Method of making a honeycomb having channels containing a porous adsorbent

Patent metadata

Field	Value
Publication number	US-9610561-B2
Application number	US-201514809460-A
Country	US
Kind code	B2
Filing date	Jul 27, 2015
Priority date	Aug 11, 2014
Publication date	Apr 4, 2017
Grant date	Apr 4, 2017

Abstract

A method of making a filter article having a honeycomb substrate having adsorbent filled channels, including:
sealing the first end of a porous, cellular honeycomb substrate; filling the channels of the cellular honeycomb substrate with a dry adsorbent source material; sealing the second end of the filled honeycomb to form a sealed honeycomb; contacting the sealed honeycomb and water for a time sufficient to convert the dry precursor material in-situ to a paste; removing the seals from the first and second ends; and heating the contacted honeycomb to convert the paste to an adsorbent.

Also disclosed is a filter article having a honeycomb substrate having adsorbent filled channels and methods of using the article.

First claim

What is claimed is:

1. A method of making a honeycomb article having adsorbent filled channels, comprising:
sealing the first end of a porous, cellular honeycomb substrate;
filling the channels of the cellular honeycomb substrate with a dry adsorbent source material;
sealing the second end of the channel filled cellular honeycomb to form a sealed, filled, honeycomb;
contacting the sealed, filled, honeycomb and an aqueous liquid for a time sufficient to convert the adsorbent source material to a paste in the contacted honeycomb;
removing the seals from the first and second ends of the contacted honeycomb; and
heating the contacted honeycomb to convert the paste to an adsorbent.

2. The method of claim 1 wherein heating the contacted honeycomb is accomplished at from 25 to 1,000° C. for from 1 to 125 hrs.

3. The method of claim 1 wherein the porous, cellular honeycomb substrate comprises a ceramic, a polymer, or an activated carbon.

4. The method of claim 1 wherein the adsorbent is at least one of: nanoscale zero valent iron, a metal oxide, activated carbon, a polymer, a composite of a polymer and a metal oxide or inorganic absorbent, a composite of a polymer and carrier, or a combination thereof.

5. The method of claim 1 wherein sealing of the first end and the second end is accomplished with a tape, a film, a puck, an end cover, a press fit lid, or a combination thereof.

6. The method of claim 1 wherein the aqueous liquid is water.

7. The method of claim 1 wherein contacting the sealed filled honeycomb and an aqueous liquid for a time sufficient to convert the adsorbent source material to a paste is from 0.1 minute to 10 hrs.

8. The method of claim 1 wherein filling the channels of the cellular honeycomb substrate with an adsorbent source material is from 90 to 100 vol % of the total void volume of the honeycomb channels.

Assignees

• Corning Inc

Inventors

• Addiego William Peter
• Johnson Benedict Yorke
• Wang Lingyan

Classifications

• B01J20/26

  Synthetic macromolecular compounds · CPC title

• B01J20/08

  comprising aluminium oxide or hydroxide; comprising bauxite · CPC title

• B01J20/3291

  Characterised by the shape of the carrier, the coating or the obtained coated product · CPC title

• B01J20/3085

  Chemical treatments not covered by groups B01J20/3007 - B01J20/3078 · CPC title

• B01J20/18

  Synthetic zeolitic molecular sieves · CPC title