Aluminum titanate batch compositions and method

• US 8,974,724 B2
• Filed: 11/29/2006
• Issued: 03/10/2015
• Est. Priority Date: 11/29/2006
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Day, John Paul, Locker, Robert John, Tennent, David Lambie, Warren, Christopher John
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): KEMMERLE III, RUSSELL J
• Application Number:
  US11/605,642
• Publication Number:
  US 20080125305A1
• Time in Patent Office: 3,023 Days
• Field of Search: 264/638
• US Class Current: 264/638
• CPC Class Codes: C04B 2111/00793 as filters or diaphragms
• CPC Class Codes: C04B 2235/3208 Calcium oxide or oxide-forming salts thereof, e.g. lime
• CPC Class Codes: C04B 2235/3213 Strontium oxides or oxide-forming salts thereof
• 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 2235/3227 Lanthanum oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3234 Titanates, not containing zirconia
• 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 2235/5409 expressed by specific surface values
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/77 Density
• CPC Class Codes: C04B 35/478 based on aluminium titanates
• CPC Class Codes: C04B 35/62204 using waste materials or refuse clay-wares containing waste materials C04B33/132
• 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 38/0645 Burnable, meltable, sublimable materials
• CPC Class Codes: F01N 3/0222 the structure being monolithic, e.g. honeycombs
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Aluminum titanate precursor batch compositions comprising a recycled aluminum titanate component, at least a portion of the recycled aluminum titanate component being comprised of a recycled pre-reacted aluminum titanate composition or alternatively of an un-reacted green aluminum titanate precursor composition, and methods for producing aluminum titanate ceramic articles utilizing the inventive batch compositions.

Claims

1. A method for producing a ceramic article comprised of a sintered phase aluminum titanate composition, comprising the steps of:

providing a plasticized aluminum titanate precursor batch composition comprising;

an inorganic batch composition containing an alumina source, a silica source, and a titania source;

a recycled green aluminum titanate precursor composition; and

a sintering aid;

an organic binder; and

a liquid vehicle;

wherein the recycled green aluminum titanate precursor composition comprises at least one pore former; and

wherein the recycled green aluminum titanate precursor composition comprises particles having a median particle diameter in the range of about 10 μ

m to about 50 μ

m;

forming an extruded green body from the plasticized aluminum titanate precursor batch composition; and

firing the formed green body under conditions effective to convert the aluminum titanate precursor composition into a ceramic composition comprising a sintered phase aluminum titanate.

2. The method of claim 1, wherein the inorganic batch composition comprises green aluminum titanate precursor composition in an amount up to 50 weight percent of the inorganic batch composition.

3. The method of claim 2, wherein the green aluminum titanate precursor composition is present in an amount of from 1 to 50 weight percent of the inorganic batch composition.

4. The method of claim 1, wherein the plasticized aluminum titanate precursor batch composition further comprises at least one pore former.

5. The method of claim 1, wherein the inorganic batch composition comprises at least one metal oxide sintering aid.

6. The method of claim 5, wherein the metal oxide sintering aid comprises at least one lanthanide oxide source.

7. The method of claim 1, wherein the inorganic batch composition further comprises a strontium carbonate source and a calcium carbonate source.

8. The method of claim 7, wherein the inorganic batch composition comprises about 47 wt % alumina source, about 10 wt % silica source, about 10 wt % titania source, and about 13 wt % additional inorganic additives, inclusive of the recycled pre-reacted aluminum titanate ceramic composition.

9. A method for producing a ceramic article comprised of a sintered phase aluminum titanate composition, comprising the steps of:

providing a plasticized aluminum titanate precursor batch composition comprising;

an inorganic batch composition containing a recycled green aluminum titanate precursor composition;

an organic binder; and

a liquid vehicle;

wherein the recycled green aluminum titanate precursor composition comprises at least one pore former; and

wherein the recycled green aluminum titanate precursor composition comprises particles having a median particle diameter in the range of about 10 μ

m to about 50 μ

m;

forming an extruded green body from the plasticized aluminum titanate precursor batch composition; and

firing the formed green body under conditions effective to convert the aluminum titanate precursor composition into a ceramic composition comprising a sintered phase aluminum titanate.

10. The method of claim 9, wherein the inorganic batch composition further comprises at least one pore former.

11. The method of claim 9, wherein the inorganic batch composition further comprises at least one pore former and/or at least one sintering aid.

12. The method of claim 9, wherein the inorganic batch composition consists essentially of 100% by weight of a green aluminum titanate precursor composition.

13. A method for producing a ceramic article comprised of a sintered phase aluminum titanate composition, comprising the steps of:

providing a plasticized aluminum titanate precursor batch composition comprising;

an inorganic batch composition containing an alumina source, a silica source, and a titania source;

a recycled pre-reacted aluminum titanate composition containing a strontium carbonate source and a calcium carbonate source; and

a sintering aid;

an organic binder; and

a liquid vehicle;

wherein the recycled pre-reacted aluminum titanate composition comprises particles having a median particle diameter in the range of about 8 μ

m to about 55 μ

m;

forming an extruded green body from the plasticized aluminum titanate precursor batch composition; and

firing the formed green body under conditions effective to convert the aluminum titanate precursor composition into a ceramic composition comprising a sintered phase aluminum titanate.

14. The method of claim 13, wherein the inorganic batch composition comprises recycled pre-reacted aluminum titanate in an amount up to 25 weight percent of the inorganic batch composition.

15. The method of claim 14, wherein the recycled pre-reacted aluminum titanate is present in an amount of from 1 to 25 weight percent of the inorganic batch composition.

16. The method of claim 13, wherein the plasticized aluminum titanate precursor batch composition further comprises a pore former.

17. The method of claim 16, wherein the inorganic batch composition further comprises at least one pore former.

18. The method of claim 13, wherein the inorganic batch composition comprises at least one metal oxide sintering aid.

19. The method of claim 18, wherein the metal oxide sintering aid comprises at least one lanthanide oxide source.

20. A method for producing a ceramic article comprised of a sintered phase aluminum titanate composition, comprising the steps of:

providing a plasticized aluminum titanate precursor batch composition comprising;

an inorganic batch composition containing a recycled pre-reacted aluminum titanate composition containing a strontium carbonate source and a calcium carbonate source;

an organic binder; and

a liquid vehicle;

wherein the recycled pre-reacted aluminum titanate composition comprises particles having a median particle diameter in the range of about 8 μ

m to about 55 μ

m;

forming an extruded green body from the plasticized aluminum titanate precursor batch composition; and

firing the formed green body under conditions effective to convert the aluminum titanate precursor composition into a ceramic composition comprising a sintered phase aluminum titanate.

21. The method of claim 20, wherein the inorganic batch composition further comprises at least one pore former and/or at least one sintering aid.

22. The method of claim 20, wherein the inorganic batch composition consists essentially of 100% by weight of a recycled pre-reacted aluminum titanate composition.