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AssigneeEngelhard Corporation
InventorsJoseph C. Dettling, John J. Mooney, Robert M. Skomoroski, Saul G. Hindin
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A catalytic promoting material is supported on a monolithic support member, of the type generally referred to as a "honeycomb" support, having longitudinal fluid flow channels extending through it. The catalytically promoting material is dispersed as a coating on the walls of the fluid flow channels which are nominally polygonal, preferably nominally square, in cross section profile so that the walls forming the flow channels can be made as thin as possible consistent with an acceptable thermal and mechanical strength. However, the juncture of the channel walls forming the flow channels are filleted to provide a concave profile, preferably one having an arcuate shape in cross section, so that the corners are "filleted" or "rounded", to subtend an appreciable segment of the nominal width of the channel wall. This prevents or at least reduces the accumulation of excess catalytic material which occurs in the sharp angular corners of prior art structures.
In a carrier member adapted to have a catalytic promoting material deposited as a coating thereon and comprising a monolithic body having opposite end faces, a plurality of fluid flow channels extending through said body from one of said end faces to the other to provide fluid flow communication through said body, said channels being formed by channel walls dimensioned and configured to define along their length a nominally polygonal shaped cross section profile of said channels, the improvement comprising that the juncture of adjacent walls within said channels are formed by fillet portions of said walls, said fillet portions extending along the length of said channels and defining in cross section concave profiles of a depth sufficient to extend at least to the midpoint of a segment of a circle taken as disposed tangentially with respect to the two channel walls whose juncture is provided by said fillet and which segment subtends between about 1.5% to 40% of the nominal width of each of the two channel walls adjacent to said juncture.
In a carrier member adapted to have a catalytic promoting material disposed as a coating thereon and comprising a monolithic body having opposite end faces, a plurality of fluid flow channels extending through said body from one of said end faces to the other to provide fluid flow communication through said body, the improvement comprising that said channels are formed by channel walls dimensioned and configured so as to define along their length a central flat planar portion bounded on its opposite sides by fillet portions which form the juncture of adjacent walls within said channels, said fillet portions defining in cross section concave profiles large enough whereby when said body is coated with one or more of a refractory metal oxide precursor and a refractory metal oxide in particulate form deposited from a liquid medium containing the same flowed through said channels and said body is heated to expel said liquid medium and to form a coating of said refractory metal oxide on said channel walls, said metal oxide coating is deposited to a substantially uniform average depth on both said flat planar and said fillet portions of said walls.
A catalyst comprising a monolithic body having opposite end faces, a plurality of fluid flow channels extending through said body from one of said end faces to the other to provide fluid flow communication through said body, said channels being formed by channel walls dimensioned and configured to define along their length a nominally polygonal shaped cross section profile of said channels, the improvement comprising that the juncture of adjacent walls within said channels are formed by fillet portions of said walls, said fillet portions extending along the length of said channels and defining in cross section concave profiles of a depth sufficient to extend at least to the midpoint of a segment of a circle taken as disposed tangentially with respect to the two channel walls whose juncture is provided by said fillet, which segment subtends between about 1.5% to 40% of the nominal width of each of the two channel walls adjacent to said juncture, and a catalytically active component disposed as a coating on said channel walls.
A method of making a catalytic member comprising the steps of:
A method of making a catalytic member comprising the steps of:
A catalyst having a catalytic promoting material comprising a refractory metal oxide obtained as defined below disposed as a coating on a monolithic body, said monolithic body having opposite end faces and a plurality of fluid flow channels extending therethrough from one of said end faces to the other to provide fluid flow communication through said body, the improvement comprising that said channels are formed by channel walls dimensioned and configured so as to define along their length a central flat planar portion bounded on its opposite sides by fillet portions which form the juncture of adjacent walls within said channels, said fillet portions defining in cross section concave profiles and said metal oxide coating having a substantially uniform average depth on both said flat planar and said fillet portions of said walls.
Dependencies are inferred from the claim text.