Cordierite-based composite membrane coated on cordierite monolith
First Claim
1. A composite-membrane monolith comprising:
- a cordierite monolith having surfaces with a surface median pore size of from about 1 μ
m to about 15 μ
m; and
a cordierite-ceramic composite membrane bonded directly to surfaces of the cordierite monolith without any intervening layer between the cordierite monolith and the cordierite-ceramic composite, the cordierite-ceramic composite having membrane surfaces with a membrane median pore size of 0.3 μ
m or less and with small pores having small-pore sizes from 0.05 μ
m to 0.1 μ
m, the membrane median pore size and the small pores providing polymer coatability to the membrane surfaces,wherein;
the cordierite-ceramic composite membrane is a composite having a thermal coefficient of expansion approximately equal to the thermal coefficient of expansion of the cordierite monolith and is formed from a cordierite-ceramic composite slip comprising;
from 30 wt. % to 90 wt. % cordierite particles having a cordierite median particle size from about 1 μ
m to about 3 μ
m and smaller than the surface median pore size; and
from 10 wt. % to 70 wt. % ceramic particles other than cordierite particles, the ceramic particles having a ceramic median particle size from about 0.05 μ
m to about 0.5 μ
m and smaller than the cordierite median particle size,wherein a weight ratio of the cordierite particles to the ceramic particles in the cordierite-ceramic composite slip is from 9;
1 to 3;
7.
1 Assignment
0 Petitions
Accused Products
Abstract
Composite-membrane monoliths include a cordierite monolith having a cordierite-ceramic composite membrane bonded to surfaces thereof with a surface median pore size. The cordierite-ceramic composite membrane has membrane surfaces with a membrane median pore size of 0.3 μm or less. The cordierite-ceramic composite membrane may be a composite formed by firing the cordierite monolith subsequent to applying a cordierite-ceramic composite slip to surfaces thereof. The cordierite-ceramic slip may include cordierite particles and ceramic particles. The cordierite particles may have a cordierite median particle size smaller than the surface median pore size. The ceramic particles may have a ceramic median particle size smaller than the cordierite median particle size.
-
Citations
16 Claims
-
1. A composite-membrane monolith comprising:
-
a cordierite monolith having surfaces with a surface median pore size of from about 1 μ
m to about 15 μ
m; anda cordierite-ceramic composite membrane bonded directly to surfaces of the cordierite monolith without any intervening layer between the cordierite monolith and the cordierite-ceramic composite, the cordierite-ceramic composite having membrane surfaces with a membrane median pore size of 0.3 μ
m or less and with small pores having small-pore sizes from 0.05 μ
m to 0.1 μ
m, the membrane median pore size and the small pores providing polymer coatability to the membrane surfaces,wherein; the cordierite-ceramic composite membrane is a composite having a thermal coefficient of expansion approximately equal to the thermal coefficient of expansion of the cordierite monolith and is formed from a cordierite-ceramic composite slip comprising; from 30 wt. % to 90 wt. % cordierite particles having a cordierite median particle size from about 1 μ
m to about 3 μ
m and smaller than the surface median pore size; andfrom 10 wt. % to 70 wt. % ceramic particles other than cordierite particles, the ceramic particles having a ceramic median particle size from about 0.05 μ
m to about 0.5 μ
m and smaller than the cordierite median particle size,wherein a weight ratio of the cordierite particles to the ceramic particles in the cordierite-ceramic composite slip is from 9;
1 to 3;
7.- View Dependent Claims (2, 3, 4, 5, 6)
-
-
7. A method for forming a composite-membrane monolith, the method comprising:
-
applying a cordierite-ceramic composite slip to surfaces of a cordierite monolith, the cordierite-ceramic composite slip comprising from 30 wt. % to 90 wt. % cordierite particles and from 10 wt. % to 70 wt. % ceramic particles other than cordierite particles to form a coated cordierite monolith, the surfaces of the monolith having a surface median pore size of from about 1 μ
m to about 15 μ
m, the cordierite particles having a cordierite median particle size from about 1 μ
m to about 3 μ
m and smaller than the surface median pore size, the ceramic particles having a ceramic median particle size from about 0.05 μ
m to about 0.5 μ
m and smaller than the cordierite median particle size, the weight ratio of the cordierite particles to the ceramic particles in the cordierite-ceramic composite slip being from 9;
1 to 3;
7; andfiring the coated cordierite monolith to form the composite-membrane monolith, the cordierite-ceramic composite slip forming, during the firing, a cordierite-ceramic composite membrane as a composite having a thermal coefficient of expansion approximately equal to the thermal coefficient of expansion of the cordierite monolith and bonded directly to the surfaces of the cordierite monolith without any intervening layer between the cordierite monolith and the cordierite-ceramic composite, the cordierite-ceramic membrane having membrane surfaces with a membrane median pore size of 0.3 μ
m or less and with small pores having small-pore sizes from 0.05 μ
m to 0.1 μ
m, the membrane median pore size and the small pores providing polymer coatability to the membrane surfaces. - View Dependent Claims (8, 9, 10, 11, 12, 13, 14, 15, 16)
-
Specification