Catalyst supports and fluid treatment devices

Claim 1

A device for use in the treatment of a fluid by catalysis which device comprises a container; a fluid inlet passageway to the container; a fluid outlet passageway from the container; a plurality of discrete metal components randomly assembled in the container, each of which components is in wire-form and has an open-work three dimensional configuration, the wire at the periphery of the configuration of at least most of the components defining open spaces small enough in relation to the shape and diameter of wire at the periphery of other components to at least limit the penetration by intertangling therewith of one component into the internal open spaces of another component, at least a substantial number of the components being unrestrained from intertangling but for prevention thereof by said intrinsic configurational properties of the components; and a solid surface coating on the components comprising catalytically active material for the catalysis of a reaction involving the fluid.

Claim 2

A device for use in the treatment of a fluid by catalysis which device comprises a container; a fluid inlet passageway to the container; a fluid outlet passageway from the container; a plurality of discrete metal components randomly assembled in the container, each of which components is in wire-form and has an open-work three dimensional configuration, the wire at the periphery of the configuration of at least most of the components defining open spaces small enough in relation to the shape and diameter of wire at the periphery of other components to at least limit the penetration by intertangling therewith of one component into the internal open spaces of another component, at least a substantial number of the components being unrestrained from intertangling but for prevention thereof by said intrinsic configurational properties of the components; and a solid surface coating on the components comprising catalytically active material for the catalysis of a reaction involving the fluid.

Claim 3

A device for use in the treatment of a fluid by passing the fluid over a solid surface with which the fluid interacts, which device comprises a container; a fluid inlet passageway to the container; a fluid outlet passageway from the container; a plurality of discrete components assembled in the container, each of which components is in wire-form and has an open-work three dimensional configuration, the wire at the periphery of the configuration of at least most of the components defining open spaces small enough in relation to the shape and diameter of wire at the periphery of other components to at least limit the penetration by intertangling therewith of one component into the internal open spaces of another component, at least a substantial number of the components being unrestrained from intertangling but for prevention thereof by said intrinsic configurational properties of the components; and a solid surface coating on the components for interaction with the fluid.

Claim 4

A device for use in the treatment of a fluid by passing the fluid over a solid surface with which the fluid interacts, which device comprises a container; a fluid inlet passageway to the container; a fluid outlet passageway from the container; a plurality of discrete components assembled in the container, each of which components is in wire-form and has an open-work three dimensional configuration, the wire at the periphery of the configuration of at least most of the components defining open spaces small enough in relation to the shape and diameter of wire at the periphery of other components to at least limit the penetration by intertangling therewith of one component into the internal open spaces of another component, at least a substantial number of the components being unrestrained from intertangling but for prevention thereof by said intrinsic configurational properties of the components; and a solid surface coating on the components for interaction with the fluid.

Claim 15

A device for use in the treatment of a fluid by passing the fluid over a solid surface, which device comprises at least one component in the form of a helically wound coil of wire-form laid onto itself, or onto other such components, to form a fluid permeable body through which the fluid to be treated can flow in contact with the surfaces of the component or components, the wire at the periphery of part of any such coil defining open spaces small enough in relation to the shape and diameter of wire at the periphery of another part of that coil or at the periphery of other coils, if present, to at least limit penetration, by intertangling therewith, of part of one component into the internal open spaces of said another part of the same component or of one component into the internal open spaces of another component; and a surface coating on the components comprising catalytically active material, at least parts of such component being unrestrained from intertangling with another part of the same component or with other components, if present, but for prevention thereof by said intrinsic configurational properties of such component or components.

Claim 16

A device for use in the treatment of a fluid by passing the fluid over a solid surface, which device comprises at least one component in the form of a helically wound coil of wire-form laid onto itself, or onto other such components, to form a fluid permeable body through which the fluid to be treated can flow in contact with the surfaces of the component or components, the wire at the periphery of part of any such coil defining open spaces small enough in relation to the shape and diameter of wire at the periphery of another part of that coil or at the periphery of other coils, if present, to at least limit penetration, by intertangling therewith, of part of one component into the internal open spaces of said another part of the same component or of one component into the internal open spaces of another component; and a surface coating on the components comprising catalytically active material, at least parts of such component being unrestrained from intertangling with another part of the same component or with other components, if present, but for prevention thereof by said intrinsic configurational properties of such component or components.

Claim 20

A method of manufacturing a device for use in treatment of a fluid by passing fluid over a solid surface with which the fluid interacts, which method comprises fabricating one or more components in wire-form into an open-work three-dimensional configuration; contacting the component or components with a dispersion convertible on subsequent drying and firing into a ceramic; removing excess liquid under conditions in which contacts between adjacent wires or parts of the wire are avoided or separated; drying and firing the component or components to provide a surface layer of ceramic material on the wire; and assembling the component or components into the device for use in treatment of a fluid such that, in the device, the wire at the periphery of part of the component or at least some of the components defining open spaces small enough in relation to the shape and diameter of wire at the periphery of another part of that component or at the periphery of other components, if present, to avoid penetration, by intertangling therewith, of part of one component into the internal open spaces of said another part of the same component or of one component into the internal open spaces of another component, at least parts of the component or at least some of the components being unrestrained from intertangling with another part of the same component or with other components but for prevention thereof by said intrinsic configurational properties of such component or components.

Claim 21

A method of manufacturing a device for use in treatment of a fluid by passing fluid over a solid surface with which the fluid interacts, which method comprises fabricating one or more components in wire-form into an open-work three-dimensional configuration; contacting the component or components with a dispersion convertible on subsequent drying and firing into a ceramic; removing excess liquid under conditions in which contacts between adjacent wires or parts of the wire are avoided or separated; drying and firing the component or components to provide a surface layer of ceramic material on the wire; and assembling the component or components into the device for use in treatment of a fluid such that, in the device, the wire at the periphery of part of the component or at least some of the components defining open spaces small enough in relation to the shape and diameter of wire at the periphery of another part of that component or at the periphery of other components, if present, to avoid penetration, by intertangling therewith, of part of one component into the internal open spaces of said another part of the same component or of one component into the internal open spaces of another component, at least parts of the component or at least some of the components being unrestrained from intertangling with another part of the same component or with other components but for prevention thereof by said intrinsic configurational properties of such component or components.