DETAILED DESCRIPTION The present invention provides adsorbent substrate composites wherein solid adsorbents are bonded to aluminum substrates.
These composites can form coatings that have improved adsorption properties over pelleted or beaded adsorbent particles as well as excellent physical and thermal cycling properties.
The present invention provides methods of coating a surface of an aluminum substrate such as aluminum metal, aluminized steel or aluminized ceramic, with a layer of solid adsorbent which includes the steps of heating the surface in an oxygen containing atmosphere, preferably containing at least about 1 mol % oxygen and more preferably consisting of air, to a temperature sufficient to enable bonding of the solid adsorbent to the surface and preferably oxidation of the surface, wherein the temperature is at least about 200.
degree.
C.
, preferably between about 250.
degree.
C.
and 650.
degree.
C.
, and most preferably between about 350.
degree.
C.
and 650.
degree.
C.
, contacting the heated surface with a slurry comprising the solid adsorbent and a binder in a suspending liquid to form a slurry-coated surface, and removing sufficient liquid to form a coating thereon.
In a preferred aspect, the coated surface is additionally heated to a temperature and for a period of time sufficient to cause hardening thereof, wherein the temperature is at least 200.
degree.
C.
, preferably between about 400.
degree.
C.
and 650.
degree.
C.
, and the time is at least 0.
25 hours and preferably about 1 hour.
Other preferred aspects involve utilizing, as the solid adsorbent, crystalline molecular sieves, more preferably zeolites, and most preferably Zeolite A, Zeolite X, Zeolite Y, chabazite and mixtures thereof.
A particularly preferred aspect of the present invention provides a method of coating surface of an aluminum substrate with a layer of molecular sieve which includes the steps of heating the surface in an oxygen containing atmosphere to a temperature of about 350.
degree.
-650.
degree.
C.
to form a heated, oxidized, surface, contacting the heated, oxidized, surface with a slurry having solid materials containing about 60 to 95 wt
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