Ceramic material for a honeycomb structure

• US 4,598,054 A
• Filed: 12/26/1984
• Issued: 07/01/1986
• Est. Priority Date: 12/28/1983
• Status: Expired due to Term

• Current Assignee: NGK Insulators Limited
• Original Assignee: NGK Insulators Limited
• Inventors: Yamada, Shunichi, Hamanaka, Toshiyuki, Mochida, Shigeru
• Primary Examiner(s): Dixon, Jr., William R.
• Assistant Examiner(s): Group, Karl
• Application Number:
  US06/686,144
• Time in Patent Office: 552 Days
• Field of Search: 501/119, 501/128, 501/120, 501/121, 501/153, 501/9, 501/112, 501/89
• US Class Current: 501/112
• CPC Class Codes: C04B 35/195 Alkaline earth aluminosilicates, e.g. cordierite or anorthite
• CPC Class Codes: C04B 38/0006 Honeycomb structures from one or more corrugated sheets by winding or stacking C04B38/0083
• CPC Class Codes: C04B 38/0016 assembled from subunits

Abstract

A ceramic material for a honeycomb structure is formed from a mixture of raw materials comprising, per 100 parts by weight of the mixture, 20 to 80 parts by weight of cordierite powder and 20 to 80 parts by weight of powder having a crystalline phase consisting mainly of a solid solution of SiO₂ --Al₂ O₃ --Fe₂ O₃ --TiO₂ --MgO. The mixture consists essentially of 15.7 to 44.0% by weight of SiO₂, 29.8 to 41.0% by weight of Al₂ O₃, 0.9 to 8.3% by weight of Fe₂ O₃, 7.0 to 35.9% by weight of TiO₂ and 4.9 to 16.1% by weight of MgO.

Claims

1. A ceramic material for joining, coating or sealing a honeycomb structure comprising, per 100 parts by weight, a first mixture of 20 to 80 parts by weight of cordierite powder and 20 to 80 parts by weight of a ceramic powder having a crystalline phase consisting essentially of a solid solution of SiO₂ - Al₂ O₃ - Fe₂ O₃ - TiO₂ - MgO, said first mixture having a chemical composition consisting essentially of 15.7 to 44.0% by weight of SiO₂, 29.8 to 41.0% by weight of Al₂ O₃, 0.9 to 8.3% by weight of Fe₂ O₃, 7.0 to 35.9% by weight of TiO₂ and 4.9 to 16.1% by weight of MgO said first mixture being fired at a temperature between 1300°

to 1450°

C. to result in a fired body, said fired body having a crystalline phase consisting essentially of said cordierite and said solid solution, said fired body having a coefficient of thermal expansion of not greater than 1.6×

10^-6 /°

C. at a temperature of 40°

-800°

C.

2. A ceramic material as set forth in claim 1, wherein said first mixture is modified by adding thereto up to 5 parts by weight of SiC powder per 100 parts by weight of said modified first mixture.

3. A ceramic material as set forth in claim 1, wherein said ceramic powder mixed with the cordierite powder has a chemical composition consisting essentially of 1.0 to 20.0% by weight of SiO₂, 22.0 to 50.0% by weight of Al₂ O₃, 1.0 to 20.0% by weight of Fe₂ O₃, 19.0 to 59.5% by weight of TiO₂ and 1.2 to 20.0% by weight of MgO.

4. A ceramic material as set forth in claim 1, wherein said cordierite powder contains at least 90% by weight of cordierite crystals.