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Open mesh, random fiber, ceramic structure, monolithic catalyst support

  • US 4,083,905 A
  • Filed: 04/25/1975
  • Issued: 04/11/1978
  • Est. Priority Date: 04/25/1975
  • Status: Expired due to Term
First Claim
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1. A method for producing a cellular ceramic catalyst support which comprises the steps of coating an open-celled organic sponge with an adhesive to produce a tacky surface, flocking the tacky surface with a material selected from the group consisting of rayon and cotton fibers and wood flour, impregnating the flocked organic sponge with a slurry having a viscosity of from 300 to 3000 centipoises and consisting essentially of from 50 to 90 percent by weight alumina, from 1/2 to 4 percent by weight of a flux and from 10 to 45 percent by weight silicone resin which consists essentially of a phenyl lower alkyl silicone resin wherein the total of phenyl and lower alkyl groups divided by the number of silicone atoms is from 0.9 to 1.5 and each alkyl group has not more than 4 carbon atoms, and sintering the impregnated organic sponge at a temperature between 2450°

  • -3100°

    F. for a period of time sufficient to burn out the organic sponge material and to vitrify the slurry.

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