US4027476A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composite catalyst bed and method for making the same
Assignee: Rocket Research Co
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Filing: 1975-10-15
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Granted: 1977-06-07
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Expires: 1995-10-15
Abstract
Abstract A composite catalyst bed comprising a foam metal matrix packed with a plurality of catalyst particles. The foam metal matrix is a three dimensional, structurally rigid network of interconnected ligaments which define a plurality of interconnected pores filled by particles of a suitable catalyst, such as Shell 405. The composite structure is made by first filling the foam metal matrix with the catalyst particles and then compressing the same so that the catalyst particles become packed tightly in the matrix, with some of the catalyst particles being formed into the ligaments of the matrix. The composite catalyst bed is shown in a monopropellant reactor to decompose hydrazine based monopropellants, and also in a catalytic muffler to oxidize exhaust combustion products from an internal combustion engine. The foam metal matrix retains the catalyst particles in place to alleviate attrition of the particles, and also provides good thermal conductivity to improve performance of the catalyst.
Inventors
- 👤 Eckart W. Schmidt
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 00:29
CPC Classifications
C; C06; C06D; C06D5/00; C06D5/04; F; F01; F01N; F01N3/00; F01N3/08; F01N3/10; F01N3/24; F01N3/28; F01N3/2803; F01N3/2832; F01N3/2839; F01N3/2846; F02; F02K; F02K9/00; F02K9/42; F02K9/60; F02K9/68
Claims Analysis
Total Claims: 54
Claim 1
Independent Claim
69 words
A composite catalyst bed comprising: a. a three dimensional, structurally rigid foam metal matrix, comprising a network of interconnected ligaments which define a plurality of interconnected pores, and b. a plurality of separate Pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in and filling the pores of such matrix, with relative movement of said particles being restrained by said matrix.
Claim 2
Dependent Claim
69 words
A composite catalyst bed comprising: a. a three dimensional, structurally rigid foam metal matrix, comprising a network of interconnected ligaments which define a plurality of interconnected pores, and b. a plurality of separate Pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in and filling the pores of such matrix, with relative movement of said particles being restrained by said matrix.
Claim 3
Dependent Claim
27 words
The catalyst bed as recited in claim 1, wherein said matrix is a thermally conductive material, whereby more uniform heat distribution throughout said composite bed is achieved.
Claim 4
Dependent Claim
28 words
The catalyst bed as recited in claim 1, wherein said catalyst particles are contoured into said ligaments, whereby retention of said catalyst particles in said matrix is enhanced.
Claim 5
Dependent Claim
25 words
The catalyst bed as recited in claim 3, wherein ligaments of said matrix are hollow, whereby the catalyst particles are better contoured into said ligaments.
Claim 6
Dependent Claim
32 words
The catalyst bed as recited in claim 1, wherein said matrix has a predetermined pore size, which is approximately four to five times as great as the diameter of said catalyst particles.
Claim 7
Dependent Claim
32 words
The catalyst bed as recited in claim 5, wherein the ligaments of said matrix have a width dimension of approximately one tenth to one twentieth of the pore size of the matrix.
Claim 8
Dependent Claim
34 words
The catalyst bed as recited in claim 6, further comprising a thermally conductive housing containing said composite bed, with the matrix being in intimate contact with said housing to insure proper thermal conductivity therewith.
Claim 9
Dependent Claim
77 words
The apparatus as recited in claim 7, wherein said housing has an inlet for a fluid to be reacted in said catalyst bed and an outlet, and said catalyst bed has at least two sections, one section near the inlet having a relatively small pore size of the matrix and particle size of the catalyst, and a second section near the outlet having a relatively larger pore size of the matrix and particle size of the catalyst.
Claim 10
Dependent Claim
44 words
The apparatus as recited in claim 8, wherein there is a perforate plate means positioned between said two catalyst sections, with the foam metal matrix of the two catalyst section being connected to said plate to accomplish thermal conductivity between the two catalyst sections.
Claim 11
Dependent Claim
35 words
The apparatus as recited in claim 8, wherein the matrix of the first section is intimately connected to the matrix of the second section to insure proper thermal conductivity between said first and second sections.
Claim 12
Dependent Claim
47 words
The composite bed as recited in claim 1, wherein said matrix is made of a material selected from a group consisting of nickel, cobalt, iron, ruthenium, rhodium, palladium, osmium, iridium, platinum, copper, silver, manganese, rhenium, chromium, molybdenum, tungsten, vanadium, lanthanum, beryllium, lead, polonium-210, curium-242, and combinations thereof.
Claim 13
Dependent Claim
91 words
A process for making a composite catalyst bed, comprising: placing a three dimensional, structurally rigid foam metal matrix in a containing means, placing a plurality of separate pellet-like catalyst particles, each comprising a support carrier material that carries a catalyst material, within said matrix so as to substantially fill the matrix, and applying a compressive force to said matrix and catalyst particles to cause the surfaces of the catalyst particles and the matrix to conform to each other more closely so that the catalyst particles are better retained in the matrix.
Claim 14
Dependent Claim
91 words
A process for making a composite catalyst bed, comprising: placing a three dimensional, structurally rigid foam metal matrix in a containing means, placing a plurality of separate pellet-like catalyst particles, each comprising a support carrier material that carries a catalyst material, within said matrix so as to substantially fill the matrix, and applying a compressive force to said matrix and catalyst particles to cause the surfaces of the catalyst particles and the matrix to conform to each other more closely so that the catalyst particles are better retained in the matrix.
Claim 15
Dependent Claim
34 words
The process as recited in claim 12, wherein prior to compressing said matrix and catalyst particles, said matrix said catalyst paraticles are vibrated to insure proper distribution of the catalyst particles in the matrix.
Claim 16
Dependent Claim
27 words
The process as recited in claim 12, wherein said catalyst particles have a diameter approximately one-fourth to one-fifth of the pore size of said foam metal matrix.
Claim 17
Dependent Claim
22 words
The process as recited in claim 12, wherein said matrix with the catalyst particles therein is compressed between about 1to 20 percent.
Claim 18
Dependent Claim
23 words
The process as recited in claim 15, wherein said matrix with the catalyst particles therein is compressed between about 3 to 4 percent.
Claim 19
Dependent Claim
67 words
The process as recited in claim 12, wherein: a. the percentage of voids in bulk volume of said foam metal matrix is between about 80 to 98 percent, b. the diameter of the catalyst particles is approximately one-fourth to one-fifth the pore size of the foam metal, and c. the foam metal with the catalyst particles therein is compressed in volume between about 3 to 4 percent.
Claim 20
Dependent Claim
45 words
The process as recited in claim 12, wherein said foam metal matrix is made of a material more ductile than said catalyst particles, wherein said catalyst particles form into said foam matrix during the compression of the foam metal matrix and the catalyst particles therein.
Claim 21
Dependent Claim
25 words
The process as recited in claim 18, wherein said foam metal matrix comprises hollow ligaments to enhance the forming of the particles into the matrix.
Claim 22
Dependent Claim
110 words
A monopropellant reactor comprising: A. a housing defining a chamber and having an inlet means for injecting a monopropellant into the chamber and an outlet for discharge of products of decomposition therefrom, and b. a composite catalyst bed positioned in said chamber, said composite bed comprising: 1. a three dimensional, structurally rigid foam metal matrix, comprising a network of interconnected ligaments which define a plurality of interconnected pores, and 2. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in and filling the pores of such matrix, with relative movement of said particles being restrained by said matrix.
Claim 23
Dependent Claim
110 words
A monopropellant reactor comprising: A. a housing defining a chamber and having an inlet means for injecting a monopropellant into the chamber and an outlet for discharge of products of decomposition therefrom, and b. a composite catalyst bed positioned in said chamber, said composite bed comprising: 1. a three dimensional, structurally rigid foam metal matrix, comprising a network of interconnected ligaments which define a plurality of interconnected pores, and 2. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in and filling the pores of such matrix, with relative movement of said particles being restrained by said matrix.
Claim 24
Dependent Claim
26 words
The reactor as recited in claim 20, wherein said matrix is a thermally conductive material, whereby more uniform heat distribution throughout said composite bed is achieved.
Claim 25
Dependent Claim
27 words
The reactor as recited in claim 20, wherein said catalyst particles are contoured into said ligaments, whereby retention of said catalyst particles in said matrix is enhanced.
Claim 26
Dependent Claim
31 words
The reactor as recited in claim 20, wherein said matrix has a predetermined pore size, which is approximately four to five times as great as the diameter of said catalyst particles.
Claim 27
Dependent Claim
29 words
The reactor as recited in claim 20, wherein the ligaments of said matrix have a width dimension of approximately one-tenth to one-twentieth of the pore size of the matrix.
Claim 28
Dependent Claim
23 words
The reactor as recited in claim 20, wherein said matrix is intimately connected to said housing wall, to insure good thermal conductivity therewith.
Claim 29
Dependent Claim
32 words
The reactor as recited in claim 20, wherein there is a heater intimately connected to said foam metal matrix so as to be able to preheat said catalyst bed through said matrix.
Claim 30
Dependent Claim
14 words
The reactor as recited in claim 26, wherein said heater is an electric heater.
Claim 31
Dependent Claim
13 words
The reactor as recited in claim 26, wherein said heater is a radioisotope.
Claim 32
Dependent Claim
30 words
The reactor as recited in claim 26, wherein said heater is a source of electric current which passes electric current through said matrix which then becomes heated by such current.
Claim 33
Dependent Claim
78 words
The reactor as recited in claim 20, wherein said housing has an inlet for a fluid to be reacted in said catalyst bed and an outlet, and said catalyst bed has at least two sections, one section near the inlet having a relatively small pore size of the matrix and particle size of the catalyst, and a second downstream section near the outlet having a relatively larger pore size of the matrix and particle size of the catalyst.
Claim 34
Dependent Claim
44 words
The reactor as recited in claim 30, wherein there is a perforate plate means positioned between said two catalyst sections, with the foam metal matrix of the two catalyst sections being connected to said plate to accomplish thermal conductivity between the two catalyst sections.
Claim 35
Dependent Claim
35 words
The reactor as recited in claim 30, wherein the matrix of the first section is intimately connected to the matrix of the second section to insure proper thermal conductivity between said first and second sections.
Claim 36
Dependent Claim
46 words
The reactor as recited in claim 20, wherein said matrix is made of a material selected from a group consisting of nickel, cobalt, iron, ruthenium, rhodium, palladium, osmium, iridium, platinum, copper, silver, manganese, rhenium, chromium, molybdenum, tungsten, vanadium, lanthanum, beryllium, lead, polonium-210, curium-242, and combinations thereof.
Claim 37
Independent Claim
124 words
A method of decomposing hydrazine based monopropellants which comprises flowing the monopropellant through a composite catalyst bed in pulse mode, wherein a large number of pressure pulses are exerted against said catalyst bed, wherein the catalyst bed comprises: a. a three dimensional, structurally rigid foam metal matrix, comprising a network of interconnected ligaments which define a plurality of interconnected pores and b. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in and filling the pores of such matrix, with relative movement of said particles being restrained by said matrix, whereby with said matrix retaining said catalyst particles in proper position in said catalyst bed degradation of the catalyst particles is alleviated.
Claim 38
Independent Claim
124 words
A method of decomposing hydrazine based monopropellants which comprises flowing the monopropellant through a composite catalyst bed in pulse mode, wherein a large number of pressure pulses are exerted against said catalyst bed, wherein the catalyst bed comprises: a. a three dimensional, structurally rigid foam metal matrix, comprising a network of interconnected ligaments which define a plurality of interconnected pores and b. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in and filling the pores of such matrix, with relative movement of said particles being restrained by said matrix, whereby with said matrix retaining said catalyst particles in proper position in said catalyst bed degradation of the catalyst particles is alleviated.
Claim 39
Dependent Claim
101 words
A catalytic muffler comprising: a. a casing having an inlet through which engine exhaust gases are received and an outlet through which said exhaust gases are discharged, b. a composite catalyst bed positioned in said casing, comprising: 1. a three dimensional, structurally rigid foam metal matrix, comprising a network of interconnected ligaments which define a plurality of interconnected pores, and 2. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in and filling the pores of such matrix, with relative movement of said particles being restrained by said matrix.
Claim 40
Dependent Claim
101 words
A catalytic muffler comprising: a. a casing having an inlet through which engine exhaust gases are received and an outlet through which said exhaust gases are discharged, b. a composite catalyst bed positioned in said casing, comprising: 1. a three dimensional, structurally rigid foam metal matrix, comprising a network of interconnected ligaments which define a plurality of interconnected pores, and 2. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in and filling the pores of such matrix, with relative movement of said particles being restrained by said matrix.
Claim 41
Dependent Claim
27 words
The catalytic muffler as recited in claim 35, wherein said matrix is a thermally conductive material, whereby more uniform heat distribution throughout said composite bed is achieved.
Claim 42
Dependent Claim
28 words
The catalytic muffler as recited in claim 35, wherein said catalytic particles are contoured into said ligaments, whereby retention of said catalyst particles in said matrix is enhanced.
Claim 43
Dependent Claim
32 words
The catalytic muffler as recited in claim 35, wherein said matrix has a predetermined pore size, which is approximately four to five times as great as the diameter of said catalyst particles.
Claim 44
Dependent Claim
30 words
The catalytic muffler as recited in claim 35, wherein the ligaments of said matrix have a width dimension of approximately one-tenth to one-twentieth of the pore size of the matrix.
Claim 45
Dependent Claim
35 words
The catalytic muffler as recited in claim 35, further comprising a thermally conductive housing containing said composite catalyst bed, with the matrix being in intimate contact with said housing to insure proper thermal conductivity therewith.
Claim 46
Dependent Claim
78 words
The catalytic muffler as recited in claim 35, wherein said housing has an inlet for engine exhaust to be reacted is said catalyst bed and an outlet, and said catalyst bed has at least two sections, one section near the inlet having a relatively small pore size of the matrix and particle size of the catalyst, and a second section near the outlet having a relatively larger pore size of the matrix and particle size of the catalyst.
Claim 47
Dependent Claim
45 words
The catalytic muffler as recited in claim 41, wherein there is a perforate plate means positioned between said two catalyst sections, with the foam metal matrix of the two catalyst sections being connected to said plate to accomplish thermal conductivity between the two catalyst sections.
Claim 48
Dependent Claim
36 words
The catalytic muffler as recited in claim 41, wherein the matrix of the first section is intimately connected to the matrix of the second section to insure proper thermal conductivity between said first and second sections.
Claim 49
Independent Claim
118 words
A method of oxidizing exhaust combustion products from an internal combustion engine comprising blowing the exhaust combustion products through a catalyst bed comprising: a. a three dimensional, structurally rigid foam metal matrix, comprising a network of interconnected ligaments which define a plurality of interconnected pores, and b. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in and filling the pores of such matrix, with relative movement of said particles being restrained by said matrix, whereby with pressure pulses of said engine causing corresponding pressure pulses exerted on said catalyst bed, said catalyst particles are properly retained in the catalyst bed by the foam metal matrix.
Claim 50
Independent Claim
118 words
A method of oxidizing exhaust combustion products from an internal combustion engine comprising blowing the exhaust combustion products through a catalyst bed comprising: a. a three dimensional, structurally rigid foam metal matrix, comprising a network of interconnected ligaments which define a plurality of interconnected pores, and b. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in and filling the pores of such matrix, with relative movement of said particles being restrained by said matrix, whereby with pressure pulses of said engine causing corresponding pressure pulses exerted on said catalyst bed, said catalyst particles are properly retained in the catalyst bed by the foam metal matrix.
Claim 51
Dependent Claim
144 words
A catalytic reactor, comprising: a. a casing defining a chamber and having a first set of inlet openings and a first set of outlet openings, b. a matrix positioned in said chamber and comprising a three dimensional network of interconnected ligaments having interconnected internal passageways forming a passageway network communicating with said first inlet openings and first outlet openings, c. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in said chamber within said matrix, d. second inlet and outlet means arranged to direct a reacting fluid through said catalyst particles, and e. means to direct a heating fluid through said first inlet means and through said passageway network to heat said matrix and in turn heat said catalyst particles, whereby proper reaction of said reacting fluid in said chamber is accomplished.
Claim 52
Dependent Claim
144 words
A catalytic reactor, comprising: a. a casing defining a chamber and having a first set of inlet openings and a first set of outlet openings, b. a matrix positioned in said chamber and comprising a three dimensional network of interconnected ligaments having interconnected internal passageways forming a passageway network communicating with said first inlet openings and first outlet openings, c. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalyst material, and positioned in said chamber within said matrix, d. second inlet and outlet means arranged to direct a reacting fluid through said catalyst particles, and e. means to direct a heating fluid through said first inlet means and through said passageway network to heat said matrix and in turn heat said catalyst particles, whereby proper reaction of said reacting fluid in said chamber is accomplished.
Claim 53
Dependent Claim
104 words
A composite catalyst bed comprising: a. a three dimensional matrix comprising a network of interconnected ligaments, having internal passageways forming a network of interconnected passageways, said passageways having a wick material therein and a vaporizable liquid, with said vaporizable liquid and wick material functioning as a heat pipe to conduct heat from one portion of said matrix to another, and b. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalytic material, and positioned within said matrix, with said matrix conducting heat from higher temperature areas of said composite catalyst bed to lower temperature areas thereof.
Claim 54
Dependent Claim
104 words
A composite catalyst bed comprising: a. a three dimensional matrix comprising a network of interconnected ligaments, having internal passageways forming a network of interconnected passageways, said passageways having a wick material therein and a vaporizable liquid, with said vaporizable liquid and wick material functioning as a heat pipe to conduct heat from one portion of said matrix to another, and b. a plurality of separate pellet-like catalyst carrying particles, each comprising a supporting carrier material that carries a catalytic material, and positioned within said matrix, with said matrix conducting heat from higher temperature areas of said composite catalyst bed to lower temperature areas thereof.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-06-06 | 1980-12-06 | 1981-06-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-06-06 | 1984-12-06 | 1985-06-07 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-06-06 | 1988-12-06 | 1989-06-07 | $7700.00 | Window Closed / Lapsed |