Controlled gas pore formers in extruded ware
First Claim
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1. A method for producing a porous ceramic article, comprising the steps of:
- providing inorganic ceramic-forming ingredients;
adding an organic binder, a solvent and a pore forming agent to the inorganic ceramic-forming ingredients, wherein the pore forming agent is t-butlyperoxytrimethylsilane, di(t-butylperoxy)dimethylsilane, di(t-butylperoxy)diphenylsilane or combinations thereof;
mixing the inorganic ceramic forming ingredients, the organic binder, the solvent and the pore forming agent to form a precursor batch;
forming the precursor batch into a green body;
firing the green body to produce a porous ceramic article; and
wherein the pore forming agent is stable during the step of forming the green body and decomposes after the forming of the green body but before firing the green body.
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Abstract
The present invention provides compositions and methods for producing porous ceramic articles. The compositions and methods comprise a ceramic precursor batch comprising an organic peroxide pore forming agent where the pore forming agent is an organo-adduct of hydrogen peroxide and an organic compound or an organic peroxide of the general formula R—O—O—R′. The organic peroxide pore forming agent is stable during extrusion and other methods for forming a green body and does not decompose until the green body is dried.
27 Citations
14 Claims
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1. A method for producing a porous ceramic article, comprising the steps of:
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providing inorganic ceramic-forming ingredients; adding an organic binder, a solvent and a pore forming agent to the inorganic ceramic-forming ingredients, wherein the pore forming agent is t-butlyperoxytrimethylsilane, di(t-butylperoxy)dimethylsilane, di(t-butylperoxy)diphenylsilane or combinations thereof; mixing the inorganic ceramic forming ingredients, the organic binder, the solvent and the pore forming agent to form a precursor batch; forming the precursor batch into a green body; firing the green body to produce a porous ceramic article; and wherein the pore forming agent is stable during the step of forming the green body and decomposes after the forming of the green body but before firing the green body. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method for manufacturing a porous ceramic honeycomb body comprising the steps of:
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providing inorganic ceramic-forming ingredients; adding an organic binder, a solvent and a pore forming agent to the inorganic ceramic-forming ingredients, wherein the pore forming agent is an organic peroxide of the general formula R—
O—
O—
R′
wherein R and R′
are each independently alkyl, substituted alkyl, phenyl, napthyl, substituted phenyl, substituted napthyl groups or combinations thereof;mixing the inorganic ceramic forming ingredients, the organic binder, the solvent and the pore forming agent to form a precursor batch; extruding the precursor batch to form a honeycomb green body; at least substantially drying the honeycomb green body at a temperature below approximately 400°
C. prior to firing the green body; andfiring the green body to produce a porous ceramic article. - View Dependent Claims (12, 13, 14)
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Specification