US4698317A
Expired / Lapsed
US
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Porous cordierite ceramics, a process for producing same and use of the porous cordierite ceramics
Assignee: Kanto Chemical Co Inc
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Filing: 1985-04-23
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Granted: 1987-10-06
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Expires: 2005-04-23
Abstract
Abstract New type porous cordierite ceramics having a new characteristic interconnecting open cellular structure and a hollow microspherical cordierite glass powder with a shell devoid of any pores or provided with a few or an abundance of open pores which is used as a starting material for the porous cordierite ceramics. The porous cordierite ceramics are produced by subjecting a starting solution containing an alkyl silicate, an aluminum salt and an magnesium salt optionally with other compounds in an organic or aqueous organic solvent to spray thermal decomposition to prepare the hollow microspherical cordierite glass powder, and then processing the cordierite glass powder to a shaped body after or before an optional heat treatment and firing the shaped body at a temperature below the melting point of cordierite. The porous cordierite ceramics are useful as a carrier for gas chromatography or various chemical reactions.
Inventors
- 👤 Senya Inoue
- 👤 Akira Ono
- 👤 Mikio Kobayashi
- 👤 Hiroshi Yokoo
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 09:37
CPC Classifications
B; B01; B01J; B01J21/00; B01J21/14; B01J20/00; B01J20/02; B01J20/10; B01J20/16; B01J20/281; B01J20/282; C; C01; C01B; C01B33/00; C01B33/20; C01B33/26; C03; C03B; C03B19/00; C03B19/10; C03B19/107; C03B19/108; C03C; C03C10/00; C03C10/0036; C03C10/0045; C03C11/00; C03C11/002; C04; C04B; C04B35/00; C04B35/01; C04B35/16; C04B35/18; C04B35/195; C04B38/00; C04B38/009; C04B38/08; G; G01; G01N; G01N30/00; G01N30/02; G01N30/50; G01N30/52; G01N2030/524; G01N2030/528
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
109 words
A hollow spherical cordierite glass powder with a shell devoid of any pores or provided with a few or an abundance of open pores, which has been formed by the process which comprises providing a starting solution containing in an organic or aqueous organic solvent an alkyl silicate and aluminum and magnesium salts soluble in the organic solvent in a proportion of 44-65% by weight, 25-43% by weight and 10-16% by weight in terms of SiO 2 , Al 2 O 3 and MgO, respectively, and subjecting said starting solution to spray thermal decomposition in the presence of an oxidizing gas to produce said hollow spherical cordierite glass powder.
Claim 2
Dependent Claim
109 words
A hollow spherical cordierite glass powder with a shell devoid of any pores or provided with a few or an abundance of open pores, which has been formed by the process which comprises providing a starting solution containing in an organic or aqueous organic solvent an alkyl silicate and aluminum and magnesium salts soluble in the organic solvent in a proportion of 44-65% by weight, 25-43% by weight and 10-16% by weight in terms of SiO 2 , Al 2 O 3 and MgO, respectively, and subjecting said starting solution to spray thermal decomposition in the presence of an oxidizing gas to produce said hollow spherical cordierite glass powder.
Claim 3
Dependent Claim
40 words
A hollow spherical cordierite glass powder according to claim 1, wherein said organic solvent is selected from a lower alkanol with 1-5 carbon atoms, a dihydric or trihydric lower alcohol, a (lower alkoxy) lower alkanol and a lower dialkyl ketone.
Claim 4
Dependent Claim
31 words
A hollow spherical cordierite glass powder according to claim 1, wherein said alkyl silicate is selected from tetraalkyl silicates in which the alkyl moiety is lower alkyl with 1-5 carbon atoms.
Claim 5
Dependent Claim
54 words
A hollow spherical cordierite glass powder according to claim 1, wherein said organic or aqueous organic solvent contains one or more metal compounds capable of affording Na 2 O, K 2 O, TiO 2 or ZrO 2 and soluble in the organic or aqueous organic solvent in an amount up to 5% by weight.
Claim 6
Dependent Claim
42 words
A hollow spherical cordierite glass powder according to claim 1, wherein said spray thermal decomposition is carried out by spraying the starting solution together with an oxidizing gas from a nozzle into a heated reaction zone or the flame of a burner.
Claim 7
Dependent Claim
33 words
A hollow spherical cordierite glass powder prepared according to the process of claim 1, further including the step of heat treating said hollow spherical cordierite glass powder following said said spray thermal decomposition.
Claim 8
Dependent Claim
22 words
The hollow spherical cordierite glass powder of claim 6, wherein said heat treatment is carried out at a temperature below 950° C.
Claim 9
Dependent Claim
113 words
A process for preparing a porous cordierite ceramic having an interconnecting open cellular structure which comprises: (a) providing a starting solution containing in an organic or aqueous organic solvent an alkyl silicate and aluminum and magnesium salts soluble in said organic solvent in a proportion of 44-65% by weight, 25-43% by weight and 10-16% by weight in terms of SiO 2 , Al 2 O 3 and MgO, respectively, (b) subjecting said starting solution to spray thermal decomposition in the presence of an oxidizing gas to form a hollow microspherical cordierite glass powder, (c) processing said glass powder to a shaped body after an optional heat treatment, and (d) firing said shaped body.
Claim 10
Dependent Claim
113 words
A process for preparing a porous cordierite ceramic having an interconnecting open cellular structure which comprises: (a) providing a starting solution containing in an organic or aqueous organic solvent an alkyl silicate and aluminum and magnesium salts soluble in said organic solvent in a proportion of 44-65% by weight, 25-43% by weight and 10-16% by weight in terms of SiO 2 , Al 2 O 3 and MgO, respectively, (b) subjecting said starting solution to spray thermal decomposition in the presence of an oxidizing gas to form a hollow microspherical cordierite glass powder, (c) processing said glass powder to a shaped body after an optional heat treatment, and (d) firing said shaped body.
Claim 11
Dependent Claim
28 words
The process of claim 8, wherein said firing of the shaped body is effected at a temperature above the crystallization temperature but below the melting point of cordierite.
Claim 12
Dependent Claim
37 words
The process of claim 8, wherein said spray thermal decomposition is carried out by spraying the starting solution together with an oxidizing gas from a nozzle into a heated reaction zone or the flame of a burner.
Claim 13
Dependent Claim
38 words
The process of claim 8, wherein said processing of the glass powder to a shaped body is effected by molding, extruding, calendering, a curing-in-liquid method, a liquid drying method, a spray drying method or a freeze drying method.
Claim 14
Dependent Claim
18 words
The process of claim 8, wherein said heat treatment is carried out at a temperature below 950° C.
Claim 15
Dependent Claim
108 words
A process for preparing a hollow spherical cordierite glass powder with a shell devoid of any pores or provided with a few or an abundance of open pores, which comprises: (a) providing a starting solution containing in an organic or aqueous organic solvent an alkyl silicate and aluminum and magnesium salts soluble in the organic solvent in a proportion of 44-65% by weight, 25-43% by weight and 10-16% by weight in terms of SiO 2 , Al 2 O 3 and MgO, respectively; and (b) subjecting said starting solution to spray thermal decomposition in the presence of an oxidizing gas to produce said hollow spherical cordierite glass powder.
Claim 16
Dependent Claim
108 words
A process for preparing a hollow spherical cordierite glass powder with a shell devoid of any pores or provided with a few or an abundance of open pores, which comprises: (a) providing a starting solution containing in an organic or aqueous organic solvent an alkyl silicate and aluminum and magnesium salts soluble in the organic solvent in a proportion of 44-65% by weight, 25-43% by weight and 10-16% by weight in terms of SiO 2 , Al 2 O 3 and MgO, respectively; and (b) subjecting said starting solution to spray thermal decomposition in the presence of an oxidizing gas to produce said hollow spherical cordierite glass powder.
Claim 17
Dependent Claim
37 words
The process of claim 13, wherein said spray thermal decomposition is carried out by spraying the starting solution together with an oxidizing gas from a nozzle into a heated reaction zone or the flame of a burner.
Claim 18
Dependent Claim
23 words
The process of claim 13, further including the step of heat treating said hollow spherical cordierite glass powder following said spray thermal decomposition.
Claim 19
Dependent Claim
18 words
The process of claim 15, wherein said heat treatment is carried out at a temperature below 950° C.
Claim 20
Dependent Claim
49 words
The process of claim 8, wherein said organic or aqueous organic solvent contains one or more metal compounds capable of affording Na 2 O, K 2 O, TiO 2 or ZrO 2 and soluble in the organic or aqueous organic solvent in an amount up to 5% by weight.
Claim 21
Dependent Claim
49 words
The process of claim 13, wherein said organic or aqueous organic solvent contains one or more metal compounds capable of affording Na 2 O, K 2 O, TiO 2 or ZrO 2 and soluble in the organic or aqueous organic solvent in an amount up to 5% by weight.
Claim 22
Dependent Claim
19 words
A carrier for gas chromatography or for catalytic or biochemical reactions prepared according to the process of claim 17.
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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) | 1990-10-05 | 1991-04-06 | 1991-10-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-10-05 | 1995-04-06 | 1995-10-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-10-05 | 1999-04-06 | 1999-10-06 | $7700.00 | Window Closed / Lapsed |