Catalyst structure with catalyst particles forged into substrate surface

Abstract

A catalyst structure has catalytic particles dispersed over and forged into the surface of a metal substrate such that the particles protrude from the surface and are permanently fixed into the surface. The forging is accomplished by brush graining to press the particles into the surface The particles may be any particles which have catalytic activity for a particular purpose and which are hard enough to forge into the metal substrate.

1 . A catalytic structure comprising oxide catalyst particles dispersed over and partially forged into a surface of a substrate wherein said oxide catalyst particles are permanently fixed to said substrate and protrude from said surface of said substrate wherein said catalytic structure is produced by the process of: 
 (a) providing a substrate;    (b) forming a slurry of oxide catalyst particles of a composition capable of being forged into a surface of said substrate;    (c) applying said slurry to said surface of said substrate; and    (d) rotating a graining brush in engagement with said surface of said substrate having said slurry thereon with a force sufficient to forge said oxide catalyst particles partially into said surface and permanently fix said oxide catalyst particles to said substrate and leave said oxide catalyst particles protruding from said substrate.    
     
     
         2 . A catalytic structure as recited in  claim 1  wherein said oxide catalyst particles comprise an ozone decomposing catalyst.  
     
     
         3 . A catalytic structure as recited in  claim 2  wherein said oxide catalyst particles comprise a manganese oxide.  
     
     
         4 . A catalytic structure as recited in  claim 3  wherein said manganese oxide comprises manganese dioxide.  
     
     
         5 . A catalytic structure as recited in  claim 1  wherein said substrate comprises aluminum.  
     
     
         6 . A catalytic structure as recited in  claim 1  wherein said substrate comprises copper.  
     
     
         7 . A catalytic structure as recited in  claim 1  wherein said oxide catalyst particles are dispersed over and partially forged into opposite surfaces of said substrate.  
     
     
         8 . A catalytic structure comprising oxide catalyst particles dispersed over and partially forged into a surface of a substrate wherein said oxide catalyst particles are permanently fixed to said substrate and protrude from said surface of said substrate wherein said catalytic structure is produced by the process of: 
 (a) providing a substrate web;    (b) forming a slurry of oxide catalyst particles of a composition capable of being forged into a surface of said substrate web;    (c) applying said slurry to said surface of said substrate web;    (d) rotating a graining brush in engagement with said surface of said substrate web having said slurry thereon with a force sufficient to forge said oxide catalyst particles partially into said surface and permanently fix said oxide catalyst particles to said substrate web and leave said oxide catalyst particles protruding from said substrate web; and    (e) cutting said web into individual catalytic structures.    
     
     
         9 . A catalytic structure as recited in  claim 8  wherein said oxide catalyst particles comprise an ozone decomposing catalyst.  
     
     
         10 . A catalytic structure as recited in  claim 9  wherein said oxide catalyst particles comprise a manganese oxide.  
     
     
         11 . A catalytic structure as recited in  claim 10  wherein said manganese oxide comprises manganese dioxide.  
     
     
         12 . A catalytic structure as recited in  claim 8  wherein said substrate comprises aluminum.  
     
     
         13 . A catalytic structure as recited in  claim 8  wherein said substrate comprises copper.  
     
     
         14 . A catalytic structure as recited in  claim 8  wherein said oxide catalyst particles are dispersed over and partially forged into opposite surfaces of said substrate.  
     
     
         15 . A catalytic structure comprising oxide catalyst particles dispersed over and partially forged into a surface of a substrate wherein said oxide catalyst particles are permanently fixed to said substrate and protrude from said surface of said substrate.  
     
     
         16 . A catalytic structure as recited in  claim 15  wherein said oxide catalyst particles comprise an ozone decomposing catalyst.  
     
     
         17 . A catalytic structure as recited in  claim 16  wherein said oxide catalyst particles comprise a manganese oxide.  
     
     
         18 . A catalytic structure as recited in  claim 17  wherein said manganese oxide comprises manganese dioxide.  
     
     
         19 . A catalytic structure as recited in  claim 15  wherein said substrate comprises aluminum.  
     
     
         20 . A catalytic structure as recited in  claim 15  wherein said substrate comprises copper.  
     
     
         21 . A catalytic structure as recited in  claim 15  wherein said oxide catalyst particles are dispersed over and partially forged into opposite surfaces of said substrate.