Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same

• US 10,526,249 B2
• Filed: 05/27/2015
• Issued: 01/07/2020
• Est. Priority Date: 11/30/2012
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Divens-Dutcher, Adriane Marie, Tepesch, Patrick David, Vileno, Elizabeth Marie
• Primary Examiner(s): Orlando, Amber R
• Application Number:
  US14/722,560
• Publication Number:
  US 20160347665A1
• Time in Patent Office: 1,686 Days
• CPC Class Codes: C04B 2111/00793 as filters or diaphragms
• CPC Class Codes: C04B 2111/0081 as catalysts or catalyst carriers
• CPC Class Codes: C04B 2235/3206 Magnesium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3208 Calcium oxide or oxide-forming salts thereof, e.g. lime
• CPC Class Codes: C04B 2235/3213 Strontium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3225 Yttrium oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3227 Lanthanum oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3229 Cerium 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
• CPC Class Codes: C04B 2235/349 Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
• CPC Class Codes: C04B 2235/6021 Extrusion moulding
• CPC Class Codes: C04B 2235/6567 Treatment time
• CPC Class Codes: C04B 2235/661 Multi-step sintering
• 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 2235/9607 Thermal properties, e.g. thermal expansion coefficient
• CPC Class Codes: C04B 2235/9615 Linear firing shrinkage
• CPC Class Codes: C04B 35/478 based on aluminium titanates
• CPC Class Codes: C04B 38/00 Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof treating slag with gases or gas generating material C04B5/06 ; expanded graphite C04B35/536
• CPC Class Codes: C04B 38/0006 Honeycomb structures from one or more corrugated sheets by winding or stacking C04B38/0083
• CPC Class Codes: C04B 38/0054 the pores being microsized or nanosized
• CPC Class Codes: C04B 38/0074 : expressed as porosity percentage
• CPC Class Codes: C04B 38/0645 : Burnable, meltable, sublimable materials
• CPC Class Codes: C04B 38/068 : Carbonaceous materials, e.g. coal, carbon, graphite, hydrocarbons

Abstract

Disclosed are ceramic bodies comprised of composite cordierite aluminum magnesium titanate ceramic compositions and methods for the manufacture of same.

Claims

1. A ceramic article, comprising:

a pseudobrookite phase comprising predominately alumina, magnesia, and titania;

a second phase comprising cordierite; and

a sintering aid, comprising;

(i) at least one of a calcium oxide and strontium oxide, and

(ii) at least one of a yttrium oxide, a lanthanum oxide, and a cerium oxide;

wherein the ceramic article comprises a total porosity of at least 40% by volume, a median pore size d₅₀ in a range of 10 μ

m to 30 μ

m, and a composition expressed on an oxide basis of a(Al₂TiO₅)+b(MgTi₂O₅)+c(2MgO.2Al₂O₃.5SiO₂)+d(3Al₂O₃.2SiO₂)+e(MgO.Al₂O₃)+f(2MgO.TiO₂)+g(CaO)+h(SrO)+i(X)+j(Fe₂O₃.TiO₂)+k(TiO₂)+1(Al₂O₃), wherein X is at least one of CeO₂, Y₂O₃, and La₂O₃, and a, b, c, d, e, f, g, h, i, j, k, and l are weight fractions of each component such that (a+b+c+d+e+f+g+h+i+j+k+1)=1.00, and wherein 0.3≤

a≤

0.75, 0.075≤

b≤

0.3, 0.02≤

c≤

0.5, 0.0≤

d≤

0.4, 0.0≤

e≤

0.25, 0.0≤

f≤

0.1, 0.0≤

g≤

0.01, 0.0≤

h≤

0.02, 0.0015≤

(g+h), 0.0≤

i≤

0.05, 0.0≤

j≤

0.03, 0.0 k 0.2, and 0.0≤

1≤

0.1.

2. The ceramic article of claim 1, wherein the sintering aid comprises a cerium oxide.

3. The ceramic article of claim 1, wherein the sintering aid comprises cerium oxide and at least one of yttrium oxide and a lanthanum oxide.

4. The ceramic article of claim 1, wherein the ceramic article has a composition comprising, as expressed in weight percent on an oxide basis, from 4 to 10% MgO;

from 40 to 55% Al₂O₃;

from 25 to 44% TiO₂; and

from 5 to 25% SiO₂.