Porous bodies with enhanced pore architecture

Patent metadata

Field	Value
Publication number	US-10512894-B2
Application number	US-201715722696-A
Country	US
Kind code	B2
Filing date	Oct 2, 2017
Priority date	Jun 2, 2015
Publication date	Dec 24, 2019
Grant date	Dec 24, 2019

Abstract

A porous body is provided with enhanced fluid transport properties that is capable of performing or facilitating separations, or performing reactions and/or providing areas for such separations or reactions to take place. The porous body includes at least 80 percent alpha alumina and has a pore volume from 0.3 mL/g to 1.2 mL/g and a surface area from 0.3 m2/g to 3.0 m2/g. The porous body further includes a pore architecture that provides at least one of a tortuosity of 7.0 or less, a constriction of 4.0 or less and a permeability of 30 mdarcys or greater. The porous body can be used in a wide variety of applications such as, for example, as a filter, as a membrane or as a catalyst carrier.

First claim

What is claimed is:

1. A precursor mixture for producing a porous body, the precursor mixture comprising:
(i) at least one milled alpha alumina powder having a particle size of 0.1 microns to 6 microns,
(ii) a non-silicate binder, and
(iii) at least one principle burnout material having a particle size of 1 micron to 10 microns.

2. The precursor mixture of claim 1 , wherein the least one milled alpha alumina powder, the non-silicate binder, and the at least one principle burnout material are in a homogeneous mixture.

3. The precursor mixture of claim 1 , wherein the at least one principle burnout material is a granulated polyolefin.

4. The precursor mixture of claim 3 , wherein the granulated polyolefin is one of polyethylene and polypropylene.

5. The precursor mixture of claim 1 , further comprising unmilled alpha alumina powder.

6. The precursor mixture of claim 5 , wherein the unmilled alpha alumina powder has an average particle size from 10 microns to 100 microns.

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

8. The precursor mixture of claim 5 , further comprising an additional unmilled alpha alumina powder having a particle size greater than a particle size of the unmilled alpha alumina powder.

9. The precursor mixture of claim 8 , wherein a weight ratio of the milled alpha alumina powder to the additional unmilled alpha alumina powder is from about 0.2:1 to 5:1.

10. The precursor mixture of claim 1 , further comprising a solvent.

11. The precursor mixture of claim 1 , wherein the least one milled alpha alumina powder is dispersed in deionized water.

12. The precursor mixture of claim 1 , further comprising an auxiliary burnout material.

13. The precursor mixture of claim 12 , wherein the auxiliary burnout material is graphite.

14. The precursor mixture of claim 12 , wherein a weight ratio of the principle burnout material to the auxiliary burnout material is 1:1 to 5:4.

Assignees

• Scient Design Co

Inventors

• Suchanek Wojciech L

Classifications

• B01J23/50

  Silver · CPC title

• C04B41/5116

  Ag or Au · CPC title

• C04B38/08

  by adding porous substances · CPC title

• C04B38/0645

  Burnable, meltable, sublimable materials · CPC title

• C04B2111/0081

  as catalysts or catalyst carriers · CPC title