US4157315A
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US
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Method of preparing a supported catalyst and the catalyst prepared by the method
Assignee: Huntington Alloys Corp
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Filing: 1973-12-21
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Granted: 1979-06-05
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Expires: 1993-12-21
Abstract
Abstract A method is provided for preparing a supported catalyst composed of a structural substrate having an adherent, coherent, coating of a catalytic material which comprises applying on the substrate a dispersion comprising a stabilized colloidal silica solution having dispersed therein a fine metal powder which contains at least two of the metals nickel, chromium, and copper as mixtures or alloys or a combination thereof, and firing the coated substrate in a protective atmosphere at an elevated sintering temperature to form an adherent, coherent, coating.
Inventors
- 👤 Harold T. Michels
- 👤 Raymond P. Jackson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 06:08
CPC Classifications
B; B01; B01J; B01J23/00; B01J23/70; B01J23/76; B01J23/84; B01J23/85; B01J23/86; B01J23/866; B01D; B01D53/00; B01D53/34; B01D53/74; B01D53/86; B01J23/74; B01J23/755; B01J37/00; B01J37/02; B01J37/0215; B01J37/0225
Claims Analysis
Total Claims: 28
Claim 1
Independent Claim
171 words
A method of preparing a supported catalyst comprising a structural substrate having an adherent, coating of a catalytic material thereon, comprising: (a) applying on the substrate a dispersion comprising a stabilized colloidal silica solution having dispersed therein a fine metal powder, said metal powder consisting essentially of at least two metals selected from nickel, chromium and copper, and said metal powder consisting essentially of at least one of the group: a mixture of at least two of said metals in elemental form, an alloy of at least two of said metals, a mixture containing at least one of said metals in elemental form with one or more of said alloys, and (b) firing the coated substrate in a protective atmosphere at an elevated temperature in the range of from about 1400° F. to below the melting point of the lowest melting component for a period of time sufficient to sinter the metal powder and to provide a thin, adherent, coherent, coating containing silica and an effective amount of catalytically active material.
Claim 2
Independent Claim
171 words
A method of preparing a supported catalyst comprising a structural substrate having an adherent, coating of a catalytic material thereon, comprising: (a) applying on the substrate a dispersion comprising a stabilized colloidal silica solution having dispersed therein a fine metal powder, said metal powder consisting essentially of at least two metals selected from nickel, chromium and copper, and said metal powder consisting essentially of at least one of the group: a mixture of at least two of said metals in elemental form, an alloy of at least two of said metals, a mixture containing at least one of said metals in elemental form with one or more of said alloys, and (b) firing the coated substrate in a protective atmosphere at an elevated temperature in the range of from about 1400° F. to below the melting point of the lowest melting component for a period of time sufficient to sinter the metal powder and to provide a thin, adherent, coherent, coating containing silica and an effective amount of catalytically active material.
Claim 3
Dependent Claim
34 words
A method of claim 1, wherein the metal powder and silica in the dispersion are present in concentrations, by weight of about 99% to about 86% metal powder and 1% to about 14% silica.
Claim 4
Dependent Claim
25 words
A method of claim 1, wherein the weight ratio of metal powder to silica is about 15 parts of metal powder to 1 of silica.
Claim 5
Dependent Claim
26 words
A method of claim 1, wherein the metal powder of the dispersion consists essentially of about 15 to about 50% chromium and the balance essentially copper.
Claim 6
Dependent Claim
33 words
A method of claim 1, wherein the metal powder of the dispersion consists essentially of about 10% to about 80% nickel, about 20% to about 60% copper, and up to about 35% chromium.
Claim 7
Dependent Claim
25 words
A method of claim 5, wherein the metal powder of the dispersion consists essentially of about 10 to 80% Ni and the balance essentially copper.
Claim 8
Dependent Claim
27 words
A method of claim 1, wherein the metal powder is present in a particle size such that at least about 30% is less than about 7 microns.
Claim 9
Dependent Claim
21 words
A method of claim 1, wherein firing is carried out at a temperature of about 1400° F. to about 1900° F.
Claim 10
Dependent Claim
17 words
A method of claim 8, wherein the firing is carried out in an NH 3 -containing atmosphere.
Claim 11
Dependent Claim
10 words
A method of claim 1, wherein the dispersion is aqueous.
Claim 12
Dependent Claim
18 words
A method of claim 1, wherein a suspension agent for the metal powder is present in the dispersion.
Claim 13
Dependent Claim
16 words
A method of claim 1, wherein the substrate is a metal having an open mesh configuration.
Claim 14
Dependent Claim
11 words
A method of claim 12, wherein the metal is stainless steel.
Claim 15
Dependent Claim
118 words
A formulation especially useful for preparing a catalytically active coating consisting essentially of a stabilized colloidal silica solution having dispersed therein a metal powder of fine particle size selected from at least one of (1) a mixture consisting essentially of elemental powders of nickel and copper, (2) a mixture consisting essentially of elemental powders of chromium and nickel, (3) a mixture consisting essentially of chromium and copper, (4) a mixture consisting essentially of elemental powders of chromium, nickel and copper, (5) an alloy consisting essentially of nickel and copper, (6) an alloy consisting essentially of nickel and chromium, (7) an alloy consisting essentially of chromium and copper, and (8) an alloy consisting essentially of chromium, nickel and copper.
Claim 16
Dependent Claim
118 words
A formulation especially useful for preparing a catalytically active coating consisting essentially of a stabilized colloidal silica solution having dispersed therein a metal powder of fine particle size selected from at least one of (1) a mixture consisting essentially of elemental powders of nickel and copper, (2) a mixture consisting essentially of elemental powders of chromium and nickel, (3) a mixture consisting essentially of chromium and copper, (4) a mixture consisting essentially of elemental powders of chromium, nickel and copper, (5) an alloy consisting essentially of nickel and copper, (6) an alloy consisting essentially of nickel and chromium, (7) an alloy consisting essentially of chromium and copper, and (8) an alloy consisting essentially of chromium, nickel and copper.
Claim 17
Dependent Claim
32 words
A formulation of claim 14, wherein the dispersion contains silica and metal powder in concentrations, by weight, of about 1% to about 14% silica and about 99% to about 86% metal powder.
Claim 18
Dependent Claim
27 words
A formulation of claim 14, wherein the metal powder is present in a particle size such that at least about 30% is less than about 7 microns.
Claim 19
Dependent Claim
26 words
A formulation of claim 14, wherein the metal powder of the dispersion consists essentially of about 15% to about 50% chromium and the balance essentially copper.
Claim 20
Dependent Claim
33 words
A formulation of claim 14 wherein the metal powder of the dispersion consists essentially of about 10% to about 80% nickel, about 20 to about 60% copper, and up to about 35% chromium.
Claim 21
Dependent Claim
18 words
A formulation of claim 14, wherein a suspension agent for the metal powder is present in the dispersion.
Claim 22
Dependent Claim
10 words
A formulation of claim 14, wherein the dispersion is aqueous.
Claim 23
Dependent Claim
33 words
A method of claim 1, wherein the coated substrate is fired in an atmosphere selected from H 2 , N 2 --H 2 , NH 3 , an inert gas, and a vacuum.
Claim 24
Dependent Claim
13 words
A method of claim 1, wherein the protective atmosphere is non-oxidizing or reducing.
Claim 25
Dependent Claim
87 words
A catalyst for purifying exhaust gases produced by a process, said catalyst being supported on a substrate, which comprises the steps of: mixing particles of nickel and copper or nickel, copper and chromium with a stabilized colloidal silica solution; applying said mixture to a substrate; sintering said particles in a non-oxidizing atmosphere; oxidizing said sintered particles in air or an oxygen-containing gas; and activating said sintered mixture at a temperature ranging from 704° to 815° C. under an atmosphere of a reductive gas or a non-oxidizing gas.
Claim 26
Dependent Claim
87 words
A catalyst for purifying exhaust gases produced by a process, said catalyst being supported on a substrate, which comprises the steps of: mixing particles of nickel and copper or nickel, copper and chromium with a stabilized colloidal silica solution; applying said mixture to a substrate; sintering said particles in a non-oxidizing atmosphere; oxidizing said sintered particles in air or an oxygen-containing gas; and activating said sintered mixture at a temperature ranging from 704° to 815° C. under an atmosphere of a reductive gas or a non-oxidizing gas.
Claim 27
Independent Claim
101 words
A method for preparing a catalyst for purifying exhaust gases from internal combustion engines and the like, said catalyst being supported on a substrate, which comprises the steps of: mixing particles of nickel and copper or nickel, copper and chromium with a stabilized silica solution; applying said mixture on a substrate; sintering said particulate mixture at a temperature ranging from 760° C. in a non-oxidizing atmosphere; oxidizing said sintered particles in air or an oxygen-containing gas; activating said sintered mixture at a temperature ranging from about 704° to 815° C. under an atmosphere of a reductive gas or a non-oxidizing gas.
Claim 28
Independent Claim
101 words
A method for preparing a catalyst for purifying exhaust gases from internal combustion engines and the like, said catalyst being supported on a substrate, which comprises the steps of: mixing particles of nickel and copper or nickel, copper and chromium with a stabilized silica solution; applying said mixture on a substrate; sintering said particulate mixture at a temperature ranging from 760° C. in a non-oxidizing atmosphere; oxidizing said sintered particles in air or an oxygen-containing gas; activating said sintered mixture at a temperature ranging from about 704° to 815° C. under an atmosphere of a reductive gas or a non-oxidizing gas.
References Cited (Backward Citations)
US3518206A
Cited
US3674526A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1982-06-04 | 1982-12-04 | 1983-06-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1986-06-04 | 1986-12-04 | 1987-06-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1990-06-04 | 1990-12-04 | 1991-06-05 | $7700.00 | Window Closed / Lapsed |