US3925259A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Catalytic structure for the purification of waste gases and its method of preparation
Assignee: Huntington Alloys Corp
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Filing: 1973-11-12
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Granted: 1975-12-09
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Expires: 1993-11-12
Abstract
Abstract A catalytic structure providing high surface area and low resistance to flow is prepared from a powder comprising an alloy containing chromium and copper by depositing the powder on a shaped preform with the aid of a fugitive binder and heating the coated substrate to effect liquid-phase sintering of the powder. In one embodiment an alloy of Cr-Ni-Cu coated on an open mesh preform serves as a catalyst in the purification of an automotive exhaust stream.
Inventors
- 👤 Robert Harvey Kane
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 10:37
CPC Classifications
B; B01; B01D; B01D53/00; B01D53/34; B01D53/92; B01D53/94; B01D53/9445; B01D53/945; B01J; B01J23/00; B01J23/70; B01J23/76; B01J23/84; B01J23/85; B01J23/86; B01J23/868; B01J23/88; B01J23/885; B01J23/89; B01J23/8933; B01J23/8993; B01J37/00; B01J37/0009; B01J37/0018; C; C22; C22C; C22C30/00; C22C30/02; B01D2255/00; B01D2255/20; B01D2255/207; B01D2255/20753; B01D2255/20761; B01D2255/20784; B01D2255/90; B01D2255/902; B01D2255/9025; Y; Y02; Y02A; Y02A50/00; Y02A50/20; Y02T; Y02T10/00; Y02T10/10; Y02T10/12
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
72 words
A METHOD OF MAKING A SHAPED CATALYTIC STRUCTURE COMPRISED OF A CHROMIUM AND COPPER-CONTAINING ALLOY COMPRISING: A. FORMING INTO A STRUCTURE OF DESIRED SHAPE A FINE POWDER COMPRISED OF AN ALLOY CONTAINING CHROMIUM AND COPPER, AND B. HEATING THE SHAPED POWDER TO A TEMPERATURE ABOVE ABOUT 2050*F IN A NON-OXIDIZING ATMOSPHERE FOR A PERIOD OF TIME SUFFICIENT TO EFFECT A LIQUID-PHASE SINTERING OF SAID FINE POWDER; THEREBY FORMING A COHERENT SHAPED STRUCTURE.
Claim 2
Independent Claim
72 words
A METHOD OF MAKING A SHAPED CATALYTIC STRUCTURE COMPRISED OF A CHROMIUM AND COPPER-CONTAINING ALLOY COMPRISING: A. FORMING INTO A STRUCTURE OF DESIRED SHAPE A FINE POWDER COMPRISED OF AN ALLOY CONTAINING CHROMIUM AND COPPER, AND B. HEATING THE SHAPED POWDER TO A TEMPERATURE ABOVE ABOUT 2050*F IN A NON-OXIDIZING ATMOSPHERE FOR A PERIOD OF TIME SUFFICIENT TO EFFECT A LIQUID-PHASE SINTERING OF SAID FINE POWDER; THEREBY FORMING A COHERENT SHAPED STRUCTURE.
Claim 3
Independent Claim
107 words
A method of making a shaped catalytic structure comprised of an open mesh pre-formed heat resistant substrate and a catalytic layer comprised of a chromium and copper-containing alloy on said substrate comprising: a. applying a coating of a fugitive binder on said pre-formed substrate, b. depositing on said substrate a layer of a fine powder comprised of an alloy containing chromium and copper, and c. heating the resultant coated structure to a temperature above about 2050*F in a non-oxidizing atmosphere for a period of time sufficient to effect a liquid-phase sintering of said powder layer, thereby substantially removing the fugitive binder and forming a coherent shaped structure.
Claim 4
Independent Claim
107 words
A method of making a shaped catalytic structure comprised of an open mesh pre-formed heat resistant substrate and a catalytic layer comprised of a chromium and copper-containing alloy on said substrate comprising: a. applying a coating of a fugitive binder on said pre-formed substrate, b. depositing on said substrate a layer of a fine powder comprised of an alloy containing chromium and copper, and c. heating the resultant coated structure to a temperature above about 2050*F in a non-oxidizing atmosphere for a period of time sufficient to effect a liquid-phase sintering of said powder layer, thereby substantially removing the fugitive binder and forming a coherent shaped structure.
Claim 5
Dependent Claim
20 words
A method according to claim 2 in which the fine powder is an alloy consisting essentially of chromium and copper.
Claim 6
Dependent Claim
21 words
A method according to claim 2 in which the fine powder is an alloy consisting essentially of chromium, nickel and copper.
Claim 7
Dependent Claim
25 words
A method according to claim 2 in which the liquid-phase sintering is effected at a temperature in the range of about 2050*F to about 2275*F.
Claim 8
Dependent Claim
29 words
A method according to claim 5 in which the peak temperature is held for a sufficient time for 15 volume % of the powder to form as a liquid.
Claim 9
Dependent Claim
19 words
A method according to claim 2 in which the non-oxidizing atmosphere is an inert gas, hydrogen, or high vaccum.
Claim 10
Dependent Claim
44 words
A method according to claim 2 in which the coherent layers formed by sequentially repeating steps (a), (b), and then sintering the resultant multi-coated structure according to steP (c) to build up a coherent layer of about 2 to about 100 mils in thickness.
Claim 11
Dependent Claim
14 words
A method according to claim 2 in which the substrate is a nickel-containing alloy.
Claim 12
Dependent Claim
14 words
A method according to claim 2 in which the substrate is a metallized ceramic.
Claim 13
Dependent Claim
34 words
A method according to claim 2 in which the substrate is an open mesh metal in a configuration selected from expanded metal mesh, woven wire mesh, knitted metal mesh, gauze, honeycomb, and metal foam.
Claim 14
Dependent Claim
66 words
A method according to claim 2 in which the alloy powder is formed by mechanical alloying and the resultant coated structure, before reaching the peak temperature to effect liquid-phase sintering, is subjected to an intermediate temperature hold of about 1600*F to about 2000*F for a period of time sufficient to control the particle size and interparticle spacing of microconstituents which precipitate in a solid state reaction.
Claim 15
Dependent Claim
64 words
A method according to claim 2 in which the shaped structure consisting essentially of a pre-formed substrate with a coherent, adherent, layer thereon comprising an alloy containing chromium and coopper is thereafter treated at an elevated temperature in a gas phase atompshere which is oxygenating with respect to said alloy to develop an oxidation resistant stratified catalytically active surface on the coherent alloy layer.
Claim 16
Dependent Claim
22 words
A method according to claim 2 in which the fugitive binder is an organic elastomer or polyvinyl alcohol in a compatible vehicle.
Claim 17
Dependent Claim
45 words
A composite catalyst comprising an open mesh pre-formed heat resistant substrate and a catalytic layer comprised of a coherent, adherent layer comprising a substantially uniform alloy containing chromium and copper on said substrate, wherein said catalytic layer is formed by the method of claim 2.
Claim 18
Dependent Claim
26 words
A composite catalyst according to claim 15 in which the catalytic layer is comprised of an alloy consisting essentially of chromium and the balance essentially copper.
Claim 19
Dependent Claim
24 words
A composite catalyst according to claim 15 in which the catalytic layer is comprised of an alloy consisting essentially of chromium, nickel and copper.
Claim 20
Dependent Claim
17 words
A composite catalyst according to claim 15 in which the open mesh substrate is a nickel-containing alloy.
Claim 21
Dependent Claim
17 words
A composite catalyst according to claim 15 in which the open mesh substrate is a metallized ceramic.
Claim 22
Dependent Claim
35 words
A method according to claim 2 in which the alloy containing chromium and copper is prepared by a method comprising at least one of the techniques of atomization, mechanical alloying, splat cooling and plasma spraying.
Claim 23
Dependent Claim
13 words
A method according to claim 2 in which the substrate is a ceramic.
Claim 24
Dependent Claim
14 words
A composite catalyst according to claim 15 in which the substrate is a ceramic.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-12-08 | 1979-06-09 | 1979-12-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-12-08 | 1983-06-09 | 1983-12-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-12-08 | 1987-06-09 | 1987-12-09 | $7700.00 | Window Closed / Lapsed |