Phosphate-based ceramic
First Claim
1. A ceramic comprising a first phase having a general formula R1+(x/2)Zr4P6−
- xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦
x≦
2, wherein the first phase has a volumetric heat capacity (Cp1), and at least 10 weight percent of a second phase having a volumetric heat capacity (Cp2), wherein Cp2>
Cp1, wherein the ceramic has a coefficient of thermal expansion from 22°
to 1000°
C. of −
15×
10−
7/°
C. to +15×
10−
7/°
C., a permeability of at least 0.25×
10−
12 m2, a total porosity of at least 35% by volume, a median pore diameter of at least 6 micrometers, and a volumetric heat capacity Cp(solid) of at least 3.15 J/cm3 K.
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Abstract
A ceramic including a first phase having a general formula R1+(x/2)Zr4P6−xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦x≦2, wherein the first phase has a volumetric heat capacity (Cp1), and at least 10 weight percent of a second phase having a volumetric heat capacity (Cp2), wherein Cp2>Cp1. The ceramic has a coefficient of thermal expansion from 22° to 1000° C. of −15×10−7/° C. to +15×10−7/° C., a permeability of at least 0.25×10−12 m2, a total porosity of at least 35% by volume, and a median pore diameter of at least 6 micrometers, and a volumetric heat capacity of the solid Cp(solid) of at least 3.15 J/cm3 K.
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Citations
65 Claims
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1. A ceramic comprising a first phase having a general formula R1+(x/2)Zr4P6−
- xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦
x≦
2, wherein the first phase has a volumetric heat capacity (Cp1), and at least 10 weight percent of a second phase having a volumetric heat capacity (Cp2), wherein Cp2>
Cp1, wherein the ceramic has a coefficient of thermal expansion from 22°
to 1000°
C. of −
15×
10−
7/°
C. to +15×
10−
7/°
C., a permeability of at least 0.25×
10−
12 m2, a total porosity of at least 35% by volume, a median pore diameter of at least 6 micrometers, and a volumetric heat capacity Cp(solid) of at least 3.15 J/cm3 K. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
- xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦
-
20. A diesel particulate filter comprising a ceramic comprising a first phase having a general formula R1+(x/2)Zr4P6−
- xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦
x≦
2, wherein the first phase has a volumetric heat capacity (Cp1), and at least 10 weight percent of a second phase having a volumetric heat capacity (Cp2), wherein Cp2>
Cp1, wherein the ceramic has a coefficient of thermal expansion from 22°
to 1000°
C. of −
15×
10−
7/°
C. to +15×
10−
7/°
C., a permeability of at least 0.25×
10−
12 m2, a total porosity of at least 35% by volume, a median pore diameter of at least 6 micrometers, and a volumetric heat capacity Cp(solid) of at least 3.15 J/cm3 K. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65)
- xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦
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36. A method of making a ceramic, the method comprising:
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a) forming a mixture comprising raw material powders capable of reacting to form a ceramic comprising a first phase having a general formula R1+(x/2)Zr4P6−
xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦
x≦
2, and a second phase selected from the group consisting of zircon and zirconia, wherein the second phase is about 10 to 90% based on weight of the final ceramic;
b) shaping the mixture into a green body;
c) firing the green body to produce a ceramic comprising a first phase having a general formula R1+(x/2)Zr4P6−
xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦
x≦
2, wherein the first phase has a volumetric heat capacity (Cp1), and at least 10 weight percent of a second phase selected from the group consisting of zircon and zirconia, wherein the second phase has a volumetric heat capacity (Cp2), wherein Cp2>
Cp1, wherein the ceramic has a coefficient of thermal expansion from 22°
to 1000°
C. of −
15×
10−
7/°
C. to +15×
10−
7/°
C., a permeability of at least 0.25×
10−
12 m2, a total porosity of at least 35% by volume, a median pore diameter of at least 6 micrometers, and a volumetric heat capacity Cp(solid) of at least 3.15 J/cm3 K.
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Specification