US4983423A
Expired / Lapsed
US
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Method of forming a porous inorganic membrane on a porous support using a reactive inorganic binder
Assignee: Corning Inc
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Filing: 1988-05-24
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Granted: 1991-01-08
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Expires: 2008-05-24
Abstract
Abstract A porous inorganic membrane for use with a membrane device having a porous support, the membrane including refractory particles bound to each other and to the support by a thermally reactive inorganic binder which reacts at a temperature below that at which the refractory particles react. Further, a method of forming a porous inorganic membrane on a support by applying a coating of a mixture of refractory particles and a thermally reactive inorganic binder to the support. The inorganic binder reacts at a first temperature lower than a second temperature at which the refractory particles sinter. The method further includes firing the support to a firing temperature at least as high as the first temperature and less than the second temperature to react the inorganic binder, and cooling the support to form the porous membrane.
Inventors
- 👤 Robert L. Goldsmith
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 14:34
CPC Classifications
B; B01; B01D; B01D69/00; B01D69/12; B01D39/00; B01D39/14; B01D39/20; B01D67/00; B01D67/0039; B01D67/0046; B01D71/00; B01D71/02; B01D71/0215; C; C04; C04B; C04B41/00; C04B41/009; C04B41/45; C04B41/50; C04B41/5025; C04B41/80; C04B41/81; C04B41/85; C04B41/87; B01D2323/00; B01D2323/08; B01D2323/12; C04B2111/00; C04B2111/00474; C04B2111/00793
Claims Analysis
Total Claims: 38
Claim 1
Independent Claim
132 words
A method of forming a porous inorganic separation membrane on a porous support to establish a membrane device for use in membrane separations, comprising: applying a coating of a mixture of thermally refractory particles and a thermally reactive inorganic binder to the porous support to form a first layer, the inorganic binder reacting at a first temperature which is lower than a second temperature at which the refractory particles sinter; firing the support to a firing temperature at least as high as the first temperature and less than the second temperature to react the inorganic binder; and cooling the support to form the porous inorganic separation membrane from the first layer having the refractory particles bound to each other and to the support by the inorganic binder to establish the membrane device.
Claim 2
Independent Claim
132 words
A method of forming a porous inorganic separation membrane on a porous support to establish a membrane device for use in membrane separations, comprising: applying a coating of a mixture of thermally refractory particles and a thermally reactive inorganic binder to the porous support to form a first layer, the inorganic binder reacting at a first temperature which is lower than a second temperature at which the refractory particles sinter; firing the support to a firing temperature at least as high as the first temperature and less than the second temperature to react the inorganic binder; and cooling the support to form the porous inorganic separation membrane from the first layer having the refractory particles bound to each other and to the support by the inorganic binder to establish the membrane device.
Claim 3
Dependent Claim
12 words
The method of claim 1 in which the refractory particles are ceramic.
Claim 4
Dependent Claim
32 words
The method of claim 2 in which the ceramic is selected from the group consisting of silicon carbide, silicon nitride, silica, alumina, zirconia, zircon, mullite, cordierite, titania, spinel, thoria, hematite, and hafnia.
Claim 5
Dependent Claim
14 words
The method of claim 1 in which the inorganic binder includes a glass frit.
Claim 6
Dependent Claim
19 words
The method of claim 4 in which the glass frit has a melting point between 600° and 1,200° C.
Claim 7
Dependent Claim
25 words
The method of claim 4 in which the glass frit has a particle size less than or equal to the size of the refractory particles.
Claim 8
Dependent Claim
14 words
The method of claim 1 in which the inorganic binder includes fine reactive particles.
Claim 9
Dependent Claim
33 words
The method of claim 7 in which the fine reactive particles are reactive ceramic particles and are selected from the group consisting of alumina, zirconia, titania, silica, zircon, silicon carbide, and silicon nitride.
Claim 10
Dependent Claim
18 words
The method of claim 7 in which the reactive ceramic particles are less than 1 micron in size.
Claim 11
Dependent Claim
15 words
The method of claim 1 in which the inorganic binder includes an inorganic colloidal material.
Claim 12
Dependent Claim
34 words
The method of claim 10 in which the inorganic colloidal material is selected from the group consisting of colloidal silica, alumina, zirconia, titania, ceria, yttria, tin oxide, silicon carbide, silicon nitride, and mixtures thereof.
Claim 13
Dependent Claim
18 words
The method of claim 10 in which the inorganic colloidal material has a particle size below 100 millimicrons.
Claim 14
Dependent Claim
28 words
The method of claim 1 in which the mixture further includes a liquid vehicle and the inorganic binder includes a soluble inorganic material dissolved in the liquid vehicle.
Claim 15
Dependent Claim
20 words
The method of claim 13 in which the soluble inorganic material converts on firing to alumina, silica, titania, or zirconia.
Claim 16
Dependent Claim
26 words
The method of claim 1 in which the inorganic binder ranges from 2.5 wt % to 200 wt % relative to the weight of refractory particles.
Claim 17
Dependent Claim
26 words
The method of claim 1 in which the inorganic binder ranges from 10 wt % to 100 wt % relative to the weight of refractory particles.
Claim 18
Dependent Claim
20 words
The method of claim 1 in which the refractory particles and the inorganic binder are carried by a liquid vehicle.
Claim 19
Dependent Claim
18 words
The method of claim 17 further including drying the support before firing to drive off the liquid vehicle.
Claim 20
Dependent Claim
21 words
The method of claim 17 in which the mixture further includes a viscosity modifier for controlling the viscosity of the mixture.
Claim 21
Dependent Claim
36 words
The method of claim 19 in which the mixture further includes an organic binder for adhering together the refractory particles and the inorganic binder as a coating when they are applied to the support and dried.
Claim 22
Dependent Claim
14 words
The method of claim 1 in which the coating is applied by slip casting.
Claim 23
Dependent Claim
14 words
The method of claim 1 in which the coating is applied by dynamic filtration.
Claim 24
Dependent Claim
23 words
The method of claim 1 in which the support is a porous material selected from the group consisting of ceramics, carbon, and metals.
Claim 25
Dependent Claim
22 words
The method of claim 1 in which the support is a porous tube and the coating is applied on the inner surface.
Claim 26
Dependent Claim
22 words
The method of claim 17 in which the support is a porous tube and the coating is applied on the outer surface.
Claim 27
Dependent Claim
30 words
The method of claim 1 in which the support is a porous monolith having a plurality of passageways and the coating is applied on the surfaces of the monolith passageways.
Claim 28
Dependent Claim
24 words
The method of claim 1 further including applying at least one successive coating of inorganic particles to the support to overlie the first layer.
Claim 29
Dependent Claim
28 words
The method of claim 27 in which the inorganic coating particles of each successive coating are smaller in size than the inorganic coating particles in an underlying layer.
Claim 30
Dependent Claim
22 words
The method of claim 28 in which the underlying layer is dried, but not fired, prior to application of the successive coating.
Claim 31
Dependent Claim
91 words
The method of claim 27 in which at least one of the successive coatings is a mixture of refractory particles as the inorganic coating particles and a thermally reactive inorganic binder, and the method further includes applying the mixture to the support after cooling the support, refiring the support to a firing temperature less than the second temperature of the refractory particles in any underlying layer and in the successive coating until the inorganic binder in the successive coating reacts, and cooling the support to form a composite porous inorganic membrane.
Claim 32
Dependent Claim
22 words
The method of claim 30 in which each underlying layer is dried, but not fired, prior to application of the successive coating.
Claim 33
Dependent Claim
87 words
The method of claim 27 in which at least one of the successive coatings is inorganic particles smaller in size than the inorganic coating particles in an underlying layer, and the method further includes applying the inorganic coating particles to the support after cooling the support, refiring the support to a firing temperature below the second temperature of the inorganic coating particles of any underlying layer until the inorganic coating particles in the successive coating sinter, and cooling the support to form a composite porous inorganic membrane.
Claim 34
Dependent Claim
22 words
The method of claim 32 in which the underlying layer is dried, but not fired, prior to application of the successive coating.
Claim 35
Dependent Claim
91 words
The method of claim 27 in which at least one of the successive coatings is inorganic coating particles smaller in size than the inorganic coating particles of any underlying layer, and the method further includes applying the coating to the support after cooling the support, refiring the support to a firing temperature below the second temperature of the inorganic coating particles of any underlying layer until a glass frit in the underlying layer melts and flows into the successive coating, and cooling the support to form a composite porous inorganic membrane.
Claim 36
Dependent Claim
22 words
The method of claim 34 in which the underlying layer is dried, but not fired, prior to application of the successive coating.
Claim 37
Independent Claim
140 words
A method of forming a porous inorganic separation membrane on a porous support to establish a membrane device for use in membrane separations, comprising: mixing thermally refractory ceramic particles, a thermally reactive inorganic binder which reacts at a first temperature lower than a second temperature at which the refractory ceramic particles sinter, and a liquid vehicle; applying the mixture to the porous support to establish a coating on the support; drying the support to drive off the liquid vehicle from the coating; firing the support to a firing temperature at least as high as the first temperature and less than the second temperature to react the inorganic binder; and cooling the support to form the porous separation membrane having the refractory ceramic particles bound to each other and to the support by the inorganic binder to establish the membrane device.
Claim 38
Independent Claim
140 words
A method of forming a porous inorganic separation membrane on a porous support to establish a membrane device for use in membrane separations, comprising: mixing thermally refractory ceramic particles, a thermally reactive inorganic binder which reacts at a first temperature lower than a second temperature at which the refractory ceramic particles sinter, and a liquid vehicle; applying the mixture to the porous support to establish a coating on the support; drying the support to drive off the liquid vehicle from the coating; firing the support to a firing temperature at least as high as the first temperature and less than the second temperature to react the inorganic binder; and cooling the support to form the porous separation membrane having the refractory ceramic particles bound to each other and to the support by the inorganic binder to establish the membrane device.
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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) | 1994-01-07 | 1994-07-09 | 1995-01-08 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-01-07 | 1998-07-09 | 1999-01-08 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-01-07 | 2002-07-09 | 2003-01-08 | $7700.00 | Window Closed / Lapsed |