US 12,246,307 B2
Ceramic article and methods of making the same
Matthew J. Thompson, Stow, OH (US); Thomas Szymanski, Hudson, OH (US); Randall Clayton Yeates, Sugar Land, TX (US); and James M. Ralph, Copley, OH (US)
Assigned to SAINT-GOBAIN CERAMICS & PLASTICS, INC., Worcester, MA (US)
Filed by SAINT-GOBAIN CERAMICS & PLASTICS, INC., Worcester, MA (US)
Filed on Oct. 12, 2023, as Appl. No. 18/486,105.
Application 18/486,105 is a division of application No. 17/645,006, filed on Dec. 17, 2021, granted, now 11,826,725.
Claims priority of provisional application 63/199,441, filed on Dec. 29, 2020.
Prior Publication US 2024/0042419 A1, Feb. 8, 2024
Int. Cl. B01J 21/04 (2006.01); B01J 23/22 (2006.01); B01J 23/38 (2006.01); B01J 23/40 (2006.01); B01J 23/42 (2006.01); B01J 23/44 (2006.01); B01J 23/46 (2006.01); B01J 23/48 (2006.01); B01J 23/50 (2006.01); B01J 23/52 (2006.01); B01J 23/72 (2006.01); B01J 23/745 (2006.01); B01J 23/75 (2006.01); B01J 23/755 (2006.01); B01J 35/61 (2024.01); B01J 35/63 (2024.01); B01J 37/02 (2006.01); B01J 37/04 (2006.01); B01J 37/08 (2006.01)
CPC B01J 21/04 (2013.01) [B01J 23/42 (2013.01); B01J 23/44 (2013.01); B01J 23/50 (2013.01); B01J 23/72 (2013.01); B01J 23/755 (2013.01); B01J 35/633 (2024.01); B01J 35/635 (2024.01); B01J 37/0215 (2013.01); B01J 37/04 (2013.01); B01J 37/08 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A process for the manufacture of a ceramic article comprising a rigid formation of alumina particles and a catalytically active metal in contact with said particles, said process comprising:
(a) providing a plurality of first alpha alumina particles having a known weight and a d50 particle size between about 0.2 and 100 microns;
(b) providing a plurality of second alpha alumina particles having a known weight and selected from the group consisting essentially of fused alumina and tabular alumina, said second alumina particles having a d50 particle size between about 5 and 400 microns, wherein the ratio of the first alpha alumina particle's d50 particle size to the second alpha alumina particle's d50 particle size is between 1:4 and 1:40, and wherein the ratio of said first alpha alumina's weight to said second alpha alumina's weight is between 1:1 and 15:1;
(c) mixing said pluralities of alpha alumina particles thereby forming a mixture, wherein said particles are randomly distributed throughout the mixture;
(d) forming said mixture into a plurality of malleable articles;
(e) heating said malleable articles to the sintering temperature of said alpha alumina particles thereby forming each malleable article into a rigid formation of alpha alumina particles, wherein the particles in each plurality of particles are randomly distributed throughout the rigid formation; and
(f) depositing a catalytically active metal on said first and second alpha alumina particles.