US4563566A
Expired / Lapsed
US
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Method of manufacturing particles having high surface areas and a particle made by the method
Assignee: Plasmafusion Inc
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Filing: 1983-03-22
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Granted: 1986-01-07
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Expires: 2003-03-22
Abstract
Abstract A method of manufacturing porous, irregularly-shaped particles having high surface areas and a particle made thereby is disclosed wherein small grains of a material are adhered together to form larger particles of porous, irregularly shaped form having high surface areas. Thereafter, the larger particles are injected into the effluent of a liquid stabilized plasma gun device to fuse together the individual grains forming each larger particle, thereby increasing the adherence of the individual grains, while maintaining the porous, irregularly-shaped properties thereof.
Inventors
- 👤 John A. Reents
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 06:29
CPC Classifications
B; B01; B01J; B01J2/00; B01J2/16; B01J2/28; B01J37/00; B01J37/34; B01J37/349; B22; B22F; B22F1/00; B22F1/14; B22F1/148
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
107 words
A method of manufacturing porous particles having high surface areas, comprising the steps of: providing a supply of fine grains of a material, adhering together the fine grains into porous, irregularly-shaped particles having high surface areas, each of the porous, irregularly-shaped particles being made up of at least two of the fine grains, collecting the porous, irregularly-shaped particles, and then fusing together the individual grains forming each porous, irregularly shaped particle by injecting the porous, irregularly-shaped particles into the effluent of a plasma gun device having liquid stabilization to strengthen the adherence of the individual grains, while substantially maintaining the porous and high surface area properties thereof.
Claim 2
Independent Claim
107 words
A method of manufacturing porous particles having high surface areas, comprising the steps of: providing a supply of fine grains of a material, adhering together the fine grains into porous, irregularly-shaped particles having high surface areas, each of the porous, irregularly-shaped particles being made up of at least two of the fine grains, collecting the porous, irregularly-shaped particles, and then fusing together the individual grains forming each porous, irregularly shaped particle by injecting the porous, irregularly-shaped particles into the effluent of a plasma gun device having liquid stabilization to strengthen the adherence of the individual grains, while substantially maintaining the porous and high surface area properties thereof.
Claim 3
Dependent Claim
12 words
The method of claim 1 wherein the material is a catalytic material.
Claim 4
Dependent Claim
22 words
The method of claim 2 wherein the catalytic material is an element selected from the group consisting of nickel, palladium and platinum.
Claim 5
Dependent Claim
22 words
The method of claim 1 wherein the plasma gun device having liquid stabilization is of the type wherein the liquid is water.
Claim 6
Dependent Claim
43 words
The method of claim 4 wherein the plasma gun device generates a plasma effluent with a concentration of charged particles between about 2.00×10 24 and 0.3×10 23 per cubic centimeter in number and with a temperature between about 15,000° K. and 60,000° K.
Claim 7
Dependent Claim
24 words
The method of claim 1 further comprising the steps of: collecting the fused particles, and thereafter coating the fused particles with a catalytic material.
Claim 8
Dependent Claim
28 words
The method of claim 6 wherein the fine grained material is selected from the group consisting of corundum Al 2 O 3 and zirconium silicate ZrSiO 4 .
Claim 9
Dependent Claim
22 words
The method of claim 6 wherein the catalytic material is an element selected from the group consisting of nickel, palladium, and platinum.
Claim 10
Dependent Claim
15 words
The method of claim 6 wherein the step of coating is by chemical vapor deposition.
Claim 11
Dependent Claim
107 words
A particle having a high surface area manufactured in accordance with the method of providing a supply of fine grains of a material, adhering together the fine grains into porous, irregularly-shaped particles having high surface areas, each of the porous, irregularly-shaped particles being made up of at least two of the fine grains, collecting the porous, irregularly-shaped particles, and then fusing together the individual grains forming each porous, irregularly shaped particle by injecting the porous, irregularly-shaped particles into the effluent of a plasma gun device having liquid stabilization to strengthen the adherence of the individual grains, while substantially maintaining the porous and high surface area properties thereof.
Claim 12
Dependent Claim
107 words
A particle having a high surface area manufactured in accordance with the method of providing a supply of fine grains of a material, adhering together the fine grains into porous, irregularly-shaped particles having high surface areas, each of the porous, irregularly-shaped particles being made up of at least two of the fine grains, collecting the porous, irregularly-shaped particles, and then fusing together the individual grains forming each porous, irregularly shaped particle by injecting the porous, irregularly-shaped particles into the effluent of a plasma gun device having liquid stabilization to strengthen the adherence of the individual grains, while substantially maintaining the porous and high surface area properties thereof.
Claim 13
Independent Claim
107 words
A method of manufacturing porous irregularly-shaped catalytic particles having high surface areas, comprising the steps of: providing a supply of material in granular form, adhering together grains of the material into porous, irregularly-shaped particles having high surface areas, collecting the porous, irregularly-shaped particles, then injecting the porous, irregularly-shaped particles into the effluent of a plasma gun device having liquid stabilization to fuse together the grains forming each porous, irregularly-shaped particle, thereby increasing the adherence of the grains while maintaining the porous and high surface area properties of the particles, collecting the fused porous, irregularly-shaped particles, and thereafter coating the fused porous, irregularly-shaped particles with a catalytic material.
Claim 14
Independent Claim
107 words
A method of manufacturing porous irregularly-shaped catalytic particles having high surface areas, comprising the steps of: providing a supply of material in granular form, adhering together grains of the material into porous, irregularly-shaped particles having high surface areas, collecting the porous, irregularly-shaped particles, then injecting the porous, irregularly-shaped particles into the effluent of a plasma gun device having liquid stabilization to fuse together the grains forming each porous, irregularly-shaped particle, thereby increasing the adherence of the grains while maintaining the porous and high surface area properties of the particles, collecting the fused porous, irregularly-shaped particles, and thereafter coating the fused porous, irregularly-shaped particles with a catalytic material.
Claim 15
Dependent Claim
15 words
The method of claim 11 wherein the plasma gun device is liquid stabilized by water.
Claim 16
Dependent Claim
27 words
The method of claim 12 wherein the granular material is selected from the group consisting of corundum A1 2 O 3 and zirconium silicate ZrSiO 4 .
Claim 17
Dependent Claim
22 words
The method of claim 13 wherein the catalytic material is an element selected from the group consisting of nickel, palladium and platinum.
Claim 18
Dependent Claim
15 words
The method of claim 14 wherein the step of coating is by chemical vapor deposition.
Claim 19
Dependent Claim
19 words
The method of claim 11 wherein the step of adhering is performed by a fluid bed spray granulator apparatus.
Claim 20
Dependent Claim
17 words
The method of claim 11 wherein the step of adhering is performed by a spray drying apparatus.
Claim 21
Dependent Claim
101 words
A catalytic particle manufactured in accordance with the method of providing a supply of material in granular form, adhering together grains of the material into porous, irregularly-shaped particles having high surface areas, collecting the porous, irregularly-shaped particles, then injecting the porous, irregularly-shaped particles into the effluent of a plasma gun device having liquid stabilization to fuse together the grains forming each porous, irregularly-shaped particle, thereby increasing the adherence of the grains while maintaining the porous and high surface area properties of the particles, collecting the fused porous, irregularly-shaped particles, and thereafter coating the fused porous, irregularly-shaped particles with a catalytic material.
Claim 22
Dependent Claim
101 words
A catalytic particle manufactured in accordance with the method of providing a supply of material in granular form, adhering together grains of the material into porous, irregularly-shaped particles having high surface areas, collecting the porous, irregularly-shaped particles, then injecting the porous, irregularly-shaped particles into the effluent of a plasma gun device having liquid stabilization to fuse together the grains forming each porous, irregularly-shaped particle, thereby increasing the adherence of the grains while maintaining the porous and high surface area properties of the particles, collecting the fused porous, irregularly-shaped particles, and thereafter coating the fused porous, irregularly-shaped particles with a catalytic material.
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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) | 1989-01-06 | 1989-07-08 | 1990-01-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-01-06 | 1993-07-08 | 1994-01-07 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-01-06 | 1997-07-08 | 1998-01-07 | $7700.00 | Window Closed / Lapsed |