POROUS CERAMIC ARTICLE AND METHOD OF MANUFACTURING THE SAME

• US 20140342898A1
• Filed: 04/11/2014
• Published: 11/20/2014
• Est. Priority Date: 05/20/2013
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Backhaus-Ricoult, Monika, Glose, Christopher Raymond
• Granted Patent: US 9,376,347 B2
• Time in Patent Office: Days
• US Class Current: 501/80
• 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 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 2235/3218 Aluminium (oxy)hydroxides, e.g. boehmite, gibbsite, alumina sol
• 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 2235/3232 Titanium oxides or titanates, e.g. rutile or anatase
• CPC Class Codes: C04B 2235/3272 Iron oxides or oxide forming salts thereof, e.g. hematite, magnetite
• CPC Class Codes: C04B 2235/3409 Boron oxide, borates, boric acids, or oxide forming salts thereof, e.g. borax
• 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 2235/3463 Alumino-silicates other than clay, e.g. mullite
• CPC Class Codes: C04B 2235/3472 Alkali metal alumino-silicates other than clay, e.g. spodumene, alkali feldspars such as albite or orthoclase, micas such as muscovite, zeolites such as natrolite
• CPC Class Codes: C04B 2235/5252 having a specific pre-form
• CPC Class Codes: C04B 2235/528 Spheres
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/5463 Particle size distributions
• CPC Class Codes: C04B 2235/65 Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
• 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 35/10 : based on aluminium oxide
• CPC Class Codes: C04B 35/111 : Fine ceramics
• CPC Class Codes: C04B 35/195 : Alkaline earth aluminosilicates, e.g. cordierite or anorthite
• CPC Class Codes: C04B 35/478 : based on aluminium titanates
• CPC Class Codes: C04B 35/62645 : Thermal treatment of powders or mixtures thereof other than sintering
• CPC Class Codes: C04B 35/62655 : Drying, e.g. freeze-drying, spray-drying, microwave or supercritical drying
• 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 38/009 : Porous or hollow ceramic granular materials, e.g. microballoons C04B18/027, C04B20/002 take precedence

Abstract

The present disclosure relates to porous ceramic articles and a method of making the same. The porous ceramic articles have microstructure of sinter bonded or reaction bonded large pre-reacted particles and pore network structure exhibiting large pore necks. The method of making the porous ceramic articles involves using pre-reacted particles having one or more phases. A plastic ceramic precursor composition is also disclosed. The composition includes a mixture of at least one of dense, porous, or hollow spheroidal pre-reacted particles and a liquid vehicle.

Claims

1. A plastic ceramic precursor batch composition for making a porous ceramic article, comprising:

at least one of dense, porous, and hollow pre-reacted particles; and

a liquid vehicle, wherein

the pre-reacted particles comprise one or more phases.

2. The plastic ceramic precursor batch composition of claim 1, wherein the pre-reacted particles comprise two or more phases.

3. The plastic ceramic precursor batch composition of claim 1, wherein the pre-reacted particles comprise at least one of sintered, partially reacted, and fully reacted particles.

4. The plastic ceramic precursor batch composition of claim 3, wherein the sintered pre-reacted particles comprise fine particles sintered together to form the pre-reacted particles, the partially reacted particles comprise fine particles sintered together and a portion of the sintered fine particles reacted to form another phase different from the fine particles adjacent the sintered connection, and the fully-reacted particles comprise a multiphase microstructure.

5. The plastic ceramic precursor batch composition of claim 1, wherein the pre-reacted particles have a median particle size of equal to or greater than 10 μ

m.

6. The plastic ceramic precursor batch composition of claim 1, wherein the pre-reacted particles comprise spheroidal particles comprising at least one of a sphere, torus (doughnut), prolate spheroid (egg, raindrop, American football), and oblate spheroid (pancake, lentil) particles.

7. The plastic ceramic precursor batch composition of claim 1, further comprising at least one of an inorganic powder, an organic powder, and an inorganic binder.

8. The plastic ceramic precursor batch composition of claim 1, wherein the pre-reacted particles comprise porous pre-reacted particles.

9. The plastic ceramic precursor batch composition of claim 8, wherein the porous pre-reacted particles comprise a porosity in a range of 10% to 50%.

10. The plastic ceramic precursor batch composition of claim 8, wherein the porous pre-reacted particles comprise a median pore size in a range of 200 μ

m to 10 μ

m.

11. The plastic ceramic precursor batch composition of claim 1, wherein the pre-reacted particles comprise mechanical strength to survive intact shear stresses from mixing and extrusion.

12. The plastic ceramic precursor batch composition of claim 1, wherein

the pre-reacted particles comprise at least one of alumina, silica, titania, cordierite, magnesia, strontium oxide, calcium oxide, lanthanum oxide, boron oxide, cerium oxide, yttrium oxide, or other rare earth oxide, zirconium oxide, an alkali oxide, aluminum titanate solid solution pseudobrookite, mullite, spinel, feldspar, and glass.

13. The plastic ceramic precursor batch composition of claim 1, wherein

the pre-reacted particles comprise at least two of alumina, silica, titania, cordierite, magnesia, strontium oxide, calcium oxide, lanthanum oxide, boron oxide, cerium oxide, yttrium oxide, or other rare earth oxide, zirconium oxide, an alkali oxide, aluminum titanate solid solution pseudobrookite, mullite, spinel, feldspar, and glass.

14. A crystalline cordierite article made by shaping and firing the plastic ceramic precursor batch composition of claim 12.

15. A crystalline aluminum titanate solid solution pseudobrookite article made by shaping and firing the plastic ceramic precursor batch composition of claim 12.

16. The plastic ceramic precursor batch composition of claim 12, further comprising at least one additional source of alumina, silica, magnesia, titania, strontium oxide, calcium oxide, lanthanum oxide, boron oxide, cerium oxide, yttrium oxide, or other rare earth oxide, zirconium oxide, and one or more alkali oxides.

17. The plastic ceramic precursor batch composition of claim 1, further comprising a pore former.