Permeable composite material, method for producing said composite material, and use of the same

• US 6,841,075 B2
• Filed: 08/30/2001
• Issued: 01/11/2005
• Est. Priority Date: 09/20/1997
• Status: Expired due to Term

• Current Assignee: Evonik Degussa GmbH
• Original Assignee: Creavis Gesellschaft Fuer Technologie Und Innovation Mbh
• Inventors: Hoerpel, Gerhard, Hying, Christian, Schmidt, Friedrich Georg, Penth, Bernd
• Primary Examiner(s): Fortuna, Ana M.
• Application Number:
  US09/941,587
• Publication Number:
  US 20020023874A1
• Time in Patent Office: 1,230 Days
• Field of Search: 210/490, 210/500.25, 210/500.26, 210/650, 264/54.1, 555/23, 555/24, 552/823, 85/45, 96/4, 204/157.3, 95/45, 952/78, 952/83
• US Class Current: 210/650
• CPC Class Codes: B01D 2265/06 Details of supporting structures for filtering material, e.g. cores
• CPC Class Codes: B01D 2323/08 Specific temperatures applied
• CPC Class Codes: B01D 2323/081 Heating
• CPC Class Codes: B01D 2325/02 Details relating to pores or porosity of the membranes
• CPC Class Codes: B01D 2325/0283 Pore size
• CPC Class Codes: B01D 46/0056 with rotational movement
• CPC Class Codes: B01D 46/24 Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
• CPC Class Codes: B01D 46/4263 Means for active heating or cooling
• CPC Class Codes: B01D 46/48 Removing dust other than cleaning filters , e.g. by using collecting trays
• CPC Class Codes: B01D 46/521 using folded, pleated material
• CPC Class Codes: B01D 46/71 with pressurised gas, e.g. pulsed air
• CPC Class Codes: B01D 53/228 characterised by specific membranes
• CPC Class Codes: B01D 53/32 by electrical effects other than those provided for in group B01D61/00
• CPC Class Codes: B01D 53/8675 Ozone
• CPC Class Codes: B01D 53/885 Devices in general for catalytic purification of waste gases
• CPC Class Codes: B01D 67/0041 by agglomeration of particles in the dry state
• CPC Class Codes: B01D 67/0048 by sol-gel transition
• CPC Class Codes: B01D 67/0069 by deposition from the liquid phase, e.g. electrochemical deposition B01D67/0046 takes precedence
• CPC Class Codes: B01D 67/0072 by deposition from the gaseous phase, e.g. sputtering, CVD, PVD
• CPC Class Codes: B01D 67/0093 Chemical modification
• CPC Class Codes: B01D 69/141 : Heterogeneous membranes, e.g. containing dispersed material; Mixed matrix membranes
• CPC Class Codes: B01D 71/02 : Inorganic material
• CPC Class Codes: B01D 71/024 : Oxides
• CPC Class Codes: B01D 71/028 : Molecular sieves carbon B01D71/021
• CPC Class Codes: B01D 71/0281 : Zeolites
• CPC Class Codes: B01J 35/58 : Fabrics or filaments
• CPC Class Codes: B01J 37/0215 : Coating
• CPC Class Codes: B01J 37/0225 : of metal substrates
• CPC Class Codes: B01J 37/033 : Using Hydrolysis
• CPC Class Codes: Y10S 55/10 : Residue burned
• CPC Class Codes: Y10T 428/249957 : Inorganic impregnant

Abstract

A claim is laid to a permeable composite, a process of production of the composite as well as the use of this composite. The composite essentially contains a perforated and permeable carrier, on and in or on or in which another component that essentially contains metallic compounds with elements from group III to VI of the periodic system is stabilized. Stabilization of the component on or in the carrier is carried out by heating a suspension consisting of the component suspended in a metallic oxide sol that has been applied onto or into or onto and into the carrier.

In this way, it is possible to produce a permeable composite that is ideally suited for use in filtration and membrane technologies under very mild conditions either by heating for a short time or warming for a longer time.

Claims

1. Permeable flexible composite based on at least one peiforated and permeable carrier, which contains on at least one side of the carrier and inside the carrier at least one inorganic component, which comprises (A) and (B), which permeable flexible composite is obtained by application of a suspension to a perforated and permeable carrier and subsequently heating at least once during which said at least one inorganic component is solidified on and in the carrier, wherein the composite has a thickness from 5 to 1000 μ

m, and wherein the carrier has a mesh opening of 50 to 500 μ

m.

wherein the suspension comprises a sol of at least one oxide of an element selected from the group consisting of metals, metalloids, and composition metals, obtained by hydrolyzing a nitrate, halogenide, carbonate or alcoholate compound of said element, and a compound of at least one element from group III to VII of the periodic system, the suspension containing no organic binder,

wherein (A) is said at least one oxide of an element, and (B) is said compound; and

wherein (B) has a particle size greater than the particle size of (A).

2. Composite according to claim 1, wherein the composite is permeable for gases, solids or liquids.

3. Composite according to claim 1, wherein the composite is permeable for particles with a size of 0.5 nm to 10 μ

m.

4. Composite according to claim 1, wherein the carrier contains fibers from at least one of the following materials:

carbon, glass, metals, alloys, ceramic materials, minerals, plastics, amorphous substances, natural products, composites or at least one combination of these materials.

5. Composite according to claim 1, wherein the carrier contains at least woven fibers made from metal or alloys.

6. Composite according to claim 1, wherein the carrier contains at least one mesh made from steel.

7. Composite according to claim 1, wherein said inorganic component has a particle size of 0.001 to 25 μ

m.

8. Composite according to claim 7, wherein (B) contains at least one compound containing at least one of the elements Sc, Y, Ti, Zr, Nb, V, Cr, Mo, W, Mn, Fe, Co, B, Al, In, TI, Si, Ge, Sn, Pb, Sb and Bi, with at least one of the elements Te, Se, S, O, Sb, As, P, N, C, and Ga.

9. Composite according to claim 1, wherein the particle size ratio of (A) to (B) is less than 1:

1 and up to and including 1;

100.

10. Composite according to claim 1, wherein the quantitative proportion of particles of (A) to particles of (B) is between 0.01 to 1 and 1 to 0.01.

11. Composite according to claim 1, wherein the composite is flexible to a smallest radius of up to 2 nm.

12. Process of preparing a composite as claimed in claim 1, comprising applying said suspension comprising said sol of at least one oxide of an element selected from the group consisting metals, metalloids, and composition metals, obtained by hydrolyzing a nitrate, halogenide, carbonate or alcoholate compound of said element, and a compound of at least one element from group III to VII of the periodic system, the suspension containing no organic binder, to said perforated and permeable mesh carrier, and subsequently heating at least once during which said at least one inorganic component is solidified on and in the carrier.

13. Process according claim 12, wherein the suspension is applied onto or into or onto and into at least one carrier by stamping on, pressing on or in, rolling on, applying with a blade or brush, dipping, spraying, or pouring.

14. Process according to claim 12, wherein perforated and permeable carrier contains one of the following materials:

carbon metals, alloys, glass, ceramic materials, plastics, amorphous substances, natural products, composites or at least one combination of these materials.

15. Process according to claim 12, wherein the sols are obtained by hydrolyzing with one liquid, one gas or one solid.

16. Process according to claim 15, wherein water, water vapor, ice, alcohol or an acid or a combination of these compounds is used as the one liquid, the one gas or the one solid for the hydrolysis.

17. Process according to claim 15, wherein the compound to be hydrolyzed is placed in alcohol or in an acid or a combination thereof before hydrolysis.

18. Process according to claim 15, wherein the hydrolysis of the compounds to be hydrolyzed is carried out with at least half the molar ratio of water, in relation to the hydrolyzable group of the hydrolyzable compound.

19. Process according to claim 15, wherein the hydrolyzed compound is treated with at least one organic or inorganic acid.

20. Process according to claim 19, wherein the organic or inorganic acid has a concentration of 10 to 60%.

21. Process according to claim 12, wherein said (A) is at least one oxide of an element selected from the group consisting of Ti, Zr, Al, Si, Sn, Ce and Y.

22. Process according to claim 21, wherein said (A) is at least one oxide of an element selected from the group consisting of Zr, Si, Sn, Ce and Y.

23. Process according to claim 12, wherein (B) is at least one compound from the oxides of the elements of the transition element groups or the elements from group III to V of the periodic system.

24. Process according to claim 23, wherein the oxides are selected from oxides of the elements Sc, Y, Ti, Zr, V, Cr, Nb, Mo, W, Mn, Fe, Ce, Co, B, Al, In, TI, Si, Ge, Sn, Pb and Bi.

25. Process according to claim 12, wherein the percentage by mass of the suspended components is 0.1 to 500 times the amount of hydrolyzed compound used.

26. Process according to claim 12, wherein the suspension on or in or on and in the carrier is stabilized by heating the composite to between 500 and 1000°

C.

27. Process according to claim 26, wherein the composite is subjected to a temperature of between 50 and 10°

C. for 10 minutes to 5 hours.

28. Process according to claim 26, wherein the composite is subjected to a temperature of between 100 and 800°

C. for 1 second to 10 minutes.

29. A process for the separation of material mixtures comprising filtering material mixtures through the composite of claim 1 to separate components thereof.

30. A process for the separation of liquid mixtures, mixtures containing at least one liquid and at least one gas, mixtures containing at least one solid and at least one liquid, and mixtures containing at least one gas and at least one solid or at least one liquid or one gas comprising filtering said mixtures through the composite of claim 1 to separate components thereof.

31. A process for pressurized separation (process) comprising filtering a mixture of materials under pressure with the composite of claim 1 to separate components thereof.

32. A process for micro-filtration, ultra-filtration or nano-filtration comprising filtering micro-sized, ultra-sized or nano-sized particle containing mixtures through a membrane of the composite of claim 1 to separate the micro-sized, ultra-sized or nano-sized particles.

33. A process comprising carrying out a catalytic process with the composite of claim 1.

34. A formselective membrane comprising the composite of claim 1.

35. A wound module comprising the form-selective membrane of claim 34.

36. A flat module comprising the form-selective membrane of claim 34.

37. A diaphragm or battery separator comprising the composite of claim 1.

38. Composite according to claim 1, wherein said (A) is at least one oxide of an element selected from the group consisting of Zr, Si, Sn, Ce and Y.