Corning Incorporated

Corning Glass Works

Shy-Hsien Wu

Kenneth E Zaun

Yuming Xie

Margaret Kathleen Faber

Dell Joseph St Julien

John Forrest Wight, Jr

Donald L Guile

Evelyn M Deliso

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 plastically deformable aqueous mixture capable of being shaped into a body, the mixture being composed of any one or combination of ceramic, glass-ceramic, glass, molecular sieve, carbon, or metal powders, cellulose ether organic binder, water insoluble hydrophobic polymer co-binder having an average molecular weight of at least about 8,000, plasticizer, and water. A method of making a body which involves mixing the above components in a high shear mixer at a temperature of about 30.degree. C. to 70.degree. C. to form a homogeneous mixture, extruding the mixture at a temperature of about 30.degree. C. to 70.degree. C. into a green body, followed by drying and firing to produce the product body.

Plastic formable mixtures and method of use therefor

A method of making a homogeneous formable mixture involves simultaneously mixing organic binder which can be cellulose ethers, cellulose ether derivatives, and combinations of these, powder material capable of being formed into a body when combined with the organic binder, water-insoluble wax, and vehicle of which at least about 90 wt % is water, at a temperature which is at least as high the temperature at which the wax begins to deform under shear. A method of making a shaped body involves shaping the above-described mixture into a green body, followed by drying and heating the green body at a temperature and for a time sufficient to form the product body. Preferably the mixture is extruded at a temperature between room temperature and the melting point of the wax, into a honeycomb. The honeycomb has no voids and a smooth skin. A formable mixture made up of organic binder, powder, and wax as described above, wherein the wax which makes up at least 3 wt. % as a superaddition based on the inorganic solid components in the mixture.

Rapid setting compositions and method of making and using same

An activated carbon body and method for making the body which involves forming a wet mixture of in percent by weight based on activated carbon, about 2% to 10% organic binder which can be cellulose ethers, and/or their derivatives, 0 to about 4% of polyvinyl alcohol, about 5% to 40% bentonite clay, about 10% to 50% silicone resin, vehicle having a boiling point of at least about 100.degree. C., and the balance of the mixture being activated carbon particles. The mixture is formed into a green body which is then dried and heat-treated.

Method for producing activated carbon bodies having silicone resin binder

A method for making a dried crack-free body involves forming a wet mixture of powder which can be ceramic, glass-ceramic, glass, molecular sieve, activated carbon, and combinations thereof, plasticizing organic binder which can be cellulose ethers, and/or their derivatives, and vehicle of water and at least one of the additional components of oleic acid, linoleic acid, linotenic acid, ricinoleic acid, or their derivatives, the vehicle content being at least about 35% by weight based on the powder content. The mixture is formed into a green body and dried. If the powder is conducting, the drying is done by a controlled humidity drying procedure which involves i) heating the green body at a temperature of about 35.degree. C. to 90.degree. C. at a relative humidity of about 90% to 95% for a time of about 1 to 7 hours, and thereafter ii) heating the green body at a temperature at about 88.degree. C. to 95.degree. C. at a relative humidity at about 90% to 95% for about 1 to 7 hours. If the powder is non-conducting the drying is done by either microwave or dielectric drying.

Drying process to produce crack-free bodies

The invention relates to the use of aqueous emulsions of silicone resins in forming cellular zeolite substrates which can be dried rapidly without incurring blistering while still exhibiting good strength and zeolite activity.

Molecular sieve structures using aqueous emulsions

A carbon body and method for making the body. The body is characterized by carbon particles bonded together with bentonite clay and a cured epoxy resin. The bentonite content is about 5% to about 30% by weight based on carbon. The epoxy resin and curing agent content as measured before curing is about 5% to about 40% by weight based on carbon. The curing agent as measured before curing makes up about 5 parts to about 40 parts per 100 weight parts based on the epoxy resin. The resin has an average functionality of at least 3. The body has higher strength after exposure to temperatures of up to about 250.degree. C. in air than bodies absent the bentonite and resin. Additionally, the body has the properties of surface area retention after exposure to high temperatures, and water resistance. The method for making the body involves forming an aqueous mixture comprising of in percent by weight based on carbon, about 4% to about 10% thermally gellable organic binder which can be cellulose ether(s), derivatives of cellulose ethers, and combinations of these, 0 to about 7% of co-binder, the bentonite, resin, and curing agent. The mixture is formed into a green body which is then dried, subjected to a first heat-treatment or curing, and then to a second heat treatment to restore surface area.

Activated carbon bodies having epoxy resin and bentonite binders

A plastically deformable mixture and method for making a body from the mixture are disclosed. The mixture is composed of powder materials, which when fired form as predominant phases: ceramic, glass-ceramic, glass, and combinations thereof, 0 to an effective amount of burnout agent, water, organic binder which can be cellulose ether, cellulose ether derivatives or combinations thereof, and hydrophilic and hydrophobic additives, to increase the wettability and/or lubricity of the mixture. One advantageous composition for ram extrusion is composed of ceramic-forming powders, water, and in percent by weight based on the powders, about 2% to 8% organic binder which can be methylcellulose, methylcellulose derivatives, and combinations thereof, about 0.3% to 1.0% sodium stearate, and about 0.5% to 2.0% oleic acid. Another such advantageous composition is composed of ceramic-forming powders, about 25% to 35% by weight graphite based on the powder material, as a burnout agent, water, and in percent by weight based on the powders and the burnout agent, about 2% to 8% organic binder which can be methylcellulose, methylcellulose derivatives, and combinations thereof, about 0.5% to 2.5% sodium stearate and about 0.3% to 1.0% oleic acid. The method of forming the body involves shaping the mixture into a green body, drying the green body, and heating to form the product body.

Formable ceramic compositions and method of use therefor

A plastically deformable metallic mixture is provided using finely divided metallic particulate matter, organic binding agent, polar liquid, anionic dispersing agent and nonionic surfactant. The invention is also directed at a mixture further comprising water-miscible organic solvent. The mixture of this invention is generally stable, froth-free, homogeneous and uniformly dispersed. A process is described by which the mixtures can be formed into useful articles and structures having superior skin qualities.

Plastically deformable metallic mixtures and their use

A method of producing crack-free green activated carbon structures using a carbon matrix containing high gel strength binders such as methyl cellulose binders is disclosed. The invention also relates to a method of drying activated carbon structures by first contacting the structure with microwave radiation and then drying the structure in a conventional oven.

Method of producing crack-free activated carbon structures

The invention relates to a method for rapidly setting or stiffening a soft, freshly formed body such as fragile and complex thin-walled cellular substrate to prevent damage and distortions and to preserve the integrity of the substrate during the pre-firing stages of the manufacturing process. A method is disclosed for rapidly setting such objects by impregnating the object with a rapid-setting compound for a time and at a temperature sufficient to irreversibly stiffen the object, and thereafter removing any excess compound from the object. Useful rapid-setting compounds having a high affinity for water, and having appropriate molecular blocking configuration are disclosed.

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Horseheads, NY, United States of America

Shy-Hsien Wu