they are
maintained out of contact with the underlying active
composition.
[0029] In a further aspect of the present invention, the porous
protective material may optionally include or may be overcoated
with a hydrophobic material which substantially prevents water
(liquid or vapor) from contacting the catalytic or adsorptive
composition. It has been observed that in the presence of liquid
water and the contaminants that may be contained therein,
degradation of the catalyst composition is accelerated and
conversion rates of pollutants to less harmful materials are more
quickly degraded than in the absence of liquid water and the
contained contaminants. It is anticipated that adsorptive
compositions will similarly benefit from protection from water.
[0030] In a still further aspect of the invention, the catalytic or
adsorptive composition coated on the substrate may first be coated
with the hydrophobic protective material and the porous protective
material is coated over it.
[0031] For reasons of convenience, the invention will be further
described and exemplified using its catalytic embodiment. Those
skilled in the art will appreciate that the adsorptive embodiment
of the invention can be substituted and applied and utilized in a
substantially similar manner as described for the catalytic
embodiment using substantially similar techniques.
[0032] The atmosphere contacting surface is the outer surface of
any device such as a motor vehicle radiator which can effectively
receive the catalyst composition and overcoat of the protective
material(s) and which comes into contact with a
pollutant-containing gas such as ambient air. Any device in which
there is a flow of ambient air thereover or therethrough may be
treated in accordance with the present invention. Of particular
importance to the present invention is the rendering of the outer
surface of the substrate (e.g., radiator) capable of catalytically
converting pollutants to less harmful materials without adversely
affecting the substrate and its function. Thus, if the substrate is
a radiator, the catalyst composition and protective material
overcoat(s) shall not substantially adversely affect either the
heat exchange properties or the physical integrity of the radiator.
The catalyst composition is protected by at least one porous,
preferably adsorbent protective material to insure against
premature degradation of the catalyst composition and optionally
one hydrophobic protective material to protect the catalyst
composition from water (liquid and/or vapor). The porous protective
material and the hydrophobic protective material may also be mixed
and coated onto the catalyst composition as one layer.
[0033] A particular embodiment of the present invention is directed
towards protective materials and methods for improving the
durability of catalysts used for treating the atmosphere. Such
catalysts include, for example, ozone converting catalytic
compositions (especially compositions containing MnO.sub.2), and
catalysts useful for treating carbon monoxide and hydrocarbons as
well. Manganese dioxide is a particularly preferred catalyst
material for use in the present invention to treat ozone, and
precious metals such as platinum and/or palladium are preferred to
treat hydrocarbons and carbon monoxide.
[0034] In this embodiment, the invention is specifically directed
to the use of protective materials which may be overcoated on
catalytic systems (e.g., catalyst coated automobile radiators)
which are useful for cleaning the atmosphere by catalytically
treating pollutants contained in the atmosphere. The function of
the protective materials is to prevent atmospheric catalyst
degrading contaminants (e.g., solid or aerosol particulates, water,
SOx, NOx, water borne salts, high molecular weight hydrocarbons,
etc.) which lead to masking, fouling, and/or poisoning of the
catalyst composition from interacting with the catalyst
composition. Since the purpose of an automobile radiator is to
provide heat exchange and cooling for the engine, the radiator is
usually located at the front of the vehicle where it has ample
access to large volumes of ambient air. As a result, the radiator
operates in a relatively dirty environment and is exposed to all
types of solid, gaseous and liquid airborne and roadway
contaminants. A catalyst composition applied to the radiator for
purposes of treating atmospheric pollutants such as ozone should
preferably be able to function over an extended period of time in a
severely dirty environment. Long term road tests of ozone
destruction catalysts applied to automobile radiators have shown
that deactivation of catalyst performance occurs over time as the
mileage on the vehicle increases. Visual inspection of prior art
radiators which had been surface coated only with an ozone
catalyst, e.g., a MnO.sub.2 containing catalyst and removed from
service after extended on-road aging (e.g., 50,000 or 100,000
miles) showed the readily apparent deposition of dirt, salts, and
other solid contaminants on the surface of the catalyst
composition. These unprotected compositions suffered a significant
loss of activity measured at about 50% or higher. Chemical analyses
also confirmed the deposition of sulfate, sodium, chloride,
calcium, silica, alumina and carbon on the catalyst composition.
Although many mechanisms may exist for deactivation of such
road-aged catalysts, it is believed that deposition of atmospheric
contaminants (particularly SOx aerosols, and particulate matter
both large and small) account for a significant decrease in
catalyst performance over time.
[0035] The practice of the methods of the present invention
minimize contact of airborne contaminants with the radiator
catalyst composition. This is accomplished by applying an overcoat
of a porous, preferably adsorbent protective material on the
surface of the catalyst composition. The function of the porous
protective material is to trap and hold airborne particulates, high
molecular weight hydrocarbons, aerosols, water borne salts and
catalyst deactivating gases such as SOx, so that they do not come
into contact with the active catalyst composition underneath. The
porous protective material is preferably dense enough to trap
contaminants but also porous enough to allow free passage of the
ambient air which contains the pollutant to be treated (e.g. ozone,
hydrocarbons, carbon monoxide) to the catalyst composition below.
In this way, the catalyst composition is kept substantially
contaminant free and is therefore able to provide high levels of
long lasting pollutant conversion.
[0036] Suitable porous protective materials may include, but are
not limited to zeolites, clays, alumina, silica, alkaline earth
oxides, rare earth oxides, carbon, inert metal oxides as well as
mixtures thereof.
[0037] The zeolites for use in the present invention as the
protective material include acid and/or ion exchanged and/or
dealuminated zeolites examples of such zeolites include but are not
limited to zeolite-Y, ferrierite, zeolite-A, beta-zeolite, ZSM-5,
other molecular sieves and mixtures thereof.
[0038] Clays include, for example, attapulgite, kaolin and mixtures
thereof.
[0039] Aluminas include, silica alumina, gamma alumina, alpha
alumina, colloidal alumina, and mixtures thereof including those
having high and low surface areas.
[0040] Typical useful silicas include silicalite, silica gel, fumed
silica, aerogels, high silica content silica-aluminas, colloidal
silica and mixtures thereof.
[0041] Examples of useful alkaline earth oxides include calcium
oxide/hydroxide, calcium magnesium aluminates, barium carbonate,
barium oxide/hydroxide, strontium carbonate, strontium
oxide/hydroxide, spinels and mixtures thereof.
[0042] Typical and useful rare earth oxides include ceria, lanthana
and mixtures thereof.
[0043] Examples of carbon for use in the present invention include
granular activated carbon, carbon black, permanganate on carbon and
mixtures thereof.
[0044] In addition to the examples mentioned above inert metal
oxides such as, for example, titania, zirconia, silica, and
mixtures thereof can be employed as the protective material.
[0045] The preferred porous protective material for use in the
practice of the invention is aluminum oxide, more preferred is high
surface area silica containing aluminum oxide
[0046] Protective materials may optionally also be combined with
and may include hydrophobic substances which render the area around
the catalyst composition water repellant. The hydrophobic material
may also be provided as a separate overcoat either over or under
the porous component. Suitable hydrophoblic substances for use in
the present invention include, but are not limited to water
dispersible polymers, polymer emulsions such as fluoropolymer water
based latex emulsions (FC-824 and FC-808 manufactured by 3M
Company) and water based Teflon emulsions (e.g. TF5035 manufactured
by 3M Company), and silicone polymers, such as water based silicone
emulsions (e.g. BS-1306 and BS-1001A manufactured by Wacker
Silicones Corp.). The protective material, as more fully explained
hereinafter, may be applied by any number of methods such as
dipping or spraying a slurry containing the protective material.
The porous protective material and the optional hydrophobic
protective material may each be applied in separate layers to the
catalytic surface or they may be applied as a mixture.
[0047] The protective material may be employed to cover a variety
of catalyst compositions. As previously indicated, such catalyst
compositions include base metals, precious metals, salts and oxides
thereof and combinations thereof. Manganese dioxide is an
especially preferred catalytic material especially for the
conversion of ozone. It is also anticipated that manganese dioxide
will itself be useful as the porous protective material for
overcoating and protecting catalyst coatings when practicing the
catalytic embodiment of the invention.
[0048] The base metals which may be employed for the catalyst
composition include all base metals which can effectively convert
ozone to oxygen and/or carbon monoxide to carbon dioxide. The
preferred base metals include manganese, iron, copper, chromium,
and zinc compounds containing the same and combinations thereof.
The base metals are typically used in the form of oxides.
[0049] The precious metals are preferably selected from those
customarily used in catalyst compositions for the purification of
engine exhaust, e.g., platinum, palladium, rhodium and mixtures
thereof. Silver and gold may also be used.
[0050] The catalyst composition may also be provided with a
suitable support material which preferably has a high surface area.
The preferred support materials are refractory oxides such as those
selected from the group consisting of ceria, alumina, titania,
silica, zirconia, and mixtures thereof with alumina being the most
preferred refractory oxide support. It is preferred that the
refractory oxide support have a high surface area to maximize the
amount of the catalytic material within a given unit area. The term
"high surface area" as it pertains to the refractory oxide support
shall generally mean that the surface area of the support is at
least 100 m.sup.2/g preferably in the range of from about 100 to
300 m.sup.2/g.
[0051] The catalyst composition may be applied to the radiator
surface by techniques commonly used in the industry, e.g., dipping
and/or spraying.
[0052] The catalyst compositions described above once deposited or
made part of the substrate are then protected with at least one
protective material, preferably, a porous material having adsorbent
properties and mixtures thereof as described above. The porous
protective material may be in the form of a single layer or
multiple layers lying between the catalyst composition and the
atmospheric airflow containing the pollutants which are to be
treated. The same or different protective materials may be used for
the multiple layer configuration optionally including one or more
layers of a hydrophobic protective material as described
previously. For example, the catalyst composition as deposited on
the surface of the substrate may be overcoated with one or more
layers of a porous protective material such as alumina with the
alumina coating optionally having one or more layers of a
hydrophobic protective material (e.g. latex based emulsion) coated
thereover.
[0053] In an alternative embodiment, the protective materials may
encapsulate the catalyst composition. Such encapsulated catalyst
compositions may be prepared by coating individual particles of the
catalyst composition by dipping or spraying with a slurry
containing one or more protective materials, e.g., the porous
protective material and/or the hydrophobic protective material.
[0054] In operation of the present invention, ambient air is drawn
or forced over the catalytic surface by natural wind currents or by
air drawing devices such as fans. For land use motor vehicles, the
radiator surfaces are preferably the surfaces which are coated with
the catalyst composition, and the air drawing device is the motor
vehicle radiator fan. It should be understood, however, that other
substrates such as air conditioning condensers, charge air coolers,
transmission coolers, inserted devices which may be separately
heated and the like may be treated in a like manner.
[0055] In a preferred embodiment of the present invention, the
atmosphere contacting surfaces are appropriate surfaces of a motor
vehicle radiator, particularly in automobile radiator. By treating
the radiator surface as described herein pollutants can be readily
removed from the atmosphere while the catalyst is able to maintain
useful conversion rates for extended periods of time. The normal
function of the radiator is not substantially affected by the
coating(s).
[0056] The present invention will be better understood by those
skilled in the art by reference to accompanying FIGS. 1-3. What is
particularly important in accordance with the present invention is
that the catalyst composition is protected from degrading
contaminants by the application of at least one protective material
as described herein. As the ambient air encounters the catalytic
surface of e.g., the radiator, hydrocarbons, carbon monoxide and/or
ozone are catalytically reacted to produce less harmful materials
such as oxygen, carbon dioxide, and water vapor. Additionally,
gaseous contaminants such as high molecular weight hydrocarbons,
SOx and NOx and other contaminants such as dirt, carbon, aerosols,
particulates, water, water borne salts, soil and the like are kept
away from the catalyst composition through the use of the
protective material(s).
[0057] It will be appreciated by those skilled in the art that when
the substrate is associated with a vehicle, any suitable vehicle
can be employed. Vehicles include cars, trucks, trains, boats,
ships, airplanes, dirigibles, balloons, and the like. Preferably in
a motor vehicle, the atmosphere contacting surfaces are surfaces
located toward the front of the vehicle in the vicinity of the
cooling system fan. Useful contact surfaces include the outside
(i.e. airside) surfaces of the radiator, air conditioner condenser,
and the like which are all located and supported within the housing
of the vehicle.
[0058] In a preferred embodiment of the invention the protective
material includes a hydrophobic substance which functions to
protect the catalyst composition from liquid water and/or water
vapor. The hydrophobic protective material is preferably applied as
a separate layer or layers either directly over the porous
protective overcoat coated on the catalyst composition or
indirectly thereover (i.e. wherein the hydrophobic protective
material coating layer is between the catalyst composition surface
coating and the porous protective material layer). As an
alternative, the hydrophobic substance may be incorporated into one
or more porous protecting material coating layers, or may be used
in conjunction with one or more other protective materials to
encapsulate the catalyst and/or adsorbent composition prior to
coating the support. The hydrophobic substance may also be used as
the only protective material to overcoat the catalyst or adsorptive
substrate coating.
[0059] The hydrophobic protecting material can prevent liquid water
and/or water vapor from contacting the catalyst composition and is
at least substantially stable under the temperature conditions
typically associated with a substrate such as a motor vehicle
radiator. The hydrophobic protecting material will be stable at
temperatures from about 0 to 300.degree. C., preferably 0 to
200.degree. C., more preferably 0 to 150.degree. C. and most
preferably 0 to 100.degree. C.
[0060] Various arrangements of the protective material optionally
including a hydrophobic substance and the catalyst composition are
shown in FIGS. 1A-1E. Although single overcoats of the porous and
hydrophobic protective coatings and the components thereof are
depicted in the Figures, it will be appreciated that multiple coats
either alternating or continuous are also within the scope of the
invention.
[0061] Referring to FIG. 1A there is shown a first arrangement in
accordance with the present invention in which a substrate 100,
such as a radiator, is coated with a catalyst or adsorptive
(collectively hereinafter, "active") composition layer 102 and a
coating layer 104 thereover comprising a porous, adsorbent material
such as alumina, silica or mixture thereof.
[0062] The present invention may optionally provide for a
hydrophobic layer as described previously. Referring to FIGS. 1B-1D
and first to FIG. 1B, the hydrophobic layer 106 is placed above the
coating layer 104. The hydrophobic layer 106 provides water
repellency to the substrate and thereby prevents water from
adversely affecting the active composition.
[0063] In an alternative embodiment, the hydrophobic layer 106 is
placed between the coating layer 104 and the active composition 102
as shown in FIG. 1C. In a still further embodiment the protective
material (e.g. alumina) used for the coating layer 104 and the
hydrophobic material (e.g. polymeric silicones or fluoropolymers)
are combined into a single layer 108 as shown specifically in FIG.
1D.
[0064] In a further alternative embodiment individual particles of
the active composition are encapsulated by the protective material
as shown in FIGS. 1E and 1F typically by spray drying the particles
with the protective material. Such spray drying techniques are well
known in the art. In particular as shown specifically in FIG. 1E
the substrate 100 has thereon one or more layers 120 comprised of
encapsulated particles 122 which, as shown in FIG. 1F are comprised
of the active composition 102 with at least one protective layer
104 thereover optionally with at least one layer 106 of a
hydrophobic substance.
[0065] The application of the active composition and protective
materials is described with reference to FIGS. 2 and 3. A radiator
assembly of a motor vehicle is shown in FIG. 2 including a housing
10, a grille 12, an air conditioner condenser 14, a radiator 16 and
a radiator fan 18. It will be understood that other vehicle
components are typically found in a motor vehicle.
[0066] Referring to FIG. 2, the preferred atmosphere contacting
surfaces include the air side tube 13 and fin 15 surfaces of the
air conditioning condenser 14, as well as the air side tube 17 and
fin 19 surfaces of the radiator 16. These surfaces are located
within the housing 10 of a motor vehicle. They are typically under
the hood of the motor vehicle between the front of the vehicle and
the engine. The air conditioner condenser 14 and the radiator 16
can be directly or indirectly supported by the housing 10 of the
vehicle.
[0067] The surfaces 13, 15 and 17, 19 of the air conditioner
condenser 14 and the radiator 16, respectively can be treated in
accordance with the present invention to provide a catalytic or
adsorptive surface covered with a protective material as described
above in connection with FIGS. 1A-1E. The most preferred atmosphere
contacting surface is the outer surface of the radiator 16. A
typical radiator has front and rear surfaces with spaced apart flat
tubes having therebetween a plurality of radiator corrugated
plates. More specifically and referring to FIG. 3, there is shown a
radiator 16 including spaced apart tubes 40 for the flow of a first
fluid and a series of corrugated plates 42 therebetween defining a
pathway 44 for the flow of a second fluid transverse to the flow of
the first fluid. The first fluid such as antifreeze is supplied
from a source (not shown) to the tubes 40 through an inlet 46. The
antifreeze enters the radiator 16 at a relatively high temperature
through the inlet 46 and eventually leaves the radiator through an
outlet 48. The second fluid such as air passes through the pathway
44 and thereby comes into heat exchange relationship with the first
fluid passing through the tubes 40.
[0068] In accordance with the present invention, the surfaces of
the corrugated plates 42 of the radiator 16 can be treated to
provide a catalytic or adsorptive surface which is protected from
contaminants including particulate matter, gases, water and the
like.
[0069] As previously discussed, another embodiment of the invention
is specifically directed to the use of protective materials which
may be overcoated on adsorptive systems (e.g., automobile radiators
coated with adsorptive compositions) which are useful for cleaning
the atmosphere by adsorbing pollutants particularly hydrocarbons
contained in the atmosphere. The function of the protective
materials is to prevent adsorptive material degrading contaminants
present in the atmosphere (in particular solid or aerosol
particulates, water, water borne salts and high molecular weight
hydrocarbons) which would lead to masking, fouling, and/or
poisoning of the adsorptive composition from interacting with the
adsorptive material. Since the purpose of an automobile radiator is
to provide heat exchange and cooling for the engine, the radiator
is usually located at the front of the vehicle where it has ample
access to large volumes of ambient air. As a result, the radiator
operates in a relatively dirty environment and is exposed to all
types of solid, gaseous and liquid airborne and roadway
contaminants. An adsorptive material applied to the radiator for
purposes of adsorbing atmospheric pollutants such as hydrocarbons
and carbon monoxide should preferably be able to function over an
extended period of time in a severely dirty environment.
[0070] The practice of the methods of the present invention
minimize contact of airborne contaminants with the radiator
adsorptive composition. This is accomplished by applying an
overcoat of a porous, preferably adsorbent protective material on
the surface of the adsorptive composition. The function of the
porous protective material is to trap and hold airborne
particulates, aerosols, water borne salts and high molecular weight
hydrocarbons so that they do not come into contact with the
adsorptive material underneath. The porous protective material is
preferably dense enough to trap contaminants but also porous enough
to allow free passage of the ambient air which contains the
pollutant to be treated (e.g., hydrocarbons, carbon monoxide) to
the adsorptive composition below. In this way, the adsorptive
composition is kept substantially contaminant free and is therefore
able to provide high levels of long lasting pollutant adsorption.
Useful and preferred adsorptive materials/compositions include
zeolites such as acid and/or ion exchanged and/or dealuminated
zeolites examples of such zeolites include but are not limited to
zeolite-Y, ferrierite, zeolite-A, beta-zeolite, ZSM-5, other
molecular sieves and mixtures thereof; carbon and Group IIA
alkaline earth metal oxides such as calcium oxide. The adsorbed
pollutants may be subsequently collected, if desired, by
desorption, for example, followed by destruction by catalytic
reaction or incineration.
EXAMPLE 1
[0071] A Ford Taurus radiator was coated in four separate sections
("quadrants") with four MnO.sub.2 based ozone destroying catalyst
formulations. A brief description of each formulation is given
below: Section 1: same as Section 2 formulation without the alumina
coating.
[0072] Section 2: 3.5 .mu.m average particle size MnO.sub.2 coating
containing a silicone/acrylic binder blend and overcoated with an
SRS-II alumina coating.
[0073] Section 3: 3.5 .mu.m particle size reference MnO.sub.2
coating prepared from an unstable (i.e. coagulated) slurry
formulation.
[0074] Section 4: 1 .mu.m average particle size MnO.sub.2 coating
containing an acrylic binder without the alumina overcoat.
[0075] The MnO.sub.2 binder system used in the Section 1 and 2
formulations contained a 3:1 blend of acrylic/styrene acrylic latex
binder (Rhoplex P-376 from Rohm & Haas) with a reactive
silicone latex binder resin (M-50E from Wacker Silicones Corp.).
The MnO.sub.2 binder system used in the non-preferred reference
Section 3 formulation contained an EVA (ethylene vinyl acetate)
latex binder from National Starch (Duroset E-646). The MnO.sub.2
binder system used in the Section 4 formulation contained an
acrylic latex binder from National Starch (Nacrylic X-4280). The
SRS-II alumina binder is system used in the overcoat formulation
coated on Section 2 contained an acrylic/styrene acrylic latex
binder from Rohm & Haas (Rhoplex P-376). The SRS-II alumina was
purchased from Grace. The BET surface area of this material was ca.
300 m.sup.2/g and it contained approximately 5% silica. The mean
particle size was approximately 7.5 .mu.m as measured by a Horiba
LA-500 Laser Diffraction Particle Size Distribution Analyzer. The
alumina overcoat was applied at a loading of ca. 0.22 g/in.sup.3 of
radiator volume. The MnO.sub.2 catalyst loadings were approximately
0.44 g/in.sup.3 of radiator volume.
[0076] The coated radiator was placed within an air duct and
subjected to long term aging in the presence of continuous ambient
airflow. The airflow entering the radiator was maintained at an
approximate 9.5 mph linear velocity (ca. 600,000/h radiator space
velocity). The radiator was heated internally with hot
recirculating coolant (50:50 mixture of antifreeze and water), and
the coolant temperature entering the radiator was maintained
between 70 and 90.degree. C. depending on the ambient air
temperature. Because of low ambient air temperature, a fraction of
the air exiting the radiator was recirculated back to the radiator
inlet in order to maintain the radiator coolant temperature between
70 and 90.degree. C.
[0077] Ozone conversion of the four different catalyst compositions
was measured periodically to assess any deactivation in performance
over time. This was accomplished by placing the radiator in a
different test rig (air duct system) than was used to complete the
long-term aging. Ozone conversion was measured at three different
airflows corresponding to radiator space velocities of 200,000,
400,000 and 600,000/h. Additionally, ozone conversion was measured
at three different temperature conditions ("90.degree. C.",
"75.degree. C.", and 45.degree. C.). For the 90.degree. C.
temperature condition, the radiator test rig was operated in
"single-pass" airflow mode where 100% of the air entering the
radiator was fresh ambient air. In this configuration the coolant
temperature to the radiator was maintained at 90.degree. C. The
ambient air entering the radiator was preheated to ca.
20-40.degree. C. with an air pre-heater (in order to achieve the
90.degree. C. coolant temperature), and the air temperature exiting
the radiator was allowed to vary as the airflow was changed during
the ozone conversion measurements (i.e. the higher the airflow the
lower the air temperature). For the other temperature conditions
used to measure ozone destruction performance, the test rig was
operated in "full circulation" airflow mode where the air exiting
the radiator was recirculated back to the radiator inlet. In this
configuration, the air exiting the radiator was maintained at a
constant 45 or 75.degree. C. while ozone conversion measurements
were taken at different airflows.
[0078] Initial conversion results for the four catalyst coating
formulations are shown in Table 1. Initial conversions for Sections
1, 3, and 4 were virtually identical (e.g., 85% at 600,000/h space
velocity and the 90.degree. C. coolant condition), but the
overcoated sample of Section 2 was ca. 6% lower (78%,
respectively). The radiator was aged for 14 days at ambient
temperature conditions (i.e. the coolant heaters were turned off)
and then the radiator was aged an additional 25 days at normal
operating temperature (i.e. 70-90.degree. C.). Ozone conversion
results at the completion of aging are shown in Table 2.
[0079] After aging, the section 3 coating containing the
non-preferred reference catalyst formulation typically had the
lowest conversion (e.g. 37% at 600,000/h space velocity and the
90.degree. C. coolant temperature condition). Section 4 containing
the small particle catalyst formulation was a little better (41%,
respectively), and Section 1 containing the larger particle
catalyst formulation was better yet (46%, respectively). Section 2
with the overcoated catalyst formulation, however, was
significantly better (65%, 10 respectively). At the 90.degree. C.
temperature test condition and a space velocity of 600,000/h, the
Section 2 catalyst formulation lost only an absolute 13% in ozone
conversion activity during the entire aging period while the other
three lost at least an absolute 40% (Table 3). Clearly the SRS-II
alumina overcoat on Section 2 had a dramatic effect on improving
the long-term durability of the MnO.sub.2 catalyst underneath. This
is particularly significant since the initial activity of this
section was less due to the presence of the overcoat. Despite a
reduction in initial activity, the long-term activity maintenance
was excellent.
1TABLE 1 Temper- Space Ozone Conversion (%) ature (C) Velocity (/h)
Section 1 Section 2 Section 3 Section 4 90 600,000 85.0 78.3 84.5
85.0 400,000 91.4 86.4 90.9 90.7 200,000 95.5 92.9 98.9 95.3 75
600,000 92.8 85.6 92.4 88.0 400,000 94.7 91.0 94.7 92.1 200,000
97.2 95.2 97.6 96.7 45 600,000 82.2 73.1 81.9 80.1 400,000 89.4
82.8 89.1 87.1 200,000 96.8 93.2 96.4 95.0
[0080]
2TABLE 2 Temper- Space Ozone Conversion (%) ature (C) Velocity (/h)
Section 1 Section 2 Section 3 Section 4 90 600,000 46.1 65.0 37.0
41.0 400,000 53.7 73.0 45.0 50.5 200,000 74.4 87.5 65.5 74.4 75
600,000 42.7 62.9 33.4 38.3 400,000 49.0 70.0 39.9 44.6 200,000
67.1 84.0 58.3 59.9 45 600,000 25.4 46.2 21.3 22.5 400,000 32.3
55.5 26.4 27.0 200,000 49.9 75.5 42.2 39.2
[0081]
3 TABLE 3 Ozone Conversion %.sup.a Section 1 Fresh 85.0 Section 1
Aged 46.1 Section 2 Fresh 78.3 Section 2 Aged 65.0 Section 3 Fresh
84.5 Section 3 Aged 37.0 Section 4 Fresh 85.0 Section 4 Aged 41.0
.sup.aOzone Conversion Test Conditions: 90.degree. C. Coolant
Temperature, 600,000/hr Space Velocity, ca 200 ppb ozone
EXAMPLE 2
[0082] Volvo S-70 and S-70T (turbo) radiators were coated in three
separate sections ("stripes") with three MnO.sub.2 based ozone
destroying catalyst formulations. A brief description of each
formulation is given below:
[0083] Section 1: 3.5 .mu.m average particle size MnO.sub.2 coating
containing a silicone/acrylic binder blend and overcoated with
SRS-II alumina.
[0084] Section 2: same as Section 1 formulation without the alumina
overcoat.
[0085] Section 3: 3.5 .mu.m average particle size MnO.sub.2 coating
containing an EVA/acrylic binder blend and overcoated with SRS-II
alumina.
[0086] The MnO.sub.2 binder system used in the Section 1 and 2
formulations contained a 3:1 blend of acrylic/styrene acrylic latex
binder (Rhoplex P-376 from Rohm & Haas) with a reactive
silicone latex binder resin (M-50E from Wacker Silicones Corp.).
The MnO.sub.2 binder system used in the Section 3 formulation
contained a 1:1 blend of acrylic/styrene acrylic latex binder
(Rhoplex P-376 from Rhom & Haas) with an EVA (ethylene vinyl
acetate) latex binder from National Starch (Duroset Elite 22). The
SRS-II alumina binder system used in the overcoat formulations
coated in Sections 1 and 3 contained only the acrylic/styrene
acrylic latex binder (Rhoplex P-376) from Rohm & Haas. The
SRS-II alumina was purchased from Grace. The BET surface area of
this material was ca. 300 m.sup.2/g and it contained approximately
5% silica. The mean particle size was approximately 6.5 .mu.m as
measured by a Horiba LA-500 Laser Diffraction Particle Size
Distribution Analyzer. The alumina overcoats were applied at
loadings of ca. 0.18 g/in.sup.3 of radiator volume. The MnO.sub.2
catalyst loadings were approximately 0.35 g/in.sup.3 of radiator
volume.
[0087] The coated radiators were placed on Volvo S-70 and S-70 T
(turbo) vehicles and subjected to accelerated on-road mileage
accumulation (ca. 1,000 miles per day). The radiators of both
vehicles were removed after accumulating approximately 16,000 miles
in the Detroit, Mich. metropolitan area during February 1999. The
ozone conversion of the coated sections on each radiator was
evaluated to assess any deactivation in performance over time. The
radiators were then re-installed on the vehicles, and an additional
16,000 miles was accumulated on each (32,000 total miles) in the
Phoenix, Ariz. metropolitan area during March 1999. The radiators
were once again removed, and the ozone conversion of the coated
sections on each radiator was evaluated to further assess any
deactivation in performance over time. Finally, the radiators were
re-installed on the vehicles, and an additional 18,000 miles was
accumulated on each (50,000 total miles) in the Phoenix, Ariz.
metropolitan area during April 1999. The radiators were removed one
last time, and the ozone conversion of the coated sections on each
radiator was evaluated to further assess any deactivation in
performance over time.
[0088] Ozone conversion was measured by placing the radiators in a
full-scale radiator test rig (air duct), heating the radiators
internally with hot recirculating coolant (50:50 mixture of
antifreeze and water), and blowing ozone-containing air over the
radiators. Ozone conversion was measured at three different
airflows corresponding to radiator space velocities of 200,000,
400,000, and 600,000/h. Additionally, the radiator test rig was
operated to achieve three different temperature conditions
(90.degree. C., 75.degree. C., and 45.degree. C.). For the
90.degree. C. condition, the test rig was operated in "single-pass"
airflow mode where 100% of the air entering the radiator was fresh
ambient air. In this configuration the coolant temperature to the
radiator was maintained at 90.degree. C. The ambient air entering
the radiator was preheated to ca. 20.degree. C. to 40.degree. C.
(in order to maintain the 90.degree. C. coolant temperature), and
the air temperature exiting the radiator was allowed to vary as the
airflow was changed during the ozone conversion measurements (i.e.
the higher the airflow the lower the air temperature). For the
other temperature conditions used to measure ozone destruction
performance, the test rig was operated in "full recirculation"
airflow mode where the air exiting the radiator was recirculated
back to the radiator inlet. In this configuration, the air exiting
the radiator was maintained at a constant 45 or 75.degree. C. while
ozone conversion measurements were taken at different airflows.
[0089] Ozone conversion results fresh and after on-road aging for
the three formulations on the S-70 radiator are shown in Tables
4-8. Although both of the alumina-overcoated sections had initial
lower conversions, these sections showed substantially less decline
in conversion with on-road aging. In fact, as illustrated in Table
8, the overcoated Section 3 catalyst formulation showed virtually
no deactivation over 51,000 miles whereas the non-overcoated
Section 2 catalyst lost an absolute 23% in ozone conversion.
Although, ozone conversion for the three sections was virtually
identical after 32,000 miles, after 51,000 miles, both of the
overcoated catalyst formulations on Sections 1 and 3 had
significantly better ozone conversion than the non-overcoated
catalyst formulation on Section 2. Additional on-road aging would
be expected to result in continued faster deactivation for the
non-overcoated formulation relative to the two overcoated
formulations.
4TABLE 4 Volvo S-70 Fresh Temperature Ozone Conversion (%) (C.
.degree.) Space Velocity (/h) Section 3 Section 2 Section 1 90
600,000 48.4 61.9 53.3 400,000 53.9 68.5 61.0 200,000 65.5 80.2
71.6 75 600,000 52.6 65.8 58.3 400,000 58.3 72.3 64.2 200,000 70.3
80.0 75.0 45 600,000 41.7 51.4 43.5 400,000 47.1 61.6 50.2 200,000
63.4 74.5 67.5
[0090]
5TABLE 5 Volvo S-70 aged 16,140 miles Temperature Ozone Conversion
(%) (C. .degree.) Space Velocity (/h) Section 3 Section 2 Section 1
90 600,000 49.7 51.9 51.7 400,000 55.0 61.5 60.0 200,000 67.7 74.3
71.4 75 600,000 50.8 50.8 50.6 400,000 55.8 59.7 58.3 200,000 72 4
76.3 73.7 45 600,000 45.6 49.6 45.3 400,000 50.8 52.0 50.1 200,000
63.2 68.1 65.8
[0091]
6TABLE 6 Volvo S-70 aged 32,087 miles Temperature Ozone Conversion
(%) (C. .degree.) Space Velocity (/h) Section 3 Section 2 Section 1
90 600,000 47.6 45.7 46.7 400,000 53.1 51.6 53.4 200,000 65.9 65.6
65.6 75 600,000 48.3 44.1 47.3 400,000 57.0 54.9 56.9 200,000 71.4
67.9 69.5 45 600,000 44.7 36.9 38.3 400,000 48.8 43.9 46.1 200,000
64.7 57.4 60.0
[0092]
7TABLE 7 Volvo S-70 aged 50,863 miles Temperature Ozone Conversion
(%) (C. .degree.) Space Velocity (/h) Section 3 Section 2 Section 1
90 600,000 47.5 39.0 43.9 400,000 54.2 49.6 53.0 200,000 67.8 63.0
67.2 75 600,000 49.9 39.5 47.0 400,000 60.3 49.9 54.7 200,000 71.3
62.0 70.5 45 600,000 41.2 26.2 29.9 400,000 47.3 33.3 40.0 200,000
60.8 46.9 55.5
[0093]
8 TABLE 8 Ozone Conversion %.sup.b Section 1 Fresh 53.3 Section 1
Aged 16,140 miles 51.7 Section 1 Aged 32,087 miles 46.7 Section 1
Aged 50,863 miles 43.9 Section 2 Fresh 61.9 Section 2 Aged 16,140
miles 51.9 Section 2 Aged 32,087 miles 45.7 Section 2 Aged 50,863
miles 39.0 Section 3 Fresh 48.4 Section 3 Aged 16,140 miles 49.7
Section 3 Aged 32,087 miles 47.6 Section 3 Aged 50,863 miles 47.5
.sup.bOzone Conversion Test Conditions: 90.degree. C. Coolant
Temperature; 600,000 (1/hr) Space Velocity, ca. 200 ppb ozone
[0094] Similar fresh and aged ozone conversion results for the same
three formulations coated on the S-70 T radiator are shown in
Tables 9-13. Although all sections showed some decline in activity
with on-road aging, the overcoated sections declined at a
significantly slower rate. In fact, as illustrated in Table 13, the
overcoated Section 1 and 3 catalyst formulations showed an absolute
loss in ozone conversion of approximately 13% after 50,000 miles
whereas the non-overcoated Section 2 catalyst lost an absolute 22%
in ozone conversion. In addition, after 50,000 miles, both of the
alumina overcoated catalyst formulations (particularly the Section
3 catalyst) had higher ozone conversion than the non-overcoated
catalyst formulation. Additional on-road aging would be expected to
result in continued faster deactivation for the non-overcoated
formulation relative to the two overcoated formulations.
9TABLE 9 Volvo S-70T Fresh Temperature Ozone Conversion (%) (C.
.degree.) Space Velocity (/h) Section 3 Section 2 Section 1 90
600,000 67.2 67.0 60.5 400,000 75.8 73.7 68.2 200,000 85.1 85.4
82.0 75 600,000 62.4 60.7 53.2 400,000 68.3 67.3 62.7 200,000 83.1
82.9 80.2 45 600,000 53.0 50.7 43.6 400,000 62.3 61.2 55.4 200,000
77.4 76.2 72.2
[0095]
10TABLE 10 Volvo S-70T aged 16,233 miles Temperature Ozone
Conversion (%) (C. .degree.) Space Velocity (/h) Section 3 Section
2 Section 1 90 600,000 56.8 50.5 51.1 400,000 63.7 60.1 59.5
200,000 81.8 78.6 77.4 75 600,000 57.4 54.2 52.2 400,000 65.0 61.8
60.8 200,000 80.4 77.7 77.0 45 600,000 47.6 42.5 40.2 400,000 56.5
50.7 50.3 200,000 74.7 69.5 69.8
[0096]
11TABLE 11 Volvo S-70T aged 32,277 miles Temperature Ozone
Conversion (%) (C. .degree.) Space Velocity (/h) Section 3 Section
2 Section 1 90 600,000 57.7 48.1 48.7 400,000 63.6 57.4 58.3
200,000 76.9 71.5 72.4 75 600,000 56.9 50.4 50.3 400,000 67.2 59.2
60.5 200,000 79.8 71.7 73.9 45 600,000 48.4 37.8 38.0 400,000 50.9
46.0 44.6 200,000 66.8 59.3 58.7
[0097]
12TABLE 12 Volvo S-70T aged 50,173 miles Temperature Ozone
Conversion (%) (C. .degree.) Space Velocity (/h) Section 3 Section
2 Section 1 90 600,000 54 4 45.0 46.9 400,000 61.7 52.0 53.4
200,000 78.0 69.9 72.0 75 600,000 55.9 43.1 46.6 400,000 64.1 51.5
55.8 200,000 80.0 69.4 74.4 45 600,000 42.0 29.9 32.3 400,000 49.4
37.3 42.5 200,000 67.1 53.8 59.8
[0098]
13 TABLE 13 Ozone Conversion %.sup.c Section 1 Fresh 60.5 Section 1
Aged 16,233 miles 51.1 Section 1 Aged 32,277 miles 48.7 Section 1
Aged 50,173 miles 46.9 Section 2 Fresh 67.0 Section 2 Aged 16,233
miles 50.5 Section 2 Aged 32,277 miles 48.1 Section 2 Aged 50,173
miles 45.0 Section 3 Fresh 67.2 Section 3 Aged 16,233 miles 56.8
Section 3 Aged 32,277 miles 57.7 Section 3 Aged 50,173 miles 54.4
.sup.cOzone Conversion Test Conditions: 90.degree. C. Coolant
Temperature; 600,000 (1/hr) Space Velocity; ca. 200 ppb ozone.
EXAMPLE 3
[0099] A Ford Taurus radiator was coated in three separate sections
("stripes") with three MnO.sub.2 based ozone destroying catalyst
formulations. A brief description of each formulation is given
below:
[0100] Section 1: 3.5 .mu.m average particle size MnO.sub.2 coating
containing an EVA/acrylic binder blend and overcoated with SRS-II
alumina.
[0101] Section 2: same as Section 1 formulation without the alumina
overcoat.
[0102] Section 3: 3.5 .mu.m average particle size MnO.sub.2 coating
containing an EVA/acrylic binder blend and overcoated with SRS-II
alumina and further overcoated with FC-824 water repellent.
[0103] The MnO.sub.2 binder system used in all sections contained a
1:1 blend of acrylic/styrene acrylic latex binder (Rhoplex P-376
from Rhom & Haas) with an EVA (ethylene vinyl acetate) latex
binder from National Starch (Duroset Elite 22). The SRS-II alumina
binder system used in the overcoat formulations coated in Sections
1 and 3 contained only the acrylic/styrene acrylic latex binder
(Rhoplex P-376) from Rohm & Haas. The SRS-II alumina was
purchased from Grace. The BET surface area of this material was ca.
300 m.sup.2/g and it contained approximately 5% silica. The mean
particle size was approximately 6.5 .mu.m as measured by a Horiba
LA-500 Laser Diffraction Particle Size Distribution Analyzer. The
alumina overcoats were applied at loadings of ca. 0.22 g/in.sup.3.
The MnO.sub.2 catalyst loadings were approximately 0.38 g/in.sup.3
of radiator volume.
[0104] The FC-824 water repellent was purchased from 3M
Corporation, and it comprised a proprietary fluoropolymer latex
emulsion in water. This emulsion was diluted to 2.5% solids in
water and was subsequently sprayed onto the Section 3 catalyst
formulation such that the catalyst coating was thoroughly wetted.
Excess solution was then removed with an airknife, and the entire
radiator was then dried at 90.degree. C. for approximately 1
hour.
[0105] The coated radiator was placed on a Ford Taurus vehicle and
subjected to accelerated on-road mileage accumulation (ca. 1,000
miles per day). The radiator was removed after accumulating 18,000
miles in the Phoenix, Ariz. metropolitan area during April 1999.
The ozone conversion of the coated sections on the radiator was
evaluated to assess any deactivation in performance over time. The
radiator was then re-installed on the vehicle, and an additional
18,000 miles was accumulated (36,000 total miles) in the Phoenix,
Ariz. metropolitan area during May 1999. The radiator was once
again removed, and the ozone conversion of the coated sections on
the radiator was evaluated to further assess any deactivation in
performance over time. Finally, the radiator was re-installed on
the vehicle, and an additional 14,000 miles was accumulated (50,000
total miles) in the Detroit, Mich. metropolitan area during June
1999. The radiator was removed one last time, and the ozone
conversion of the coated sections on the radiator was evaluated to
further assess any deactivation in performance over time.
[0106] Ozone conversion was measured by the same procedure
described in Examples 1 and 2.
[0107] Ozone conversion results fresh and after on-road aging for
the three formulations on the Ford Taurus radiator are summarized
in Table 14. Although all sections showed some decline in activity
with on-road aging, the two overcoated sections declined at a
slower rate. As illustrated in Table 14, the overcoated Section 1
and 3 catalyst formulations showed an absolute loss in ozone
conversion of 15 and 8%, respectively, after 50,000 miles whereas
the non-overcoated Section 2 catalyst lost an absolute 19% in ozone
conversion. Clearly, the overcoated catalyst formulations,
particularly the Section 3 catalyst formulation with the
combination of alumina and water repellent, deactivated the least
after 50,000 miles of on-road aging. In addition, both of the
overcoated catalyst formulations had higher ozone conversion after
50,000 miles aging than the non-overcoated catalyst formulation.
Additional on-road aging would be expected to result in continued
faster deactivation for the non-overcoated formulation relative to
the two overcoated formulations.
14TABLE 14 Ozone Conversion %.sup.d Section 1 Fresh 84.4 Section 1
Aged 18,506 miles 77.0 Section 1 Aged 36,168 miles 74.7 Section 1
Aged 50,335 miles 69.0 Section 2 Fresh 84.7 Section 2 Aged 18,506
miles 81.1 Section 2 Aged 36,168 miles 77.0 Section 2 Aged 50,335
miles 65.7 Section 3 Fresh 76.5 Section 3 Aged 18,506 miles 70.8
Section 3 Aged 36,168 miles 73.0 Section 3 Aged 50,335 miles 68.4
.sup.dOzone Conversion Test Conditions: 90.degree. C. Coolant
Temperature; 600,000 (1/hr) Space Velocity; ca. 200 ppb ozone.
* * * * *