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Cordierite-based composite membrane coated on cordierite monolith

  • US 8,784,541 B2
  • Filed: 11/10/2011
  • Issued: 07/22/2014
  • Est. Priority Date: 11/10/2011
  • Status: Active Grant
First Claim
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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.

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