Corning Incorporated

Kenneth E Zaun

Shy-Hsien Wu

Irwin M Lachman

Jimmie L Williams

Margaret Kathleen Faber

Mallanagouda D Patil

Yuming Xie

Evelyn M Deliso

Dell Joseph St Julien

William Peter Addiego

John Forrest Wight, Jr

Roger F Bartholomew

Julia A Sharps

Melcenia R Williams

Zeolite/alumina composite, and a method for making, the composite for use as a catalyst substrate or catalyst carrier and comprising zeolite having a silica/alumina ratio of greater than 300 and gamma alumina having a specific surface area of greater than 100 m /g. The zeolite/alumina composite exhibits a modulus of rupture of at least 750 psi. Additionally, the invention is also directed at a three catalyst (TWC) system for use in the removal of hydrocarbons, carbon monoxide and oxides of nitrogen from waste gas, the TWC system comprising the following components: (1) a zeolite/alumina composite catalyst support exhibiting a modulus of rupture of at least 750 psi and having a zeolite with a silica/zeolite ratio of at least 300 and the alumina comprising a gamma alumina having a specific surface area of greater than 100 m /g; and, (2) a noble metal catalyst impregnated on the catalyst support, the noble metal selected from the group consisting of platinum, rhodium, iridium and palladium.

Zeolite/alumina catalyst support compositions and method of making the same

Zeolite based material and a method for making the zeolite, comprising a zeolite having a silica/alumina ratio of at least 300 and a surface area of 250 m /g and no greater than about 20 parts, by weight, of a silica binder. The combination of properties this zeolite based material exhibits includes the following: (1) a modulus of rupture of at least 1500 psi; (2) a surface area of at least 100 m /g; (3) a coefficient of thermal expansion of less than about &plus;/&minus;10 ppm/&deg; C.; and, (4) a thermal shock resistance of at least 850&deg; C. The zeolite-based material can include a third component, specifically a gamma alumina having a specific surface area of greater than 100 m /g.

High strength and high surface area catalyst, catalyst support or adsorber compositions

A powder-formed cellular honeycomb body of novel tapered, curved and/or very high cell density configuration is provided through a reforming procedure wherein a precursor honeycomb shaped from a plasticized powder batch material is filled with a compatible plastic filler, reshaped at a temperature at which the plastic deformation characteristics of the honeycomb and filler are matched, and then solidified after removal of the filler to fix the final configuration of the body.

Manufacture of cellular honeycomb structures

A small pore hydrophilic molecular sieve body and method of making same involves forming a plasticized mixture of hydrophilic molecular sieve powder having a pore size of no greater than about 5.0 angstroms, temporary binder, silicone resin binder emulsion, and polar vehicle, shaping the mixture into a green monolithic body, and drying and heat-treating the green monolithic body to impart strength to the green body and form the product molecular sieve monolith. The body is made up of about 80% to 95% by weight molecular sieve with the balance being silica binder.

Method of making small pore hydrophilic molecular sieve bodies

A getter for immobilizing water and organic molecules which may be present as impurities in an enclosure for a high power laser. The getter is formulated from selected zeolite compositions having a pore or channel size suitable for immobilizing water and a size range of organic molecules up to about 40 microns. A binder is used to provide a getter having sufficient strength to allow use of the getter in a laser enclosure in a telecommunications application. The binder also provides a substantially dust free getter body to maintain the cleanliness of the interior of the laser enclosure. Getters which immobilize only organics or only water are contemplated.

Impurity getters in laser enclosures

A body made of activated carbon particles bonded together with a clay binder which can be attapulgite and/or sepiolite, and a plasticizing organic binder. The organic binder is more typically cellulose ether and/or cellulose ether derivative at a level of about 2 to 12 wt. % and the clay about 2% to about 30 wt % based on the carbon and clay. A method for making the body involves forming an aqueous mixture composed of the clay, organic binder and carbon, forming the mixture into a body, and drying the formed body.

Activated carbon bodies having clay binder and method of making same

Thin-walled honeycomb structures of activated carbon, useful for the adsorption of hydrocarbon vapors are prepared without the need for firing or sintering at elevated temperatures. The structures are prepared by forming a substantially homogeneous batch from an admixture of thermally gellable cellulose ether and/or derivative thereof such as methylcellulose, an additional organic binder such as a polyvinyl alcohol resin, and particles of activated carbon; plasticizing the batch with liquid, extruding the batch into a honeycomb shape; and drying the extruded shape at a temperature up to about 225.degree. C.

Activated carbon structures

A washcoated substrate and method for producing the washcoat on the substrate are disclosed which comprises forming a slurry comprising at least one ionizable compound of A, where A is selected from barium, strontium, and combinations thereof, and A is in an amount sufficient to yield AO in an amount of about 0.2-20% by weight of the washcoat, an aluminum oxide yielding species, and a medium wherein at least a portion of the ionizable compound ionizes to form ions of A, contacting the slurry with a substrate to form a green coating containing A and the aluminum oxide yielding species thereon, and heat treating the resulting green-coated substrate at a temperature and for a time sufficient to form a washcoat consisting essentially of AO-Al.sub.2 O.sub.3 on the substrate, wherein A is homogeneously distributed throughout the Al.sub.2 O.sub.3, the washcoat having a specific surface area, as measured by the N.sub.2 BET method, of at least about 50 m.sup.2 /g, which surface area remains after at least two repeated exposures of the washcoat to temperatures of greater than about 500.degree. C. Additionally, the slurry solid can be removed from the liquid, fired to form a material comprising AO-Al.sub.2 O.sub.3, and another slurry formed of the fired material and a medium. This slurry can then be contacted with a substrate to form the green coating which is then heat treated to form the washcoat.

High surface area washcoated substrate and method for producing same

A monolithic ceramic structure, useful as a support for catalytic material or as a fluid filter, has a high surface area phase which consists essentially of a porous metal oxide material, at least 50% by weight of which is alumina, titania, and/or zirconia, and phosphate dispersed substantially throughout the porous metal oxide material. The presence of the phosphate stabilizes the porous metal oxide material against thermal degradation during sintering or exposure to elevated temperatures encountered in catalytic service and thereby aids in the retention of higher overall surface area in the monolithic structure.

Phosphate-containing structures with catalytic material distributed

A monolithic ceramic structure, useful as a support for catalytic material or as a fluid filter, has a high surface area phase which consists essentially of a porous metal oxide material, at least 50% by weight of which is alumina, titania, and/or zirconia, and phosphate dispersed substantially througout the porous metal oxide material. The presence of the phosphate stabilizes the porous metal oxide material against thermal degradation during sintering or exposure to elevated temperatures encountered in catalytic service and thereby aids in the retention of higher overall surface area in the monolithic structure.

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Corning, NY, United States of America

Kenneth E Zaun