US4888317A
Expired / Lapsed
US
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Catalyst-agglomerate bodies encapsulated in a structure and method for their production
Assignee: Corning Inc
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Filing: 1988-07-15
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Granted: 1989-12-19
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Expires: 2008-07-15
Abstract
Abstract A structure with encapsulated catalyst-agglomerate bodies which are integral to a porous structure is presented. The catalysts may be singly and/or multiply dispersed on and/or throughout a high surface area material and subsequently mixed with batch material prior to firing the structure. This results in a structure wherein encapsulated catalyst-agglomerate bodies in a porous structure exhibit the same catalytic activity as in a break in aged catalyst coated substrate.
Inventors
- 👤 Thomas P. DeAngelis
- 👤 Irwin M. Lachman
- 👤 Raja R. Wusirika
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 07:21
CPC Classifications
B; B01; B01J; B01J35/00; B01J35/30; B01J37/00; B01J37/0009; B01J29/00; B01J37/04
Claims Analysis
Total Claims: 27
Claim 1
Independent Claim
49 words
A hardened porous sintered structure comprising a single and/or a plurality of catalysts dispersed on and throughout a plurality of high surface area agglomerate bodies wherein said bodies are within the wall of the structure and/or protrude out of said wall and said bodies are integral with said structure.
Claim 2
Dependent Claim
49 words
A hardened porous sintered structure comprising a single and/or a plurality of catalysts dispersed on and throughout a plurality of high surface area agglomerate bodies wherein said bodies are within the wall of the structure and/or protrude out of said wall and said bodies are integral with said structure.
Claim 3
Dependent Claim
42 words
A honeycomb structure comprising a single and/or a plurality of catalysts dispersed on and throughout a plurality of high surface area agglomerate bodies wherein said bodies are contained within the walls and/or protrude out of said walls and integral with said structure.
Claim 4
Dependent Claim
42 words
A honeycomb structure comprising a single and/or a plurality of catalysts dispersed on and throughout a plurality of high surface area agglomerate bodies wherein said bodies are contained within the walls and/or protrude out of said walls and integral with said structure.
Claim 5
Dependent Claim
36 words
The structure of claim 1 wherein said catalysts are selected from the group consisting essentially of the elements, and/or oxides, and/or chemical precursors of iridium, rhodium, rhenium, ruthenium, platinum, palladium, silver, gold and/or some combination thereof.
Claim 6
Dependent Claim
32 words
The structure of claim 1 wherein said catalysts are dispersed as a single species and/or multiple species on a high surface area oxide, a precursor of said oxide, or a combination thereof.
Claim 7
Dependent Claim
42 words
The structure of claim 1 wherein said catalysts are selected from the group consisting essentially of the elements and/or oxides, and/or chemical precursors of iron, vanadium, copper, cobalt, nickel, chromium, manganese, titanium, zirconium, zinc, molybdenum, tungsten, niobium, tantalum and/or a combination thereof.
Claim 8
Dependent Claim
12 words
The structure of claim 1 wherein said catalysts are zeolites and/or alumina.
Claim 9
Dependent Claim
40 words
The structure of claim 1 wherein said structure consists of materials selected from the group consisting of silicates, cermets, glass-ceramics, glasses, cordierite, lithium aluminosilicates, mullite, alumina, spinels, zircon, feldspars, quartz, fused silica, kaolin clays, aluminum titanate, and/or a combination thereof.
Claim 10
Dependent Claim
38 words
The structure of claim 1 wherein said high surface area agglomerates are selected from the group consisting essentially of alumina, zirconia, spinels, silica, titania, rare earth metal oxides, alkaline earth metal oxides, and zeolites and/or a combination thereof.
Claim 11
Dependent Claim
13 words
The structure of claim 1 wherein said structure consists essentially of sintered metal.
Claim 12
Dependent Claim
36 words
The structure of claim 9 wherein said structure consists essentially of metal selected from the group consisting of the stainless steel 300 and/or 400 series, iron, aluminum, copper, tin, chromium, magnesium, calcium, and/or a combination thereof.
Claim 13
Dependent Claim
81 words
The structure of claim 9 wherein said structure consists essentially of metal selected from the group in weight percent as analyzed, of 5-50% aluminum, 30-90% iron, the sum of aluminum and iron constituting at least 80% of the total composition, 0-10% tin, 0-10% copper, 0-10% chromium, the sum of tin, copper, and chromium being less than 20%, and optionally not more than 1% of an alkaline earth metal as a sintering aid selected from the group consisting of magnesium and calcium.
Claim 14
Dependent Claim
29 words
The structure of claim 1 wherein said high surface area agglomerate bodies are encapsulated in a housing whereby said high surface area agglomerate bodies are unbound in said housing.
Claim 15
Dependent Claim
15 words
The structure of claim 12 wherein said housing consists essentially of open and/or closed porosity.
Claim 16
Dependent Claim
23 words
The structure of claim 1 wherein said high surface area agglomerate bodies consist essentially of a diameter of about 5 to 200 microns.
Claim 17
Dependent Claim
23 words
The structure of claim 1 wherein said high surface area agglomerate bodies consist essentially of a diameter of about 5 to 100 microns.
Claim 18
Dependent Claim
15 words
The structure of claim 1 wherein said structure consists essentially of open and/or closed porosity.
Claim 19
Dependent Claim
11 words
The structure of claim 1 wherein said structure is a monolith.
Claim 20
Dependent Claim
10 words
The structure of claim 1 wherein said structure is extrudable.
Claim 21
Dependent Claim
20 words
The structure of claim 1 wherein said high surface area agglomerate bodies are homogeneously dispersed on and throughout said structure.
Claim 22
Dependent Claim
11 words
The structure of claim 1 wherein said structure is a honeycomb.
Claim 23
Independent Claim
78 words
A method for producing a hard porous sintered structure consisting essentially of a single and/or a plurality of catalysts dispersed on and throughout high surface area agglomerate bodies wherein said bodies are within the wall of the structure and/or protrude out of said wall comprising the steps of: (a) mixing said high surface area catalyst-agglomerate bodies with batch materials and organic binder to form a structural body, and (b) firing said structural body to a hardened sintered structure.
Claim 24
Independent Claim
78 words
A method for producing a hard porous sintered structure consisting essentially of a single and/or a plurality of catalysts dispersed on and throughout high surface area agglomerate bodies wherein said bodies are within the wall of the structure and/or protrude out of said wall comprising the steps of: (a) mixing said high surface area catalyst-agglomerate bodies with batch materials and organic binder to form a structural body, and (b) firing said structural body to a hardened sintered structure.
Claim 25
Dependent Claim
15 words
The method of claim 21 wherein said high surface area agglomerate bodies are spray dried.
Claim 26
Dependent Claim
18 words
The method of claim 21 wherein said high surface area agglomerate bodies are coated with an organic binder.
Claim 27
Dependent Claim
19 words
The method of claim 21 wherein said high surface area agglomerate bodies are homogeneously mixed with said batch material.
References Cited (Backward Citations)
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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) | 1992-12-18 | 1993-06-19 | 1993-12-19 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-12-18 | 1997-06-19 | 1997-12-19 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-12-18 | 2001-06-19 | 2001-12-19 | $7700.00 | Window Closed / Lapsed |