Search

CN-122028976-A - High porosity macroporous monolithic substrate

CN122028976ACN 122028976 ACN122028976 ACN 122028976ACN-122028976-A

Abstract

A monolithic substrate includes a matrix of glass ceramic composite material defining a continuous interconnected pore structure. The porosity of the glass ceramic composite is at least 48 volume percent as determined by mercury intrusion porosimetry. At least 20% of the porosity is contributed by pores having a pore diameter between 0.1 μm and 1 μm, as determined by mercury intrusion porosimetry.

Inventors

  • D.M. BILL

Assignees

  • 康宁股份有限公司

Dates

Publication Date
20260512
Application Date
20241121
Priority Date
20231130

Claims (20)

  1. 1. A monolithic substrate comprising: a matrix of glass ceramic composite material, the matrix defining a continuous interconnected pore structure, Wherein the glass-ceramic composite has a porosity of at least 48 volume percent, as determined by mercury intrusion porosimetry, and Wherein at least 20% of the porosity is contributed by pores having a pore diameter between 0.1 μm and 1 μm, as determined by mercury intrusion porosimetry.
  2. 2. The monolithic substrate of claim 1 wherein up to 5% by volume of the porosity is contributed by pores having a pore diameter of less than 0.1 μιη, as determined by mercury intrusion porosimetry.
  3. 3. The monolithic substrate of any one of claims 1 to 2 wherein up to 3% by volume of the porosity is contributed by pores having a pore diameter of less than 0.1 μιη, as determined by mercury intrusion porosimetry.
  4. 4. A monolithic substrate according to any one of claims 1 to 3, wherein at most 1% by volume of the porosity is contributed by pores having a pore diameter of less than 0.1 μm, as determined by mercury intrusion porosimetry.
  5. 5. The monolithic substrate of any one of claims 1 to 4 wherein up to 5% by volume of the porosity is contributed by pores having a pore diameter of less than 0.05 μιη, as determined by mercury intrusion porosimetry.
  6. 6. The monolithic substrate of any one of claims 1 to 5 wherein the interconnected pore structure has a median pore diameter of between 0.1 μιη and 1 μιη as determined by mercury intrusion porosimetry.
  7. 7. The monolithic substrate of any one of claims 1 to 6 wherein the interconnected pore structure has a median pore diameter of less than 1 μιη as determined by mercury intrusion porosimetry.
  8. 8. The monolithic substrate of any one of claims 1 to 7 wherein the interconnected pore structure has a median pore diameter of less than 1 μιη as determined by mercury intrusion porosimetry.
  9. 9. The monolithic substrate of any one of claims 1 to 8 wherein the porosity is at least 50 volume percent as determined by mercury intrusion porosimetry.
  10. 10. The monolithic substrate of any one of claims 1 to 9 wherein the porosity is at least 50 volume percent as determined by mercury intrusion porosimetry.
  11. 11. The monolithic substrate of any one of claims 1 to 10 wherein the porosity is at least 55 volume percent as determined by mercury intrusion porosimetry.
  12. 12. The monolithic substrate of any one of claims 1 to 11 wherein the porosity is at least 48 to 75 volume percent as determined by mercury intrusion porosimetry.
  13. 13. The monolithic substrate of any one of claims 1 to 12 wherein the porosity is at least 50 to 75 volume percent as determined by mercury intrusion porosimetry.
  14. 14. The monolithic substrate of any one of claims 1 to 13 wherein the interconnected pore structure has a multimodal pore size distribution.
  15. 15. The monolithic substrate of claim 14 wherein the multimodal pore size distribution is comprised of a first differential intrusion peak at a first pore diameter between 0.1 μιη and 1 μιη and a second differential intrusion peak at a second pore diameter between 1.5 μιη and 30 μιη.
  16. 16. The monolithic substrate of claim 15 wherein the second differential intrusion peak is at a pore diameter of at least 5 μιη.
  17. 17. The monolithic substrate of any one of claims 1 to 16 wherein at least 50% of the porosity is contributed by pores having a pore diameter between 0.1 μιη and 1 μιη, as determined by mercury intrusion porosimetry.
  18. 18. The monolithic substrate of any one of claims 1 to 17 wherein at least 80% of the porosity is contributed by pores having a pore diameter between 0.1 μιη and 1 μιη, as determined by mercury intrusion porosimetry.
  19. 19. The monolithic substrate of any one of claims 1 to 18 wherein the interconnected pore structure has a unimodal pore size distribution having a single differential intrusion peak.
  20. 20. The monolithic substrate of any one of claims 1-19 wherein the glass-ceramic composite comprises at least 50 wt% amorphous silica.

Description

High porosity macroporous monolithic substrate Cross Reference to Related Applications The present application claims priority from U.S. c. ≡119 to U.S. provisional application serial No. 63/604,603 filed on day 2023, 11 and 30, the contents of which are hereby incorporated by reference in their entirety. Background A method of removing CO 2 from a gas, either from a point source or from ambient air, includes flowing a stream laden with CO 2 through a monolith containing an adsorbent that adsorbs CO 2. The CO 2 may later be desorbed to effect removal (e.g., via heating the monolith). Similarly, exhaust emissions or other fluid streams may be subjected to pollution abatement or otherwise treated by flowing the fluid stream through a catalyst coated monolith. To coat a conventional substrate with a functional material (e.g., a catalyst or adsorbent), the high surface area material may be applied to the substrate in the form of a slurry, which is then dried and calcined to form the ceramic washcoat. A common example of such a high surface area material is gamma alumina. The catalyst or sorbent material may be applied (coated) with or onto the high surface area material to enable the coated substrate to treat exhaust emissions, capture CO 2, or for another purpose or function. Disclosure of Invention In various aspects, the present disclosure provides a monolithic substrate. The monolithic substrate comprises a matrix of a glass-ceramic composite material defining a continuous interconnected pore structure, wherein the porosity of the glass-ceramic composite material is at least 48% by volume as determined by mercury intrusion porosimetry, and wherein at least 20% of the porosity is contributed by pores having a pore diameter between 0.1 μm and 1 μm as determined by mercury intrusion porosimetry. In various aspects, up to 5% by volume of the porosity is contributed by pores having a pore diameter of less than 0.1 μm, as determined by mercury intrusion porosimetry. In various aspects, up to 3% by volume of the porosity is contributed by pores having a pore diameter of less than 0.1 μm, as determined by mercury intrusion porosimetry. In various aspects, up to 1% by volume of the porosity is contributed by pores having a pore diameter of less than 0.1 μm, as determined by mercury intrusion porosimetry. In various aspects, up to 5% by volume of the porosity is contributed by pores having a pore diameter of less than 0.05 μm, as determined by mercury intrusion porosimetry. In various aspects, the interconnected pore structure has a median pore diameter between 0.1 μm and 1 μm, as determined by mercury intrusion porosimetry. In various aspects, the interconnected pore structure has a median pore diameter of less than 1 μm, as determined by mercury intrusion porosimetry. In various aspects, the interconnected pore structure has a median pore diameter of less than 1 μm, as determined by mercury intrusion porosimetry. In various aspects, the porosity is at least 50% by volume, as determined by mercury intrusion porosimetry. In various aspects, the porosity is at least 50% by volume, as determined by mercury intrusion porosimetry. In various aspects, the porosity is at least 55 volume percent, as determined by mercury intrusion porosimetry. In various aspects, the porosity is at least 48% to 75% by volume, as determined by mercury intrusion porosimetry. In various aspects, the porosity is at least 50% to 75% by volume, as determined by mercury intrusion porosimetry. In various aspects, the interconnected pore structure has a multimodal pore size distribution. In various aspects, the multimodal pore size distribution is a first differential intrusion peak contained at a first pore diameter between 0.1 μm and 1 μm and a second differential intrusion peak at a second pore diameter between 1.5 μm and 30 μm. In various aspects, the second differential intrusion peak is at a pore diameter of at least 5 μm. In various aspects, at least 50% of the porosity is contributed by pores having a pore diameter between 0.1 μm and 1 μm, as determined by mercury intrusion porosimetry. In various aspects, at least 80% of the porosity is contributed by pores having a pore diameter between 0.1 μm and 1 μm, as determined by mercury intrusion porosimetry. In various aspects, the interconnected pore structure has a unimodal pore size distribution having a single differential intrusion peak. In various aspects, the glass-ceramic composite comprises at least 50 wt% amorphous silica. In various aspects, the glass-ceramic composite comprises at least 70 wt% amorphous silica. In various aspects, the glass-ceramic composite comprises at least 90 wt% amorphous silica. In various aspects, the glass ceramic composite comprises at least 50% sintered diatom particles. In various aspects, the glass-ceramic composite comprises at least 70 wt% sintered diatomaceous earth particles. In various aspects, the glass ceramic composite comprises at least 90 wt% sint