US4657880A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Preparation of high surface area agglomerates for catalyst support and preparation of monolithic support structures containing them
Assignee: Corning Glass Works
•
Filing: 1985-03-18
•
Granted: 1987-04-14
•
Expires: 2005-03-18
Abstract
Abstract High surface area agglomerates of a porous oxide for the support of catalysts are provided. The agglomerates, in coarse particulate form, are incorporated into a sinterable ceramic structure as a discrete discontinuous phase. The agglomerates provide the high surface area necessary for effective catalyst support within the ceramic structure, which is sintered to provide appreciable density and strength.
Inventors
- 👤 Irwin M. Lachman
- 👤 Carlo Golino
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 18:35
CPC Classifications
B; B01; B01J; B01J37/00; B01J37/0009; B01J37/0027; B01J35/00; B01J35/50; B01J35/56; B01J35/57; B01J35/60; B01J35/61; B01J35/613; C; C04; C04B; C04B35/00; C04B35/01; C04B35/16; C04B35/18; C04B35/48; C04B35/481; C04B35/622; C04B38/00; C04B38/0006; B01J21/00; B01J21/12; C04B2111/00; C04B2111/00474; C04B2111/0081; Y; Y10; Y10S; Y10S502/00; Y10S502/524; Y10T; Y10T428/00; Y10T428/24; Y10T428/24149
Claims Analysis
Total Claims: 25
Claim 1
Independent Claim
186 words
A method of preparing a monolithic catalyst support structure having a first substantially continuous high-strength ceramic phase and a second discontinuous catalyst-support phase of high surface area porous oxide embedded therein comprising: (a) mixing into a substantially homogenous body (i) a high surface area porous oxide having a surface area of at least 20 m 2 /g selected from the group consisting of alumina, silica, spinel, titania, zeolite, zirconia, and mixtures of these; and (ii) a first binder for the oxide, said binder being capable of agglomerating said oxide; (b) drying the body; (c) forming the body into particles having a median diameter of 50-250 microns; (d) mixing 15-50 parts by weight of the particles of porous oxide so formed, 50-85 parts by weight of a ceramic matrix material, in particulate form, and 3-20 parts by weight of a second binder; (e) forming the mixture of step (d) into a honeycomb shape such that said ceramic material forms a substantially continous matrix phase in which said porous oxide particles are embedded; and (f) heating the shaped mixture at a temperature sufficient to sinter the ceramic material.
Claim 2
Independent Claim
186 words
A method of preparing a monolithic catalyst support structure having a first substantially continuous high-strength ceramic phase and a second discontinuous catalyst-support phase of high surface area porous oxide embedded therein comprising: (a) mixing into a substantially homogenous body (i) a high surface area porous oxide having a surface area of at least 20 m 2 /g selected from the group consisting of alumina, silica, spinel, titania, zeolite, zirconia, and mixtures of these; and (ii) a first binder for the oxide, said binder being capable of agglomerating said oxide; (b) drying the body; (c) forming the body into particles having a median diameter of 50-250 microns; (d) mixing 15-50 parts by weight of the particles of porous oxide so formed, 50-85 parts by weight of a ceramic matrix material, in particulate form, and 3-20 parts by weight of a second binder; (e) forming the mixture of step (d) into a honeycomb shape such that said ceramic material forms a substantially continous matrix phase in which said porous oxide particles are embedded; and (f) heating the shaped mixture at a temperature sufficient to sinter the ceramic material.
Claim 3
Dependent Claim
28 words
A method of claim 1 in which the binder for the oxide is a silicone resin, polymerized furfuryl alcohol, methyl cellulose, polyvinyl alcohol, or a mixture of these.
Claim 4
Dependent Claim
41 words
A method of claim 1 in which the ceramic material is cordierite, mullite, clay, talc, zirconia, zirconia-spinel, alumina, silica, lithium aluminosilicates, alumina-zirconia composites, or mixtures of these, and in which the ceramic material has a particle size finer than 200 mesh.
Claim 5
Dependent Claim
75 words
A method of claim 3 in which the ceramic material of step (d) is cordierite, the porous oxide of step (a) is a spinel or a mixture of alumina and silica, the binder of step (a) is polymerized furfuryl alcohol, and in which step (a) includes the sub-steps of (1) mixing the porous oxide material into monomeric furfuryl alcohol, and (2) contacting the mixture so formed with an aqueous inorganic acid to polymerize the alcohol.
Claim 6
Dependent Claim
40 words
A method of claim 3 in which the porous oxide of step (a) is a spinel or a mixture of alumina and silica, the binder of step (a) is methyl cellulose, and the ceramic material of step (d) is cordierite.
Claim 7
Dependent Claim
23 words
A method of claim 1 in which the ceramic material contains a component capable of causing microcracking to occur in the ceramic phase.
Claim 8
Dependent Claim
11 words
A monolithic-catalyst support structure prepared by the method of claim 1.
Claim 9
Dependent Claim
12 words
A monolithic-catalyst support structure support prepared by the method of claim 2.
Claim 10
Dependent Claim
12 words
A monolithic-catalyst support structure support prepared by the method of claim 3.
Claim 11
Dependent Claim
12 words
A monolithic-catalyst support structure support prepared by the method of claim 4.
Claim 12
Dependent Claim
12 words
A monolithic-catalyst support structure support prepared by the method of claim 5.
Claim 13
Dependent Claim
12 words
A monolithic-catalyst support structure support prepared by the method of claim 6.
Claim 14
Independent Claim
150 words
A method of preparing a monolithic catalyst support structure having a first substantially continuous high-strength ceramic phase and a second discontinuous catalyst-support phase of high surface area porous oxide embedded therein comprising: (a) mixing (i) 15-50 parts by weight of particles having a median diameter of 50-250 microns, which particles are comprised of a high surface area porous oxide having a surface area of at least 20 m 2 /g selected from the group consisting of alumina, silica, spinel, titania, zeolite, zirconia, and mixtures of these, (ii) 50-85 parts by weight of a ceramic matrix material in particulate form, and (iii) 3-20 parts by weight of a binder; (b) forming the mixture into a honeycomb shape such that said ceramic material forms a substantially continuous matrix phase in which said porous oxide particles are embedded; and (c) heating the shaped mixture at a temperature sufficient to sinter the ceramic material.
Claim 15
Independent Claim
150 words
A method of preparing a monolithic catalyst support structure having a first substantially continuous high-strength ceramic phase and a second discontinuous catalyst-support phase of high surface area porous oxide embedded therein comprising: (a) mixing (i) 15-50 parts by weight of particles having a median diameter of 50-250 microns, which particles are comprised of a high surface area porous oxide having a surface area of at least 20 m 2 /g selected from the group consisting of alumina, silica, spinel, titania, zeolite, zirconia, and mixtures of these, (ii) 50-85 parts by weight of a ceramic matrix material in particulate form, and (iii) 3-20 parts by weight of a binder; (b) forming the mixture into a honeycomb shape such that said ceramic material forms a substantially continuous matrix phase in which said porous oxide particles are embedded; and (c) heating the shaped mixture at a temperature sufficient to sinter the ceramic material.
Claim 16
Dependent Claim
10 words
A catalyst support prepared by the method of claim 13.
Claim 17
Dependent Claim
116 words
A monolithic catalyst support structure having a first substantially continuous high-strength ceramic phase and a second discontinuous catalyst-support phase of high surface area porous oxide embedded therein, the catalyst support structure being characterized in that (1) said high surface area catalyst-support phase consists of a porous oxide selected from alumina, spinel, silica, titania, zeolite, zirconia, or mixtures or these, (2) said high surface area catalyst-support phase is in the form of agglomerates having a median diameter of 50-250 microns and a surfaces area of at least 20 m 2 /g, and (3) the structure contains 50-85 parts by weight of the ceramic phase and 15-50 parts by weight of the high surface area porous oxide phase.
Claim 18
Dependent Claim
116 words
A monolithic catalyst support structure having a first substantially continuous high-strength ceramic phase and a second discontinuous catalyst-support phase of high surface area porous oxide embedded therein, the catalyst support structure being characterized in that (1) said high surface area catalyst-support phase consists of a porous oxide selected from alumina, spinel, silica, titania, zeolite, zirconia, or mixtures or these, (2) said high surface area catalyst-support phase is in the form of agglomerates having a median diameter of 50-250 microns and a surfaces area of at least 20 m 2 /g, and (3) the structure contains 50-85 parts by weight of the ceramic phase and 15-50 parts by weight of the high surface area porous oxide phase.
Claim 19
Dependent Claim
29 words
A catalyst support of claim 15 wherein the sintered ceramic phase consists of cordierite, mullite, clay, talc, zirconia, zirconia-spinel, alumina, silica, lithium aluminosilicate, alumina-zirconia composite, or mixture of these.
Claim 20
Dependent Claim
12 words
A catalyst support of claim 15 wherein the ceramic phase is cordierite.
Claim 21
Dependent Claim
22 words
A catalyst support of claim 16 in which the high surface area phase consists of alumina, silica, spinel, or mixtures of these.
Claim 22
Dependent Claim
22 words
A catalyst support of claim 17 in which the high surface area phase consists of alumina, silica, spinel, or mixtures of these.
Claim 23
Dependent Claim
15 words
A catalyst support of claim 19 in which the high surface area phase is alumina.
Claim 24
Dependent Claim
15 words
A catalyst support of claim 19 in which the high surface area phase is spinel.
Claim 25
Dependent Claim
20 words
A catalyst support of claim 19 in which the high surface area phase is a mixture of alumina and silica.
References Cited (Backward Citations)
US2742437A
Cited
GB1064018A
Cited
DE1442653A1
Cited
GB1142800A
Cited
US3565919A
Cited
FR1555969A
Cited
GB1315553A
Cited
US3824196A
Cited
US4007134A
Cited
US4054702A
Cited
US4151121A
Cited
GB1565800A
Cited
US4127691A
Cited
US4157375A
Cited
US4239656A
Cited
US4277376A
Cited
EP0012063A1
Cited
US4294806A
Cited
US4341663A
Cited
GB2091239A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1990-04-13 | 1990-10-13 | 1991-04-14 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-04-13 | 1994-10-13 | 1995-04-14 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-04-13 | 1998-10-13 | 1999-04-14 | $7700.00 | Window Closed / Lapsed |