High capacity structures and monoliths via paste imprinting

• US 10,675,615 B2
• Filed: 04/29/2019
• Issued: 06/09/2020
• Est. Priority Date: 11/11/2014
• Status: Active Grant

• Current Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Original Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Inventors: Fowler, Tracy A., Smith, Thomas M., Cutler, Joshua I., Walp, Jenna L.
• Primary Examiner(s): Salamon, Peter A
• Application Number:
  US16/397,573
• Publication Number:
  US 20190255521A1
• Time in Patent Office: 407 Days
• Field of Search: None
• CPC Class Codes: B01J 29/06 Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 37/0244 Coatings comprising several layers
• CPC Class Codes: B32B 2255/06 on metal layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2311/00 Metals, their alloys or their compounds
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 37/0076 characterised in that the layers are not bonded on the totality of their surfaces
• CPC Class Codes: B32B 38/0012 Mechanical treatment, e.g. roughening, deforming, stretching
• CPC Class Codes: C04B 12/04 Alkali metal or ammonium silicate cements ; Alkyl silicate cements; Silica sol cements; Soluble silicate cements alkali metal silicates per se, their preparation C01B33/32; ammonium silicates per se, their preparation C01C1/00
• CPC Class Codes: C04B 14/047 Zeolites
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/00637 as glue or binder for uniting building or structural materials
• CPC Class Codes: C04B 2111/0081 as catalysts or catalyst carriers
• CPC Class Codes: C04B 24/383 Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/24 containing alkyl, ammonium or metal silicates; containing silica sols reaction mixtures resulting in mineral polymers C04B28/006; polymeric reaction products of alkali metal silicates with isocyanates C08G18/3895
• CPC Class Codes: C04B 38/008 Bodies obtained by assembling separate elements having such a configuration that the final product is porous or by spirally winding one or more corrugated sheets

Abstract

The disclosure relate generally to structures, forms, and monoliths, and methods of preparing the same. This disclosure can produce uniform structured passageways or channels of active material, including adsorbent or catalyst, by imprinting or molding features into a paste on a support that can be subsequently assembled into a gas or liquid treating structure, i.e. a monolith. The paste, which can include an active material, binder, and other potential additives, can be applied to the support or pushed through a support (as in a mesh) as a thin film. The paste can be imprinted, stamped, shaped or otherwise handled to give features of desired height, shape, width, and positioning. When stacked or rolled, the features of one layer contact a subsequent layer, which seal to form passageways. The resulting structure can have high cell-density (>1000 cells per square inch) and a large volume fraction of active material.

Claims

1. A method for preparing a structure, the method comprising;

coating, on a support having a first side and a second side, a paste to the first side;

creating features in the paste;

layering a first coated support with a second coated support by contacting the paste on the first side of the first coated support with a side of the second coated support to form enclosed passageways; and

calcining the layered supports to form the structure.

2. The method of claim 1, wherein the paste comprises an active material.

3. The method of claim 2, wherein the paste further comprises a binder.

4. The method of claim 1, wherein the side of the second coated support is a second side of the second coated support which coated with a thin layer of paste, and the enclosed passageways are formed by the contact of the paste with features of the first coated support to the thin layer of paste on the second side of the second coated support.

5. The method of claim 1, wherein the features are created by imprinting, stamping, molding, dragging, or 3-D printing.

6. The method of claim 1, wherein a paste layer is coated on the second side of the first coated support, and features are created in the paste on the second side of the first coated support.

7. The method of claim 1, wherein the layering step comprises layering the first coated support onto a separate coated support to form layers of coated supports.

8. The method of claim 1, wherein the layering step comprises a single coated support coiled in a spiral such that the first side of the support can contact the second side of the support to form the enclosed passageways within a spiral structure.

9. The method of claim 1, wherein the support comprises a metal substrate.

10. The method of claim 1, where the support comprises a sheet, foil or mesh.

11. The method of claim 2, wherein the active material comprises a zeolite.

12. The method of claim 2, wherein the active material comprises a catalyst or adsorbent.

13. The method of claim 12, wherein at least 10% of the active material is enclosed by the paste.

14. The method of claim 1, wherein the structure is a monolith.

15. The method of claim 14, wherein the cell density of the monolith is at least 900 cpsi.

16. The method of claim 1, wherein the features are channels, and the distance between channels is less than about 900 microns.

17. The method of claim 1, further comprising tortuous pathways through the paste for fluid communication of the adsorbent with the passageways.

18. The method of claim 17, wherein the paste has a mesoporosity of at least about 15%.

19. The method of claim 1, wherein the passageways are formed at the contact of the features in the paste on the first side of the first coated support with the side of the second coated support are formed solely by the features in the surface of the paste of the first coated support, or additionally by features in a surface of a paste that is located on the side of the second coated support.

20. The method of claim 3, wherein the passageways are formed at the contact of the features in the paste on the first side of the first coated support with the side of the second coated support are formed solely by the features in the surface of the paste of the first coated support, or additionally by features in a surface of a paste that is located on the side of the second coated support.