US4608361A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Catalyst carriers and process for preparation of the same
Assignee: Honshu Paper Co Ltd
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Filing: 1983-12-08
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Granted: 1986-08-26
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Expires: 2003-12-08
Abstract
Abstract A process is disclosed for producing a sheet for a catalyst carrier for vapor-phase reactions which comprises mixing highly heat resistant ceramic fibers, organic fibers and an organic binder to form a slurry, forming the slurry into a paper sheet, impregnating the paper sheet with a silicon compound, converting the silicon compound to silica gel and heating the impregnated sheet to burn up the organic fibers and organic binder. The process produces an improved catalyst carrier for vapor-phase reactions having high porosity and good strength properties.
Inventors
- 👤 Nobutaka Kanamori
- 👤 Masaji Kurosawa
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 15:51
CPC Classifications
B; B01; B01J; B01J37/00; B01J37/0009; B01J37/0018
Claims Analysis
Total Claims: 27
Claim 1
Independent Claim
105 words
A process for producing a sheet for a catalyst carrier for vapor-phase reactions, which comprises in combination the steps of: mixing ceramic fibers, organic fibers, and an organic binder to form a slurry; forming said slurry into a sheet of paper having a density of 0.2 to 0.4 gram per cubic centimeter; impregnating said sheet of paper with a silicon compound selected from the group consisting of colloidal silica and ethyl silicate; converting said silicon compound to silica gel by drying; and heating said impregnated sheet at a temperature of up to about 1,000° C. to burn up said organic fibers and said organic binder.
Claim 2
Dependent Claim
105 words
A process for producing a sheet for a catalyst carrier for vapor-phase reactions, which comprises in combination the steps of: mixing ceramic fibers, organic fibers, and an organic binder to form a slurry; forming said slurry into a sheet of paper having a density of 0.2 to 0.4 gram per cubic centimeter; impregnating said sheet of paper with a silicon compound selected from the group consisting of colloidal silica and ethyl silicate; converting said silicon compound to silica gel by drying; and heating said impregnated sheet at a temperature of up to about 1,000° C. to burn up said organic fibers and said organic binder.
Claim 3
Dependent Claim
23 words
A process for producing a sheet for a catalyst carrier according to claim 1, wherein said organic binder is a fibrous polyvinyl alcohol.
Claim 4
Dependent Claim
36 words
A process for producing a sheet for a catalyst carrier according to claim 1, wherein said organic fibers are rayon fibers or beaten wood pulp, and said organic binder is an emulsion of vinyl acetate resin.
Claim 5
Dependent Claim
32 words
A process for producing a sheet for a catalyst carrier according to claim 1, wherein said ceramic fibers comprise highly heat resistant silica fibers, alumina fibers, alumino silicate fibers or zirconia fibers.
Claim 6
Dependent Claim
28 words
A process as in claim 4, wherein said ceramic fibers have a thickness of about 2.6 to 3.0 microns and a length of about 5 to 30 mm.
Claim 7
Dependent Claim
40 words
A process for producing a sheet for a catalyst carrier according to claim 1, wherein said silicon compound is impregnated in an amount of about 60 to 120 g/100 g of said sheet of paper, calculated as SiO 2 .
Claim 8
Dependent Claim
14 words
A process as in claim 1, wherein said heating temperature is about 800° C.
Claim 9
Dependent Claim
23 words
A process as in claim 1, wherein said organic fibers are mixed in an amount of not greater than about 15% by weight.
Claim 10
Dependent Claim
38 words
A process as in claim 1, wherein said slurry comprises 80 to 96% by weight of said ceramic fibers, 2 to 10% by weight of said organic fibers, and 2 to 10% by weight of said organic binder.
Claim 11
Dependent Claim
23 words
A process as in claim 1, wherein prior to said impregnating step said sheet of paper is corrugated to form flutes or corrugations.
Claim 12
Dependent Claim
23 words
A process according to claim 1, wherein after said heating step, a plurality of the produced sheets are formed into a catalyst carrier.
Claim 13
Dependent Claim
119 words
A process for producing a sheet for a catalyst carrier for vapor-phase reactions, which comprises: mixing ceramic fibers comprising highly heat resistant silica fibers, alumina fibers, alumino silicate fibers or zironia fibers, organic fibers in an amount of not greater than about 15% by weight, and an organic binder to form a slurry; forming said slurry into a sheet of paper having a density of 0.2 to 0.4 g/cm 3 ; impregnating said sheet of paper with a silicon compound comprising colloidal silica or ethyl silicate; converting said silicon compound to silica gel by drying; and heating said impregnated sheet at a temperature of up to about 1,000° C. to burn up said organic fibers and said organic binder.
Claim 14
Dependent Claim
119 words
A process for producing a sheet for a catalyst carrier for vapor-phase reactions, which comprises: mixing ceramic fibers comprising highly heat resistant silica fibers, alumina fibers, alumino silicate fibers or zironia fibers, organic fibers in an amount of not greater than about 15% by weight, and an organic binder to form a slurry; forming said slurry into a sheet of paper having a density of 0.2 to 0.4 g/cm 3 ; impregnating said sheet of paper with a silicon compound comprising colloidal silica or ethyl silicate; converting said silicon compound to silica gel by drying; and heating said impregnated sheet at a temperature of up to about 1,000° C. to burn up said organic fibers and said organic binder.
Claim 15
Dependent Claim
38 words
A process as in claim 12, wherein said slurry comprises 80 to 90% by weight of said ceramic fibers, 2 to 10% by weight of said organic fibers, and 2 to 10% by weight of said organic binders.
Claim 16
Dependent Claim
23 words
A process according to claim 12, wherein after said heating step, a plurality of the produced sheets are formed into a catalyst carrier.
Claim 17
Dependent Claim
14 words
A sheet for a catalyst carrier produced by a process according to claim 1.
Claim 18
Dependent Claim
14 words
A sheet for a catalyst carrier produced by a process according to claim 4.
Claim 19
Dependent Claim
14 words
A sheet for a catalyst carrier produced by a process according to claim 3.
Claim 20
Dependent Claim
14 words
A sheet for a catalyst carrier produced by a process according to claim 12.
Claim 21
Dependent Claim
14 words
A sheet for a catalyst carrier produced by a process according to claim 13.
Claim 22
Dependent Claim
29 words
A catalyst carrier for vapor-phase reactions comprising a sheet-like mass of ceramic fibers being bonded by silica gel and said catalyst carrier having a porosity of at least 75%.
Claim 23
Dependent Claim
29 words
A catalyst carrier for vapor-phase reactions comprising a sheet-like mass of ceramic fibers being bonded by silica gel and said catalyst carrier having a porosity of at least 75%.
Claim 24
Dependent Claim
25 words
A catalyst carrier as in claim 20, wherein said ceramic fibers comprise highly heat resistant silica fibers, alumina fibers, alumino silicate fibers or zirconia fibers.
Claim 25
Dependent Claim
29 words
A catalyst carrier as in claim 21, wherein said ceramic fibers having a thickness of about 2.6 to 3.0 microns and a length of about 5 to 30 mm.
Claim 26
Dependent Claim
11 words
A catalyst carrier produced by a process according to claim 11.
Claim 27
Dependent Claim
11 words
A catalyst carrier produced by a process according to claim 14.
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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) | 1989-08-25 | 1990-02-24 | 1990-08-26 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-08-25 | 1994-02-24 | 1994-08-26 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-08-25 | 1998-02-24 | 1998-08-26 | $7700.00 | Window Closed / Lapsed |