CN102844113A - 用于汽车用途的先进催化剂 - Google Patents

用于汽车用途的先进催化剂 Download PDF

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CN102844113A
CN102844113A CN2010800635885A CN201080063588A CN102844113A CN 102844113 A CN102844113 A CN 102844113A CN 2010800635885 A CN2010800635885 A CN 2010800635885A CN 201080063588 A CN201080063588 A CN 201080063588A CN 102844113 A CN102844113 A CN 102844113A
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Q·尹
X·齐
M·A·比博格
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SDC Materials Inc
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Abstract

本发明的实施方案涉及先进催化剂。该先进催化剂包括蜂窝结构，在所述蜂窝结构上具有至少一种纳米粒子。柴油机中所用的该先进催化剂是二元催化剂。煤气发动机中所用的该先进催化剂是三元催化剂。在二元催化剂和三元催化剂中，所述至少一种纳米粒子包括纳米活性材料和纳米载体。纳米载体通常是氧化铝。在二元催化剂中，纳米活性材料是铂。在三元催化剂中，纳米活性材料是铂、钯、铑或合金。该合金是铂、钯和铑的合金。

Description

用于汽车用途的先进催化剂
对相关申请的交叉引用
本申请要求2009年12月15日提交的名称为“材料加工”的美国临时专利申请序号No.61/284,329的优先权，其全文经此引用并入本文，如本文中所述。
发明背景
汽车的催化转化器使用催化剂将汽车废气中的例如三种有害化合物转化成不那么有害的化合物。这三种有害化合物包括未燃汽油形式的烃、通过汽油燃烧形成的一氧化碳和在发动机中的热迫使空气中的氮与氧结合时产生的氮氧化物。在催化转化器中使用两种主要结构——蜂窝和陶瓷珠。目前大多数汽车使用蜂窝结构。该蜂窝结构装在位于排气管之前的类似消音器的包装中。催化剂有助于将一氧化碳转化成二氧化碳，将烃转化成二氧化碳和水和将氮氧化物转化回氮和氧。
在本领域中存在多种制造在催化转化器中使用的催化剂的方法。图1A显示了制造催化剂的第一常规方法。所述第一方法被称作一浸法。在步骤105，使微米级铂（Pt）离子渗透到微米级氧化铝（Al2O3）离子中，从而产生微粒子。该微粒子具有在氧化铝离子上的铂原子。在步骤110，使用包括小尺寸氧化铝和小尺寸二氧化硅（SiO2）的微米级氧化物、一定量的氧化铝的稳定剂和一定量的助催化剂制造洗涂料（wash coat）。在步骤115，将微粒子与洗涂料混合在一起。在步骤120，获得圆柱形陶瓷整料。该整料的横截面含有300-600个通道/平方英寸。这些通道是从整料正面到背面的直线四方通道。在步骤125，用洗涂料涂布该整料。这可以通过将整料浸在洗涂料中来实现。由此该整料的通道被洗涂料层涂布。在步骤130，将整料干燥。该洗涂料层具有不规则表面，其表面积远大于平的表面。此外，该洗涂料在干燥时是多孔结构。不规则表面和多孔结构是合意的，因为它们提供了大约100-250平方米/克的高的表面积和因此更多的供微粒子结合到其上的位置。随着整料干燥，微粒子沉积在整料的表面和孔隙上。在步骤135，煅烧整料。煅烧使洗涂料的组分通过氧化物-氧化物偶联结合到整料上。形成催化剂。图1B显示了整料140通道的显微视图145，所述通道涂有具有铂原子155的洗涂料层150。
图2A显示了制造催化剂的第二常规方法。所述第二方法被称作二浸法。在步骤205，使用包括小尺寸氧化铝和小尺寸二氧化硅的微米级氧化物、一定量的氧化铝的稳定剂和一定量的助催化剂制造洗涂料。在步骤210，获得圆柱形陶瓷整料。在步骤215，例如通过浸渍用该洗涂料涂布整料。由此通道也被洗涂料层涂布。通常，该洗涂料层具有不规则表面，其表面积远大于平的表面。图2B显示了涂有洗涂料层255的整料245通道的显微视图250。回到图2A，在步骤220，将整料干燥。该洗涂料在干燥时是多孔结构。在步骤225，煅烧整料。煅烧使洗涂料的组分通过氧化物-氧化物偶联结合到整料上。然后使用本领域中公知的方法用微米级铂离子和其它助催化剂浸渍微米级氧化铝。具体而言，在步骤230中，将铂硝酸化以形成盐（PtNO3）。将PtNO3溶解在溶剂（例如水）中，由此产生分散体。在步骤235中，将整料浸到该溶液中。在步骤240中，将整料干燥。在步骤245中，煅烧整料。形成催化剂。图2C显示了整料245'通道的另一显微视图250'，所述通道涂有具有铂原子260的洗涂料层255'。
图3A显示了洗涂料层的表面在煅烧后的显微视图305。铂原子310连接到氧化铝的氧原子上。在废气经过催化转化器时，铂原子310通过将有害化合物转化成不那么有害的化合物而有助于减少有害化合物。但是，这些制造催化转化器中所用的催化剂的各种方法具有许多缺点。例如，铂原子310没有固定到它们键合的氧化铝氧原子上，并能如图3B-3C中所示移向其它可用的氧原子。随着铂原子310移动，铂原子310开始与其它铂原子聚结，以产生如图3D中所示的较大粒子315和更积极的状态。可以理解的是，随着铂粒子变大，其不利地影响催化剂，因为铂原子的表面积降低。在高温用途中，例如在老化催化转化测试中，铂原子的移动增强。此外，由于铂的成本极昂贵，不希望过度使用铂。
本发明致力于解决现有技术中的至少这些局限。
发明概述
一方面，催化转化器包括蜂窝结构，在所述蜂窝结构上具有至少一种纳米粒子。在一些实施方案中，所述至少一种纳米粒子包括纳米活性材料和纳米载体。纳米活性材料通常在纳米载体上。该纳米活性材料是铂、钯、铑或合金。该合金是铂、钯和铑的合金。该纳米载体是氧化铝。在另一些实施方案中，纳米载体包括部分还原的氧化铝表面，其限制纳米活性材料在纳米载体表面上的移动。
另一方面，催化转化器中的堇青石基底包括第一类型的纳米粒子、第二类型的纳米粒子和第三类型的纳米粒子。在一些实施方案中，第一类型的纳米粒子包括纳米活性材料和纳米载体。纳米活性材料是铂且纳米载体是氧化铝。该纳米载体包括部分还原的氧化铝表面，其限制纳米活性材料在纳米载体表面上的移动。在另一些实施方案中，第二类型的纳米粒子包含纳米活性材料和纳米载体。纳米活性材料是钯且纳米载体是氧化铝。该纳米载体包括部分还原的氧化铝表面，其限制纳米活性材料在纳米载体表面上的移动。在另一些实施方案中，第三类型的纳米粒子包含纳米活性材料和纳米载体。纳米活性材料是铑且纳米载体是氧化铝。该纳米载体包括部分还原的氧化铝表面，其限制纳米活性材料在纳米载体表面上的移动。
再一方面，制造催化转化器的方法包括使用至少一种纳米粒子制造分散体和获得洗涂料。在一些实施方案中，所述至少一种纳米粒子包括纳米活性材料和纳米载体。该纳米活性材料是铂、钯、铑或合金。该纳米载体是氧化铝。该纳米载体包括部分还原的氧化铝表面，其限制纳米活性材料在纳米载体表面上的移动。在另一些实施方案中，所述制造步骤包括在高温冷凝技术中将担载材料和不同的催化剂材料混合，由此产生所述至少一种纳米粒子，并将其与液体合并。该担载材料是氧化铝。所述不同的催化剂材料包括铂、钯和铑。通常，该高温冷凝技术是等离子体。或者，所述制造步骤包括在高温冷凝技术中混合担载材料和第一催化剂材料，由此产生第一类型的纳米粒子，在高温冷凝技术中混合担载材料和第二催化剂材料，由此产生第二类型的纳米粒子，在高温冷凝技术中混合担载材料和第三催化剂材料，由此产生第三类型的纳米粒子，将第一类型的纳米粒子、第二类型的纳米粒子和第三类型的纳米粒子收集在一起，并与液体合并。该担载材料是氧化铝。第一催化剂材料是铂。第二催化剂材料是钯。第三催化剂材料是铑。
在再一些实施方案中，所述制造催化转化器的方法进一步包括将所述分散体与所述洗涂料混合、将所述混合物施用到整料上、干燥所述整料和煅烧所述整料。或者，所述制造催化转化器的方法进一步包括将所述洗涂料施用到整料上、干燥所述整料、煅烧所述整料、将所述分散体施用到所述整料上、干燥所述整料和煅烧所述整料。
再一方面，制造三元催化转化器的方法包括使用不同类型的纳米粒子制造分散体、获得洗涂料、将所述分散体与所述洗涂料混合、将所述混合物施用到整料上、干燥所述整料和煅烧所述整料。所述制造步骤包括使用高温冷凝技术。在一些实施方案中，该高温冷凝技术是等离子体。所述不同类型的纳米粒子各自包含纳米活性材料和纳米载体。该纳米活性材料是铂、钯、铑或合金。该纳米载体是氧化铝。该纳米载体包括部分还原的氧化铝表面，其限制纳米活性材料在纳米载体表面上的移动。
再一方面，制造三元催化转化器的方法包括使用不同类型的纳米粒子制造分散体、获得洗涂料、将所述洗涂料施用到整料上、干燥所述整料、煅烧所述整料、将所述分散体施用到所述整料上、干燥所述整料、和煅烧所述整料。所述制造步骤包括使用高温冷凝技术。在一些实施方案中，该高温冷凝技术是等离子体。所述不同类型的纳米粒子各自包括纳米活性材料和纳米载体。该纳米活性材料是铂、钯、铑或合金。该纳米载体是氧化铝。该纳米载体包括部分还原的氧化铝表面，其限制纳米活性材料在纳米载体表面上的移动。
再一方面，制造二元催化转化器的方法包括使用相同类型的纳米粒子制造分散体、获得洗涂料、将所述分散体与所述洗涂料混合、将所述混合物施用到整料上、干燥所述整料、和煅烧所述整料。所述制造步骤包括使用高温冷凝技术。在一些实施方案中，该高温冷凝技术是等离子体。所述相同类型的纳米粒子各自包括纳米活性材料和纳米载体。该纳米活性材料是铂。该纳米载体是氧化铝。该纳米载体包括部分还原的氧化铝表面，其限制纳米活性材料在纳米载体表面上的移动。
再一方面，制造二元催化转化器的方法包括使用相同类型的纳米粒子制造分散体、获得洗涂料、将所述洗涂料施用到整料上、干燥所述整料、煅烧所述整料、将所述分散体施用到所述整料上、干燥所述整料和煅烧所述整料。所述制造步骤包括使用高温冷凝技术。在一些实施方案中，该高温冷凝技术是等离子体。所述相同类型的纳米粒子各自包括纳米活性材料和纳米载体。该纳米活性材料是铂。该纳米载体是氧化铝。该纳米载体包括部分还原的氧化铝表面，其限制纳米活性材料在纳米载体表面上的移动。
附图简述
图1A-1B显示制造催化剂的第一常规方法。
图2A-2C显示制造催化剂的第二常规方法。
图3A-3C显示使用第一常规方法和第二常规方法在整料上的洗涂料层的表面上的活性。
图4显示根据本发明制造先进催化剂的第一发明方法。
图5显示根据本发明制造先进催化剂的第一发明方法。
图6A显示根据本发明制造分散体的第一方法。
图6B显示根据本发明的纳米粒子。
图7A显示根据本发明制造分散体的第二方法。
图7B显示根据本发明的不同纳米粒子的集合。
发明详述
现在详细参考如附图中显示的本发明的实施方案。附图可以不按比例。在附图和下列详述中各处使用相同参考标记指示相同或类似要素。为清楚起见，没有显示和描述本文所述的实施方案的所有常规特征。当然要认识到，在任何这样的实际实施方案的开发中，必须作出实施方案特有的许多决策以实现开发者的特定目标，如与用途、安全规章和业务相关约束相符，且这些特定目标随实施方案而变和随开发者而变。此外，要认识到，这种开发努力将是获益于本公开的本领域普通技术人员的常规工程工作。
提供下列发明描述以教导如何实施，这包括目前公知的实施方案。相关领域，包括但不限于化学、物理和材料科学领域中的技术人员会认识到，可以对所述实施方案作出许多变动，同时仍获得本发明的有益结果。还显而易见地，可以通过选择本发明的一些要素而不利用其它要素来获得本发明的一些所需益处。因此，本领域工作人员会认识到，可以对本发明作出许多修改和改变，并在某些情况下甚至可能是合意的，并且是本发明的一部分。因此，提供下列描述作为本发明的原理的示例而非其限制，因为由权利要求书规定本发明的范围。
来自内燃机的有害化合物包括一氧化碳（CO）、烃（HaCb）和氮氧化物（NOx）。内燃机的两种形式是柴油机和煤气发动机。催化转化器被设计成通过将有害化合物转化成不那么有害的化合物来减少这些有害化合物。如上论述，催化转化器中所用的常规催化剂使用微粒子，例如微米级氧化物和微米级催化剂材料（例如铂）。本发明的实施方案使用纳米级氧化物和纳米级催化剂材料，制造可用在柴油机和煤气发动机的催化转化器中的先进催化剂。
术语“纳米粒子”通常被普通技术人员理解为包括具有纳米级直径的粒子，如本文所述。
柴油机
柴油机包括柴油氧化催化剂（DOC）、独立的NOx还原技术和柴油微粒过滤器（DPF）。DOC是二元催化转化器，其将（1）CO和O2转化成CO2和将（2）HaCb和O2转化成CO2和H2O。DOC使用铂作为氧化剂。制造DOC的常规方法使用微米级铂离子。而本发明的实施方案使用纳米级铂粒子。图4-5显示根据本发明制造先进DOC催化剂的两种发明方法。独立的NOx还原技术使用脲作为还原剂以减少NOx排放。DPF从柴油机废气中捕集亚粒子（例如非气态烃）。
图4显示根据本发明制造先进DOC催化剂的第一发明方法400。在步骤405，使用高温冷凝技术，例如等离子体枪，将纳米活性材料固定或附加到纳米载体上，以形成纳米粒子。在一些实施方案中，纳米活性材料是气态铂原子，且纳米载体是一定形式的氧化铝，例如铝+氧。为简洁起见，在本文中将论述铂，但本领域普通技术人员显而易见，可以使用不同的铂族金属以利用它们的不同性质。由于纳米活性材料牢固地附着到纳米载体上，因而限制和/或防止了纳米活性材料的移动或聚结/团聚。然后将该纳米粒子与液体合并，形成分散体。使用2007年12月11日提交的美国专利申请No.12/001,643中详细描述的方法制造该纳米粒子和该分散体，该专利申请经此引用并入本文。在步骤410，获得洗涂料。该洗涂料是购买的或制造的。通常，该洗涂料是浆料。使用包括氧化铝和二氧化硅的微米级氧化物制造洗涂料。在一些实施方案中，也将一定量的氧化铝的稳定剂和一定量的助催化剂添加到洗涂料中。通常，购得的洗涂料和制成的洗涂料之间没有差异。在步骤415，将该分散体与该洗涂料混合。在步骤420，获得圆柱形陶瓷整料。该整料含有大比例的堇青石，因为堇青石具有高的抗热震性。在一些实施方案中，该整料是蜂窝结构。该整料的横截面优选含有300-600个通道/平方英寸。这些通道优选是从整料正面到背面的直线四方通道。在步骤425，用洗涂料层涂布该整料。这可以通过将整料浸在洗涂料中来实现。整料的通道也被洗涂料层涂布。由于该洗涂料含有纳米粒子，因此纳米铂粒子也在整料表面上。在步骤430，将整料干燥。在步骤435，煅烧整料。煅烧使洗涂料的组分通过氧化物-氧化物偶联结合到整料上。此外，由于纳米载体具有部分还原的氧化铝表面，因此煅烧使纳米活性材料牢固地附着到纳米载体上。由此形成该先进DOC催化剂。
图5显示根据本发明制造先进DOC催化剂的第二发明方法500。在步骤505，使用高温冷凝技术，例如等离子体枪，将纳米活性材料固定或附加到纳米载体上，以形成纳米粒子。在一些实施方案中，纳米活性材料是气态铂原子且纳米载体是一定形式的氧化铝，例如铝+氧。由于纳米活性材料牢固地附着到纳米载体上，因此限制和/或防止了纳米活性材料的移动或聚结/团聚。然后将该纳米粒子与液体合并，形成分散体。在步骤510，获得洗涂料。该洗涂料是购买的或制造的。使用包括氧化铝和二氧化硅的微米级氧化物制造洗涂料。在一些实施方案中，也将一定量的氧化铝的稳定剂和一定量的助催化剂添加到洗涂料中。通常，购得的洗涂料和制成的洗涂料之间没有差异。在步骤515，获得圆柱形陶瓷整料。在步骤520，例如通过浸渍用洗涂料层涂布该整料。这样，整料的通道也被洗涂料层涂布。在步骤525，将整料干燥。在步骤530，煅烧整料。在步骤535，通过浸渍将该分散体施用到该整料上。在步骤540，将整料干燥。在步骤545，煅烧整料。煅烧使洗涂料的组分通过氧化物-氧化物偶联结合到整料上。由此形成该先进DOC催化剂。
为使洗涂料良好结合到整料上，该洗涂料的pH水平和粘度必须在一定范围内。通常，pH水平必须在4至5之间以实现氧化物-氧化物偶联。如果pH水平太低，则粘度太高；这样，洗涂料就是膏而不是浆料。如果pH水平太高，则粘度太低；这样，甚至在煅烧后，该洗涂料也没有结合到整料上。
尽管描述了纳米材料用于该先进DOC催化剂的用途，纳米材料也能用于柴油机中所用的DPF和NOx还原技术。也考虑自动化领域中的其它催化剂。
煤气发动机
煤气发动机从富氧到贫氧（例如氧化态到还原态）循环。因此，用于煤气发动机的常规催化转化器包括氧化催化剂和还原催化剂。还原催化剂是常规催化转化器中的第一阶段。还原催化剂使用铂和铑以助于减少NOx排放。例如，铑催化CO和NO2转化成N2和CO2的反应。氧化催化剂是常规催化转化器中的第二阶段。其通过使用铂和钯将未燃烃和一氧化碳氧化而减少它们。例如，铂催化CO和O2转化成CO2的反应，并催化HaCb和O2转化成CO2和H2O的反应。钯催化H2和O2转化成C2O的反应。氧化催化剂有助于一氧化碳和烃与残留氧在排气管中的的反应。因此，该煤气发动机使用三元催化转化器减少这三种有害化合物。
制造三元催化转化器的常规方法使用如上所述的微米级催化材料和载体。此外，常规方法使用多次浸渍以在整料上提供钯离子、铑离子和铂离子，因为包括例如钯离子和铑离子的浸料会产生在某些条件和/或用途中无益处的钯-铑合金。而本发明的实施方案使用纳米级催化材料和载体。此外，本发明的实施方案允许浸料包括钯离子、铑离子和铂离子而不产生钯-铑合金，因为不同离子具有不同固相。
制造用于煤气发动机的先进三元催化剂的方法类似于如上所述的制造DOC的方法。差异分别在于图4-5的初始步骤405和505。具体而言，不是在分散体中仅使用气态铂原子，还使用气态钯原子和气态铑原子。
图6A显示根据本发明制造分散体的第一方法。催化剂材料包括铂615、钯620和铑625。其它催化剂材料也是可行的。担载材料包括氧化铝630。将催化剂材料615、620、625和担载材料630在等离子体枪中混合。在气化该催化剂材料和担载材料以形成蒸气云和骤冷该蒸气云后，该蒸气云凝结出纳米粒子。图6B显示了根据本发明的纳米粒子600。纳米粒子600包含纳米活性材料610和纳米载体605。由于等离子体枪极混乱，因此催化剂材料形成为合金。这样，纳米活性材料610是合金。由于由铂、钯和铑构成的纳米活性材料610的比率取决于所用的各催化剂材料的初始比率，因此在纳米载体605上形成不同形式的合金。将纳米粒子600与液体合并形成分散体。
图7A显示根据本发明制造分散体的第二方法。不是将铂615、钯620、铑625和氧化铝630在等离子体枪中混合，而是将各催化剂材料分别与氧化铝630在等离子体枪中混合。因此，在气化和骤冷各催化剂材料后，形成三种不同的纳米粒子。将收集到的不同的纳米粒子与液体合并，形成分散体。这三种不同的纳米粒子显示在图7B中。第一纳米粒子600'是在氧化铝纳米载体605上的铂纳米活性材料635。第二纳米粒子600"是在氧化铝纳米载体605上的钯纳米活性材料640。第三纳米粒子600"'是在氧化铝纳米载体605上的铑纳米活性材料645。能够基于最初置于等离子体枪中的纳米活性材料的量控制纳米活性材料的尺寸。能够逐一和/或一起控制各不同纳米粒子600'、600"、600"'的浓度。
在使用第一方法（如图6A中所示）或第二方法（如图7A中所示）制造分散体后，分别如图4-5中所示，第一发明方法400以步骤410继续且第二发明方法500以步骤510继续。
尽管已参照许多具体细节描述了本发明，但本领域普通技术人员会认识到，可以在不背离本发明的实质的情况下以其它具体形式具体实施本发明。因此，本领域普通技术人员会理解，本发明不受上述示例性细节限制，而是由所述权利要求书规定。

Claims (75)

1.催化转化器，其包含蜂窝结构，在所述蜂窝结构上具有至少一种纳米粒子。
2.权利要求1的催化转化器，其中所述至少一种纳米粒子包含纳米活性材料和纳米载体。
3.权利要求2的催化转化器，其中所述纳米活性材料是铂。
4.权利要求2的催化转化器，其中所述纳米活性材料是钯。
5.权利要求2的催化转化器，其中所述纳米活性材料是铑。
6.权利要求2的催化转化器，其中所述纳米活性材料是合金。
7.权利要求2的催化转化器，其中所述纳米载体是氧化铝。
8.权利要求2的催化转化器，其中所述纳米载体包含部分还原的氧化铝表面，所述部分还原的氧化铝表面被构造成限制纳米活性材料在纳米载体表面上的移动。
9.催化转化器中的堇青石基底，其包含：
a.第一类型的纳米粒子；
b.第二类型的纳米粒子；和
c.第三类型的纳米粒子。
10.权利要求9的堇青石基底，其中第一类型的纳米粒子包含纳米活性材料和纳米载体。
11.权利要求10的堇青石基底，其中所述纳米活性材料是铂。
12.权利要求10的堇青石基底，其中所述纳米载体是氧化铝。
13.权利要求10的堇青石基底，其中所述纳米载体包含部分还原的氧化铝表面，所述部分还原的氧化铝表面被构造成限制纳米活性材料在纳米载体表面上的移动。
14.权利要求9的堇青石基底，其中第二类型的纳米粒子包含纳米活性材料和纳米载体。
15.权利要求14的堇青石基底，其中所述纳米活性材料是钯。
16.权利要求14的堇青石基底，其中所述纳米载体是氧化铝。
17.权利要求14的堇青石基底，其中所述纳米载体包含部分还原的氧化铝表面，所述部分还原的氧化铝表面被构造成限制纳米活性材料在纳米载体表面上的移动。
18.权利要求9的堇青石基底，其中第三类型的纳米粒子包含纳米活性材料和纳米载体。
19.权利要求18的堇青石基底，其中所述纳米活性材料是铑。
20.权利要求18的堇青石基底，其中所述纳米载体是氧化铝。
21.权利要求18的堇青石基底，其中所述纳米载体包含部分还原的氧化铝表面，所述部分还原的氧化铝表面被构造成限制纳米活性材料在纳米载体表面上的移动。
22.制造催化转化器的方法，其包括：
a.使用至少一种纳米粒子制造分散体；和
b.获得洗涂料。
23.权利要求22的方法，其中所述至少一种纳米粒子包含纳米活性材料和纳米载体。
24.权利要求23的方法，其中所述纳米活性材料是铂。
25.权利要求23的方法，其中所述纳米活性材料是钯。
26.权利要求23的方法，其中所述纳米活性材料是铑。
27.权利要求23的方法，其中所述纳米活性材料是合金。
28.权利要求23的方法，其中所述纳米载体是氧化铝。
29.权利要求23的方法，其中所述纳米载体包含部分还原的氧化铝表面，所述部分还原的氧化铝表面被构造成限制纳米活性材料在纳米载体表面上的移动。
30.权利要求22的方法，其中所述制造包括：
a.在高温冷凝技术中将担载材料和不同的催化剂材料混合，由此产生所述至少一种纳米粒子；和
b.与液体合并。
31.权利要求30的方法，其中所述担载材料是氧化铝。
32.权利要求30的方法，其中所述不同的催化剂材料包括铂、钯和铑。
33.权利要求30的方法，其中所述高温冷凝技术是等离子体。
34.权利要求22的方法，其中所述制造包括：
a.在高温冷凝技术中将担载材料和第一催化剂材料混合，由此产生第一类型的纳米粒子；
b.在高温冷凝技术中将担载材料和第二催化剂材料混合，由此产生第二类型的纳米粒子；
c.在高温冷凝技术中将担载材料和第三催化剂材料混合，由此产生第三类型的纳米粒子；
d.将第一类型的纳米粒子、第二类型的纳米粒子和第三类型的纳米粒子收集在一起；和
e.与液体合并。
35.权利要求34的方法，其中所述担载材料是氧化铝。
36.权利要求34的方法，其中第一催化剂材料是铂。
37.权利要求34的方法，其中第二催化剂材料是钯。
38.权利要求34的方法，其中第三催化剂材料是铑。
39.权利要求34的方法，其中所述高温冷凝技术是等离子体。
40.权利要求22的方法，进一步包括：
a.将所述分散体与所述洗涂料混合；
b.将所述混合物施用到整料上；
c.干燥所述整料；和
d.煅烧所述整料。
41.权利要求22的方法，进一步包括：
a.将所述洗涂料施用到整料上；
b.干燥所述整料；
c.煅烧所述整料；
d.将所述分散体施用到所述整料上；
e.干燥所述整料；和
f.煅烧所述整料。
42.制造三元催化转化器的方法，其包括：
a.使用不同类型的纳米粒子制造分散体；
b.获得洗涂料；
c.将所述分散体与所述洗涂料混合；
d.将所述混合物施用到整料上；
e.干燥所述整料；和
f.煅烧所述整料。
43.权利要求42的方法，其中所述制造包括使用高温冷凝技术。
44.权利要求42的方法，其中所述高温冷凝技术是等离子体。
45.权利要求42的方法，其中所述不同类型的纳米粒子各自包含纳米活性材料和纳米载体。
46.权利要求45的方法，其中所述纳米活性材料是铂。
47.权利要求45的方法，其中所述纳米活性材料是钯。
48.权利要求45的方法，其中所述纳米活性材料是铑。
49.权利要求45的方法，其中所述纳米活性材料是合金。
50.权利要求45的方法，其中所述纳米载体是氧化铝。
51.权利要求45的方法，其中所述纳米载体包含部分还原的氧化铝表面，所述部分还原的氧化铝表面被构造成限制纳米活性材料在纳米载体表面上的移动。
52.制造三元催化转化器的方法，其包括：
a.使用不同类型的纳米粒子制造分散体；
b.获得洗涂料；
c.将所述洗涂料施用到整料上；
d.干燥所述整料；
e.煅烧所述整料；
f.将所述分散体施用到所述整料上；
g.干燥所述整料；和
h.煅烧所述整料。
53.权利要求52的方法，所述制造包括使用高温冷凝技术。
54.权利要求53的方法，其中所述高温冷凝技术是等离子体。
55.权利要求52的方法，其中所述不同类型的纳米粒子各自包含纳米活性材料和纳米载体。
56.权利要求55的方法，其中所述纳米活性材料是铂。
57.权利要求54的方法，其中所述纳米活性材料是钯。
58.权利要求55的方法，其中所述纳米活性材料是铑。
59.权利要求55的方法，其中所述纳米活性材料是合金。
60.权利要求55的方法，其中所述纳米载体是氧化铝。
61.权利要求55的方法，其中所述纳米载体包含部分还原的氧化铝表面，所述部分还原的氧化铝表面被构造成限制纳米活性材料在纳米载体表面上的移动。
62.制造二元催化转化器的方法，其包括：
a.使用相同类型的纳米粒子制造分散体；
b.获得洗涂料；
c.将所述分散体与所述洗涂料混合；
d.将所述混合物施用到整料上；
e.干燥所述整料；和
f.煅烧所述整料。
63.权利要求62的方法，其中所述制造包括使用高温冷凝技术。
64.权利要求63的方法，其中所述高温冷凝技术是等离子体。
65.权利要求62的方法，其中所述相同类型的纳米粒子各自包含纳米活性材料和纳米载体。
66.权利要求65的方法，其中所述纳米活性材料是铂。
67.权利要求65的方法，其中所述纳米载体是氧化铝。
68.权利要求65的方法，其中所述纳米载体包含部分还原的氧化铝表面，所述部分还原的氧化铝表面被构造成限制纳米活性材料在纳米载体表面上的移动。
69.制造二元催化转化器的方法，其包括：
a.使用相同类型的纳米粒子制造分散体；
b.获得洗涂料；
c.将所述洗涂料施用到整料上；
d.干燥所述整料；
e.煅烧所述整料；
f.将所述分散体施用到所述整料上；
g.干燥所述整料；和
h.煅烧所述整料。
70.权利要求69的方法，其中所述制造包括使用高温冷凝技术。
71.权利要求70的方法，其中所述高温冷凝技术是等离子体。
72.权利要求69的方法，其中所述相同类型的纳米粒子各自包含纳米活性材料和纳米载体。
73.权利要求72的方法，其中所述纳米活性材料是铂。
74.权利要求71的方法，其中所述纳米载体是氧化铝。
75.权利要求72的方法，其中所述纳米载体包含部分还原的氧化铝表面，所述部分还原的氧化铝表面被构造成限制纳米活性材料在纳米载体表面上的移动。
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