Composite ceramic materials, articles, and method of manufacture

• US 10,472,285 B2
• Filed: 11/09/2017
• Issued: 11/12/2019
• Est. Priority Date: 11/10/2016
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Sarma, Huthavahana Kuchibhotla, Vileno, Elizabeth Marie, Wheaton, Bryan Ray
• Primary Examiner(s): Wiese, Noah S
• Application Number:
  US15/808,622
• Publication Number:
  US 20180127316A1
• Time in Patent Office: 733 Days
• CPC Class Codes: B01D 2239/1208 Porosity apparatus incorporating such gas filtering material B01D2275/30 - B01D2275/307
• CPC Class Codes: B01D 2239/1216 Pore size
• CPC Class Codes: B01D 39/2068 Other inorganic materials, e.g. ceramics
• CPC Class Codes: B01D 46/24 Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 21/063 Titanium; Oxides or hydroxides thereof
• CPC Class Codes: B01J 37/0009 Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
• CPC Class Codes: B01J 37/08 Heat treatment B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: C01G 23/006 Alkaline earth titanates
• CPC Class Codes: C04B 2235/3206 Magnesium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 2235/3222 Aluminates other than alumino-silicates, e.g. spinel (MgAl2O4)
• CPC Class Codes: C04B 2235/3224 Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
• CPC Class Codes: C04B 2235/3229 Cerium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3232 Titanium oxides or titanates, e.g. rutile or anatase
• CPC Class Codes: C04B 2235/3236 Alkaline earth titanates
• CPC Class Codes: C04B 2235/327 Iron group oxides, their mixed metal oxides, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3418 Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint glass constituents C04B2235/36
• CPC Class Codes: C04B 2235/3445 Magnesium silicates, e.g. forsterite
• CPC Class Codes: C04B 2235/3463 Alumino-silicates other than clay, e.g. mullite
• CPC Class Codes: C04B 2235/3481 : Alkaline earth metal alumino-silicates other than clay, e.g. cordierite, beryl, micas such as margarite, plagioclase feldspars such as anorthite, zeolites such as chabazite
• CPC Class Codes: C04B 2235/6021 : Extrusion moulding
• CPC Class Codes: C04B 2235/606 : Drying
• CPC Class Codes: C04B 2235/656 : characterised by specific heating conditions during heat treatment
• CPC Class Codes: C04B 2235/6562 : Heating rate
• CPC Class Codes: C04B 2235/6565 : Cooling rate
• CPC Class Codes: C04B 2235/76 : Crystal structural characteristics, e.g. symmetry
• CPC Class Codes: C04B 2235/77 : Density
• CPC Class Codes: C04B 2235/78 : Grain sizes and shapes, product microstructures, e.g. acicular grains, equiaxed grains, platelet-structures
• CPC Class Codes: C04B 2235/80 : Phases present in the sintered or melt-cast ceramic products other than the main phase
• CPC Class Codes: C04B 35/10 : based on aluminium oxide
• CPC Class Codes: C04B 35/185 : Mullite 3Al2O3-2SiO2
• CPC Class Codes: C04B 35/195 : Alkaline earth aluminosilicates, e.g. cordierite or anorthite
• CPC Class Codes: C04B 35/46 : based on titanium oxides or titanates containing also zirconium or hafnium oxides, zirconates or hafnates C04B35/49
• CPC Class Codes: C04B 35/465 : based on alkaline earth metal titanates
• CPC Class Codes: C04B 35/478 : based on aluminium titanates
• CPC Class Codes: C04B 35/6263 : characterised by their solids loadings, i.e. the percentage of solids
• CPC Class Codes: C04B 35/62665 : Flame, plasma or melting treatment
• CPC Class Codes: C04B 35/62675 : characterised by the treatment temperature
• CPC Class Codes: C04B 35/64 : Burning or sintering processes C04B33/32 takes precedence ; powder metallurgy B22F

Abstract

Composite ceramic materials are disclosed herein which comprise two or more crystalline phases, wherein a first crystalline phase comprises a first refractory material having a first melting point, and a second crystalline phase comprises a second refractory material having a second melting point which is lower than the first melting point, and the second crystalline phase comprises large domain sizes of the second refractory material. Articles comprising such a composite ceramic material, such as honeycomb bodies, catalytic substrates, and particulate filters, are also disclosed herein, in addition to methods of manufacture thereof.

Claims

1. A ceramic material comprising:

a first crystalline phase comprised of a first refractory material, the first crystalline phase having a first melting point;

a second crystalline phase comprised of a second refractory material having a second melting point which is lower than the first melting point, wherein the second crystalline phase comprises domain sizes of greater than 5,000 μ

m² as measured by Electron Backscattered Diffraction (EBSD);

wherein the first crystalline phase comprises MgTi2O5 in solid solution with tialite.

2. The ceramic material of claim 1 wherein the first crystalline phase constitutes at least 50% by volume of the ceramic material.

3. The ceramic material of claim 1 wherein the second crystalline phase constitutes less than 50% by volume of the ceramic material.

4. The ceramic material of claim 1 wherein the first crystalline phase constitutes at least 50% by weight of the ceramic material.

5. The ceramic material of claim 1 wherein the second crystalline phase constitutes less than 35% by weight of the ceramic material.

6. The ceramic material of claim 1 wherein the first crystalline phase constitutes at least 55% by weight of the material, and the second crystalline phase constitutes less than 35% by weight of the ceramic material.

7. The ceramic material of claim 1 wherein the first crystalline phase constitutes at least 60% by weight of the material, and the second crystalline phase constitutes less than 30% by weight of the ceramic material.

8. The ceramic material of claim 1 wherein the melting point of the first crystalline phase is greater than 1500°

C.

9. The ceramic material of claim 1 wherein the melting point of the second crystalline phase is less than 1500°

C.

10. The ceramic material of claim 1 wherein the melting point of the second crystalline phase is 1450°

C. or less.

11. The ceramic material of claim 1 wherein the melting point of the second crystalline phase is 1300°

C. to 1450°

C.

12. The ceramic material of claim 1 wherein the second crystalline phase comprises domain sizes of greater than 10,000 μ

m² as measured by Electron Backscattered Diffraction (EBSD).

13. The ceramic material of claim 1 wherein the second crystalline phase has an average domain size of greater than 20,000 μ

m² as measured by Electron Backscattered Diffraction (EBSD).

14. The ceramic material of claim 1 wherein the first crystalline phase further comprises mullite.

15. The ceramic material of claim 1 further comprising a third crystalline phase.

16. The ceramic material of claim 1 wherein the first crystalline phase further comprises mullite and the second crystalline phase comprises cordierite.

17. The ceramic material of claim 1, wherein the material comprises a bulk porosity of greater than 40% as measured by mercury porosimetry.

18. The ceramic material of claim 1, wherein the material comprises a plurality of pores having a pore size distribution with a d10 of 10 μ

m or greater.

19. The ceramic material of claim 1, wherein the material comprises a plurality of pores having a pore size distribution with a d50 of 15 μ

m or greater.

20. The ceramic material of claim 1, wherein the material comprises a plurality of pores having a pore size distribution with a d50 of 15 to 20 μ

m.

21. A composite ceramic material comprising:

a first crystalline phase comprised of tialite in solid solution with MgTi2O5, the first crystalline phase having a first melting point and a first maximum domain size in a select cross-sectional plane;

a second crystalline phase comprised of cordierite having a second melting point which is lower than the first melting point, and having a second maximum domain size in the select cross-sectional plane, wherein a ratio of the second maximum domain size to the first maximum domain size is 6.0 or more;

wherein the second crystalline phase has domain sizes of greater than 5,000 μ

m² as measured by Electron Backscattered Diffraction (EBSD).

22. A ceramic material comprising:

a first crystalline phase comprised of a first refractory material, the first crystalline phase having a first melting point;

a second crystalline phase comprised of a second refractory material having a second melting point which is lower than the first melting point, wherein the second crystalline phase comprises domain sizes of greater than 5,000 μ

m² as measured by Electron Backscattered Diffraction (EBSD); and

a third crystalline phase;

wherein the first crystalline phase comprises mullite, the second crystalline phase comprises cordierite, and the third crystalline phase comprises tialite and MgTi2O5.

23. The ceramic material of claim 22 wherein the first crystalline phase constitutes at least 50% by volume of the ceramic material.

24. The ceramic material of claim 22 wherein the second crystalline phase constitutes less than 50% by volume of the ceramic material.

25. The ceramic material of claim 22 wherein the first crystalline phase constitutes at least 50% by weight of the ceramic material.

26. The ceramic material of claim 22 wherein the second crystalline phase constitutes less than 35% by weight of the ceramic material.

27. The ceramic material of claim 22 wherein the first crystalline phase constitutes at least 55% by weight of the material, and the second crystalline phase constitutes less than 35% by weight of the ceramic material.

28. The ceramic material of claim 22 wherein the first crystalline phase constitutes at least 60% by weight of the material, and the second crystalline phase constitutes less than 30% by weight of the ceramic material.

29. The ceramic material of claim 22 wherein the melting point of the first crystalline phase is greater than 1500°

C.

30. The ceramic material of claim 22 wherein the melting point of the second crystalline phase is less than 1500°

C.

31. The ceramic material of claim 22 wherein the melting point of the second crystalline phase is 1450°

C. or less.

32. The ceramic material of claim 22 wherein the melting point of the second crystalline phase is 1300°

C. to 1450°

C.

33. The ceramic material of claim 22 wherein the second crystalline phase comprises domain sizes of greater than 10,000 μ

m² as measured by Electron Backscattered Diffraction (EBSD).

34. The ceramic material of claim 22 wherein the second crystalline phase has an average domain size of greater than 20,000 μ

m² as measured by Electron Backscattered Diffraction (EBSD).

35. The ceramic material of claim 22 wherein the material comprises a bulk porosity of greater than 40% as measured by mercury porosimetry.

36. The ceramic material of claim 22 wherein the material comprises a plurality of pores having a pore size distribution with a d10 of 10 μ

m or greater.

37. The ceramic material of claim 22 wherein the material comprises a plurality of pores having a pore size distribution with a d50 of 15 μ

m or greater.

38. The ceramic material of claim 22 wherein the material comprises a plurality of pores having a pore size distribution with a d50 of 15 to 20 μ

m.