A method of dispersing nanosized catalyst particles on the surface of
larger catalyst carrier particles is disclosed. The coating process is
done dry and yields high effective surface area of nanosized catalyst
particles coated on the surface of catalyst carrier particles. In this
process, nanosized catalyst particles and catalyst carriers are
mechanically mixed in a high velocity and impact force environment to
which catalyst particles are embedded, or filmed, on the surface of
catalyst carrier particles without using water or any other additional
chemicals. The catalyst composite structure produced comprises better
coating uniformity of the catalyst particle on its catalyst carrier. The
catalyst particle/catalyst carrier composite produced can be applied to a
support structure, such as a monolith as readily used in automotive or
other applications.