Patent ID: 6040266
Filing Date: 2000-03-21
Classification: B01D,B01J,F01N,Y02T

Abstract:
A method of producing an acoustic baffle/catalyst foam support material including the following steps:providing a polyurethane open cell foam material having a pore density between ten and 100 pores per inch,providing a resin material,infiltrating the polyurethane foam with the resin material to produce an impregnated foam,pyrolizing the impregnated foam to form a carbon foam skeleton, andcoating the carbon foam skeleton with one or more of the following group of materials without blocking said pores to produce a coated foam support comprising five to thirty five percent solid compared to sixty five to ninety five percent voids, the group of materials being SiC, Si.sub.3 N.sub.4, MoSi.sub.2 or metal which withstands temperatures in excess of 900.degree. C., andapplying a catalyst to the coated carbon foam skeleton without blocking said pores, and wherein such catalyst is a metal or metals from the platinum group, andrecovering said acoustic baffle/catalyst foam support material, said acoustic baffle/catalyst foam support material having a through-flow configuration.