Method for producing porous bodies with enhanced properties

Patent metadata

Field	Value
Publication number	US-10124318-B2
Application number	US-201615171273-A
Country	US
Kind code	B2
Filing date	Jun 2, 2016
Priority date	Jun 2, 2015
Publication date	Nov 13, 2018
Grant date	Nov 13, 2018

Abstract

A precursor mixture for producing a porous body, wherein the precursor mixture comprises: (i) milled alpha alumina powder having a particle size of 0.1 to 6 microns, (ii) boehmite powder that functions as a binder of the alpha alumina powders, and (iii) burnout materials having a particle sizes of 1-10 microns. In some embodiments, an unmilled alpha alumina powder having a particle size of 10 to 100 microns is also included in said precursor mixture. Also described herein is a method for producing a porous body in which the above-described precursor mixture is formed to a given shape, and subjected to a heat treatment step in which the formed shape is sintered to produce the porous body.

First claim

What is claimed is:

1. A precursor mixture for producing a porous body, wherein the precursor mixture comprises: (i) at least one milled alpha alumina powder having a particle size of 0.1 to 6 microns, (ii) boehmite powder that functions as a binder of the alpha alumina powders, and (iii) at least one burnout material having a particle size of 1-10 microns.

2. The precursor mixture of claim 1 , further comprising unmilled alpha alumina powder having a particle size of 10 to 100 microns.

3. The precursor mixture of claim 2 , wherein the weight ratio of milled to unmilled alpha alumina powder is in a range of 0.25:1 to about 5:1.

4. The precursor mixture of claim 1 , wherein unmilled alpha alumina powder is excluded from the precursor mixture.

5. The precursor mixture of claim 1 , further comprising an additive selected from solvents and lubricants.

6. The precursor mixture of claim 1 , wherein said burnout material is selected from at least one of a polyolefin powder and graphite powder.

7. The precursor mixture of claim 1 , wherein said burnout material is selected from both a polyolefin powder and graphite powder.

8. The precursor mixture of claim 7 , wherein the weight ratio of polyolefin powder to graphite powder is in a range of 0.25:1 to about 5:1.

9. The precursor mixture of claim 1 , wherein the boehmite is present in an amount of at least 10% by weight of total alumina content.

10. The precursor mixture of claim 1 , wherein the boehmite is present in an amount of at least 25% by weight of total alumina content.

11. The precursor mixture of claim 1 , wherein the boehmite is nano-sized powder with dispersed particle size <100 nm.

12. The precursor mixture of claim 1 , wherein said milled alpha alumina powder has a particle/crystallite size of 0.25-4 microns.

13. The precursor mixture of claim 1 , wherein a silicon-containing substance is substantially excluded from the precursor mixture.

14. The precursor mixture of claim 1 , wherein a sodium-containing substance is substantially excluded from the precursor mixture.

Assignees

• Scient Design Co

Inventors

• Suchanek Wojciech L
• Julian Matthew

Classifications

• B01J23/50

  Silver · CPC title

• C04B35/10 Primary

  based on aluminium oxide · CPC title

• C04B2111/0081

  as catalysts or catalyst carriers · CPC title

• C04B38/08

  by adding porous substances · CPC title

• C04B38/00

  Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof (treating slag with gases or gas generating material C04B5/06 {; expanded graphite C04B35/536}) · CPC title