US4637995A
Expired / Lapsed
US
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Preparation of monolithic catalyst supports having an integrated high surface area phase
Assignee: Corning Glass Works
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Filing: 1985-03-18
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Granted: 1987-01-20
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Expires: 2005-03-18
Abstract
Abstract A method of preparing a monolithic catalyst support having an integrated high surface area phase is provided. A plasticized batch of ceramic matrix material intimately mixed with high surface area powder is formed into the desired shape for the monolith and then heated to sinter the ceramic. The resulting monolith has a strong substrate of the ceramic matrix material and a high surface area phase provided by the high surface area powder extruded with the batch.
Inventors
- 👤 Thomas P. DeAngelis
- 👤 Irwin M. Lachman
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 04:54
CPC Classifications
B; B01; B01J; B01J37/00; B01J37/08; B01J37/0009; Y; Y10; Y10S; Y10S502/00; Y10S502/524
Claims Analysis
Total Claims: 27
Claim 1
Independent Claim
148 words
A method of preparing a monolithic catalyst support which comprises: (a) providing a substantially homogeneous body comprising an admixture of (i) a first phase sinterable ceramic matrix material, in particulate form finer than 200 mesh, selected from the group consisting of cordierite, mullite, alpha-alumina, lithium aluminosilicate, and mixtures of these, and (ii) a second phase high surface area catalyst-support material having a crystalline size no larger than 0.2 microns and a surface area of at least 40 m 2 /g, said catalyst-support material consisting of transition metal sulfide; a mixture of transition metal sulfides; porous oxide selected from the group consisting of alumina, zirconia, spinel, silica, zeolite, titania, and mixtures of these; or a mixture of said sulfide and said oxide materials; (b) forming the resultant body into a desired shape; and (c) heating the shaped body at a temperature sufficient to sinter the first phase matrix material.
Claim 2
Independent Claim
148 words
A method of preparing a monolithic catalyst support which comprises: (a) providing a substantially homogeneous body comprising an admixture of (i) a first phase sinterable ceramic matrix material, in particulate form finer than 200 mesh, selected from the group consisting of cordierite, mullite, alpha-alumina, lithium aluminosilicate, and mixtures of these, and (ii) a second phase high surface area catalyst-support material having a crystalline size no larger than 0.2 microns and a surface area of at least 40 m 2 /g, said catalyst-support material consisting of transition metal sulfide; a mixture of transition metal sulfides; porous oxide selected from the group consisting of alumina, zirconia, spinel, silica, zeolite, titania, and mixtures of these; or a mixture of said sulfide and said oxide materials; (b) forming the resultant body into a desired shape; and (c) heating the shaped body at a temperature sufficient to sinter the first phase matrix material.
Claim 3
Dependent Claim
32 words
A method of claim 1 in which mixing step (a) is performed using 50-90 parts by weight of the first phase material and 10-50 parts by weight of the second phase material.
Claim 4
Dependent Claim
21 words
A method of claim 2 in which mixing step (a) is performed using 1-30 parts by weight of a binder material.
Claim 5
Dependent Claim
37 words
A method of claim 3 in which the second phase material has a surface area of at least 100 m 2 /g and is selected from the group consisting of alumina, silica, zeolite, and mixtures of these.
Claim 6
Dependent Claim
26 words
A method of claim 4 in which the second phase material is alumina, and the binder is methyl cellulose, a silicone resin, or mixtures of these.
Claim 7
Dependent Claim
26 words
A method of claim 4 in which the second phase material is silica and the binder is methyl cellulose, a silicone resin, or mixtures of these.
Claim 8
Dependent Claim
31 words
A method of claim 4 in which the second phase material is a mixture of silica and alumina and the binder is methyl cellulose, a silicone resin, or mixtures of these.
Claim 9
Dependent Claim
27 words
A method of claim 4 in which the second phase material is a zeolite and the binder is methyl cellulose, a silicone resin, or mixtures of these.
Claim 10
Dependent Claim
26 words
A method of claim 3 in which the second phase material is titania and the binder is methyl cellulose, a silicone resin, or mixtures of these.
Claim 11
Dependent Claim
27 words
A method of claim 3 in which the second phase material is a spinel and the binder is methyl cellulose, a silicone resin, or mixtures of these.
Claim 12
Dependent Claim
18 words
A method of claim 3 in which the second phase material is zirconia or a transition metal sulfide.
Claim 13
Dependent Claim
22 words
A method of claim 5, 6, 7, 8, 9, or 10 in which the first phase sinterable material is cordierite or mullite.
Claim 14
Dependent Claim
20 words
A method of claim 5, 6, 7, 8, 9, or 10 in which the first phase sinterable material is alpha-alumina.
Claim 15
Dependent Claim
11 words
A monolithic catalyst support prepared by the method of claim 1.
Claim 16
Dependent Claim
11 words
A monolithic catalyst support prepared by the method of claim 12.
Claim 17
Dependent Claim
11 words
A monolithic catalyst support prepared by the method of claim 13.
Claim 18
Dependent Claim
119 words
A monlithic catalyst support comprising 50-90 parts by weight of a sintered ceramic matrix material and 10-50 parts per weight of a high surface area catalyst-support material dispersed throughout the matrix wherein (a) the ceramic matrix material consists of cordierite, mullite, alpha-alumina, lithium aluminosilicate, or mixtures of these; and (b) the dispersed catalyst-support material has a surface area of at least 40 m 2 / g and a crystallite size no larger than about 0.5 microns, and the catalyst-support material consists of transition metal sulfide; a mixture of transition metal sulfides; porous oxide selected from the group consisting of alumina, zirconia, spinel, silica, zeolite, titania, and mixtures of these; or a mixture of said sulfide and said oxide materials.
Claim 19
Dependent Claim
119 words
A monlithic catalyst support comprising 50-90 parts by weight of a sintered ceramic matrix material and 10-50 parts per weight of a high surface area catalyst-support material dispersed throughout the matrix wherein (a) the ceramic matrix material consists of cordierite, mullite, alpha-alumina, lithium aluminosilicate, or mixtures of these; and (b) the dispersed catalyst-support material has a surface area of at least 40 m 2 / g and a crystallite size no larger than about 0.5 microns, and the catalyst-support material consists of transition metal sulfide; a mixture of transition metal sulfides; porous oxide selected from the group consisting of alumina, zirconia, spinel, silica, zeolite, titania, and mixtures of these; or a mixture of said sulfide and said oxide materials.
Claim 20
Dependent Claim
32 words
A monolithic catalyst support of claim 17 wherein the dispersed catalyst-support material has a surface area of at least 100 m 2 /g and is alumina, silica, zeolite, or mixtures of these.
Claim 21
Dependent Claim
16 words
A monolithic catalyst support of claim 18 wherein the dispersed catalyst-support material is a transition alumina.
Claim 22
Dependent Claim
14 words
A monolthic catalyst support of claim 18 wherein the dispersed catalyst-support material is silica.
Claim 23
Dependent Claim
15 words
A monolithic catalyst support of claim 17 wherein the dispersed catalyst-support material is a spinel.
Claim 24
Dependent Claim
22 words
A monlithic catalyst support of claim 17, 18, 19, 20, or 21 in which the ceramic matrix material is cordierite or mullite.
Claim 25
Dependent Claim
18 words
A monolithic catalyst support of claim 22 having a surface area of at least 5 m 2 /g.
Claim 26
Dependent Claim
47 words
A method of claim 1 in which the second phase material is alumina, spinel, or a mixture of alumina and silica; and in which the admixture further comprises up to 20 percent by weight, based on the weight of the second phase material, of rare earth oxide.
Claim 27
Dependent Claim
49 words
A monolithic catalyst support of claim 17 wherein the dispersed catalyst-support material is alumina, spinel, or a mixture of alumina and silica; and wherein the monolithic catalyst support further comprises up to 20 percent by weight, based on the weight of the dispersed catalyst-support material, of rare earth oxide.
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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) | 1990-01-19 | 1990-07-21 | 1991-01-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-01-19 | 1994-07-21 | 1995-01-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-01-19 | 1998-07-21 | 1999-01-20 | $7700.00 | Window Closed / Lapsed |