Catalytic structure for the purification of waste gases and its method of preparation
阅读：514发布：2021-08-31
专利汇可以提供Catalytic structure for the purification of waste gases and its method of preparation专利检索，专利查询，专利分析的服务。并且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.，下面是Catalytic structure for the purification of waste gases and its method of preparation专利的具体信息内容。
1. 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.
2. 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.
3. A method according to claim 2 in which the fine powder is an alloy consisting essentially of chromium and copper.
4. A method according to claim 2 in which the fine powder is an alloy consisting essentially of chromium, nickel and copper.
5. 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.
6. 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.
7. A method according to claim 2 in which the non-oxidizing atmosphere is an inert gas, hydrogen, or high vaccum.
8. 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.
9. A method according to claim 2 in which the substrate is a nickel-containing alloy.
10. A method according to claim 2 in which the substrate is a metallized ceramic.
11. 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.
12. 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.
13. 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.
14. A method according to claim 2 in which the fugitive binder is an organic elastomer or polyvinyl alcohol in a compatible vehicle.
15. 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.
16. 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.
17. A composite catalyst according to claim 15 in which the catalytic layer is comprised of an alloy consisting essentially of chromium, nickel and copper.
18. A composite catalyst according to claim 15 in which the open mesh substrate is a nickel-containing alloy.
19. A composite catalyst according to claim 15 in which the open mesh substrate is a metallized ceramic.
20. 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.
21. A method according to claim 2 in which the substrate is a ceramic.
22. A composite catalyst according to claim 15 in which the substrate is a ceramic.
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