Microfiber Knits for Catalytic Converters

Microfibers with high specific micro-surface can be knitted into two-dimensional structures with large internal porosity. Catalytically active metals can be deposited on the fibers with high dispersion by wet-impregnation, sol-gel or CVD, respectively. These microfiber knits may be used for exhaust gas treatment systems with a triple function: particle filtration, gas conversion and muffling. The total oxidation of propane on Pd and Pt coated fibers has been studied as a test reaction. Conversion temperature could be remarkably reduced compared to cellular structures. For a bimetallic (Pt-Pd) coating, the activity is independent of humidity or oxygen concentration. Thus a catalytic converter based on micro-fiber knits appears feasible. Its high mass and heat transfer prevent hot spots. And it functions as submicron filter for combustion aerosols. Integrated electric heating can also be provided in case of low gas temperatures. First tests on engines show promising results.