Substrate and a method of manufacturing a substrate

Patent metadata

Field	Value
Publication number	US-11396010-B2
Application number	US-202016804350-A
Country	US
Kind code	B2
Filing date	Apr 27, 2020
Priority date	Sep 5, 2013
Publication date	Jul 26, 2022
Grant date	Jul 26, 2022

Abstract

A catalytic convertor comprising a substrate body (100) arranged within the catalytic convertor such that a principal flow of fluid through the catalytic convertor flows along a surface (101) of the substrate body, wherein said surface (101) has a plurality of openings (210) to micro-channels that extend away from said surface (101); and at least a portion of the surface (101) of the substrate body (100) comprises a catalytically active material, wherein the substrate body (100) is in the form of: a pellet; a sheet; solid elongate bodies; solid rods; a solid body having a plurality of bores; a non-tubular elongate body; a non-hollow body; a sheet curved in the form or a spiral; or a combination thereof.

First claim

The invention claimed is:

1. A method of manufacturing a substrate having a plurality of micro-channels formed therein, the method comprising:
providing a suspension containing a substrate material in particulate form and a polymer in a first solvent;
introducing the suspension into a mould or extruding the suspension;
contacting the suspension with a second solvent to remove at least some of the first solvent from the suspension and thereby form a green body having micro-channels from said substrate material and said polymer; and
removing at least a portion of a surface layer of said green body to uncover a plurality of micro-channel openings in the outer surface of the green body, the openings having diameters falling in the range 5 μm to 200 μm; and
sintering the green body at a temperature from 1200 to 1600° C.

2. The method of claim 1 , wherein the step of removing at least a portion of a surface layer of material is carried out using a blade.

3. The method of claim 1 , wherein the step of removing at least a portion of a surface layer of material is carried out using an abrasive.

4. The method of claim 1 , wherein the step of removing at least a portion of a surface layer of material is carried out by sanding.

5. The method of claim 1 , wherein the mould is shaped such that the green body forms a sheet material.

6. The method of claim 1 , wherein the mould is shaped to form a sheet of material having at least one protrusion extending from a major surface thereof.

7. The method of claim 1 , wherein the suspension comprises a catalytically active material.

8. The method of claim 1 , further comprising coating at least a portion of the substrate with a catalytically active coating.

9. The method of claim 1 , wherein the substrate material includes at least one member selected from the group consisting of: a ceramic, cordierite, zirconia, yttrium-stabilized zirconia, titania, silicon carbide, clay, alumina, stainless steel, FeCr alloys, alloys of iron, alloys of aluminum, aluminum titanate, or sintered metals.

10. The method of claim 1 , wherein selecting the polymer from the group consisting of polyether sulfone, polysulphone, cellulose and derivatives thereof, polyethermide, polyimide and derivatives thereof.

11. A method of manufacturing a substrate having a plurality of micro-channels formed therein, the method comprising:
providing a suspension containing a substrate material in particulate form and a polymer in a first solvent;
introducing the suspension into a mould or extruding the suspension;
contacting the suspension with a second solvent to remove at least some of the first solvent from the suspension and thereby form a green body having micro-channels from said substrate material and said polymer;
sintering the green body at a temperature from 1200 to 1600° C. to form a sintered body; and
removing at least a portion of a surface layer of said sintered body to uncover a plurality of micro-channel openings in the outer surface of the sintered body, the openings having diameters falling in the range 5 μm to 200 μm.

12. The method of claim 11 , further comprising removing at least a portion of a surface layer of said green body.

13. The method of claim 11 , wherein the step of removing at least a portion of a surface layer of material is carried out using an abrasive.

14. The method of claim 11 , wherein the step of removing at least a portion of a surface layer of material is carried out by sanding.

15. The method of claim 11 , wherein the step of removing at least a portion of a surface layer of material is carried out by contacting the surface of the sintered body with acidic solution or alkaline solution.

16. The method of claim 11 , wherein the mould is shaped such that the green body forms a sheet material.

17. The method of claim 11 , wherein the mould is shaped to form a sheet of material having at least one protrusion extending from a major surface thereof.

18. The method of claim 11 , wherein the suspension comprises a catalytically active material.

19. The method of claim 11 , further comprising coating at least a portion of the substrate with a catalytically active coating.

20. The method of claim 11 , wherein the substrate material includes at least one member selected from the group consisting of: a ceramic, cordierite, zirconia, yttrium-stabilized zirconia, titania, silicon carbide, clay, alumina, stainless steel, FeCr alloys, alloys of iron, alloys of aluminum, aluminum titanate, or sintered metals.

21. The method of claim 11 , wherein selecting the polymer from the group consisting of polyether sulfone, polysulphone, cellulose and derivatives thereof, polyethermide, polyimide and derivatives thereof.

22. The method of claim 19 , wherein the substrate material includes at least one member selected from the group consisting of: a ceramic, cordierite, zirconia, yttrium-stabilized zirconia, titania, silicon carbide, clay, alumina, stainless steel, FeCr alloys, alloys of iron, alloys of aluminum, aluminum titanate, or sintered metals.

23. The method of claim 19 , wherein selecting the polymer from the group consisting of polyether sulfone, polysulphone, cellulose and derivatives thereof, polyethermide, polyimide and derivatives thereof.

24. A method of manufacturing a catalytic convertor substrate having a plurality of micro-channels formed therein, the method comprising:
providing a suspension containing a substrate material in particulate form and a polymer in a first solvent;
introducing the suspension into a mould or extruding the suspension;
contacting the suspension with a second solvent to remove at least some of the first solvent from the suspension and thereby form a green body having micro-channels from said substrate material and said polymer;
removing at least a portion of a surface layer of said green body to uncover a plurality of micro-channel openings in the outer surface of the green body, the openings having diameters falling in the range 5 μm to 200 μm; and
sintering the green body at a temperature from 1200 to 1600° C.

25. The method of claim 24 , wherein the substrate material includes at least one member selected from the group consisting of: a ceramic, cordierite, zirconia, yttrium-stabilized zirconia, titania, silicon carbide, clay, alumina, stainless steel, FeCr alloys, alloys of iron, alloys of aluminum, aluminum titanate, or sintered metals.

26. The method of claim 24 , wherein selecting the polymer from the group consisting of polyether sulfone, polysulphone, cellulose and derivatives thereof, polyethermide, polyimide and derivatives thereof.

27. A method of manufacturing a catalytic convertor substrate having a plurality of micro-channels formed therein, the method comprising:
providing a suspension containing a substrate material in particulate form and a polymer in a first solvent;
introducing the suspension into a mould or extruding the suspension;
contacting the suspension with a second solvent to remove at least some of the first solvent from the suspension and thereby form a green body having micro-channels from said substrate material and said polymer;
sintering the green body at a temperature from 1200 to 1600° C. to form a sintered body; and
removing at least a portion of a surface layer of said sintered body to uncover a plurality of micro-channel openings in the outer surface of the sintered body, th

Assignees

• Ip2Ipo Innovations Ltd

Inventors

• Kingsbury Benjamin Francis Knatchbull
• Li Kang
• Wu Zhentao

Classifications

• B01J37/0215 Primary

  Coating · CPC title

• B01J35/40

  characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77) · CPC title

• B01J35/56 Primary

  Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths · CPC title

• C04B38/04

  by dissolving-out added substances · CPC title

• B01J37/08

  Heat treatment {(B01J37/0009, B01J37/0018 take precedence)} · CPC title