Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same

• US 9,079,799 B2
• Filed: 11/30/2012
• Issued: 07/14/2015
• Est. Priority Date: 11/30/2012
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Divens-Dutcher, Adriane Marie, Tepesch, Patrick David, Vileno, Elizabeth Marie
• Primary Examiner(s): ORLANDO, AMBER ROSE
• Application Number:
  US13/690,096
• Publication Number:
  US 20140150389A1
• Time in Patent Office: 956 Days
• Field of Search: 55522-524, 422169-172, 422177-182
• US Class Current: 1/1
• CPC Class Codes: B01D 46/2429 of the honeycomb walls or cells
• CPC Class Codes: B01D 46/24491 Porosity
• CPC Class Codes: B01D 46/24492 Pore diameter
• CPC Class Codes: B01D 46/24494 Thermal expansion coefficient, heat capacity or thermal conductivity
• CPC Class Codes: C04B 2111/00793 as filters or diaphragms
• CPC Class Codes: C04B 2235/3206 Magnesium oxides or oxide-forming salts thereof
• 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 2235/3225 Yttrium oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3227 Lanthanum oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3229 Cerium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3232 Titanium oxides or titanates, e.g. rutile or anatase
• CPC Class Codes: C04B 2235/3236 Alkaline earth titanates
• 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 2235/3463 Alumino-silicates other than clay, e.g. mullite
• CPC Class Codes: C04B 2235/3481 Alkaline earth metal alumino-silicates other than clay, e.g. cordierite, beryl, micas such as margarite, plagioclase feldspars such as anorthite, zeolites such as chabazite
• CPC Class Codes: C04B 2235/349 Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
• CPC Class Codes: C04B 2235/422 Carbon
• CPC Class Codes: C04B 2235/425 Graphite
• CPC Class Codes: C04B 2235/6567 : Treatment time
• CPC Class Codes: C04B 2235/77 : Density
• CPC Class Codes: C04B 2235/80 : Phases present in the sintered or melt-cast ceramic products other than the main phase
• CPC Class Codes: C04B 2235/9607 : Thermal properties, e.g. thermal expansion coefficient
• CPC Class Codes: C04B 35/195 : Alkaline earth aluminosilicates, e.g. cordierite or anorthite
• CPC Class Codes: C04B 35/478 : based on aluminium titanates
• CPC Class Codes: C04B 38/0006 : Honeycomb structures from one or more corrugated sheets by winding or stacking C04B38/0083

Abstract

Disclosed are ceramic bodies comprised of composite cordierite aluminum magnesium titanate ceramic compositions and methods for the manufacture of same.

Claims

1. A ceramic article comprising a first crystalline phase comprised predominantly of a solid solution of aluminum titanate and magnesium dititanate and a second crystalline phase comprising cordierite, the article having a composition, as expressed in weight percent on an oxide basis of from 4 to 10% MgO;

from 40 to 55% Al₂O₃;

from 25 to 44% TiO₂;

from 5 to 25% SiO₂, and a sintering aid, the sintering aid-comprising;

at least one of (i) calcium oxide in an amount ranging from 0.15 to 1.0 wt % and (ii) strontium oxide in an amount ranging from 0.1 to 2.0 wt %; and

at least one of (iii) a yttrium oxide, (iv) a lanthanum oxide, and (v) a cerium oxide, wherein the total amount of (iii)-(v) ranges up to 4.75 wt %.

2. The ceramic article of claim 1, wherein the sintering aid comprises a cerium oxide.

3. The ceramic article of claim 2, wherein the sintering aid comprises at least one of a yttrium oxide and a lanthanum oxide.

4. The ceramic article of claim 1 having a composition expressed on an oxide basis of:

a(Al₂TiO₅)+b(MgTi₂O₅)+c(2MgO.2Al₂O₃.5SiO₂)+d(3Al₂O₃.2SiO₂)+e(MgO.Al₂O₃)+f(2MgO.TiO₂)+g(CaO)+h(SrO)+i(X)+j(Fe₂O₃TiO₂)+k(TiO₂)+l(Al₂O₃), wherein X is at least one of CeO₂, Y₂O₃, and La₂O₃, and a, b, c, d, e, f, g, h, i, j, k, and I are weight fractions of each component such that (a+b+c+d+e+f+g+h+i+j+k+l)=1.00, and wherein 0.3≦

a≦

0.75, 0.075≦

b≦

0.3, 0.02≦

c≦

0.5, 0.0≦

d≦

0.4, 0.0≦

e≦

0.25, 0.0≦

f≦

0.1, 0.0≦

g≦

0.01, 0.0≦

h≦

0.02, 0.0015≦

(g+h), 0.00<

i≦

0.0475, 0.0≦

j≦

0.05, 0.0≦

k≦

0.2, and 0.0≦

l≦

0.1.

5. The ceramic article of claim 4, wherein 0.0025≦

g≦

0.0075.

6. The ceramic article of claim 4, wherein 0.005≦

h≦

0.015.

7. The ceramic article of claim 4, wherein the sintering aid comprises a cerium oxide.

8. The ceramic article of claim 6, wherein the sintering aid comprises at least one of yttrium oxide and a lanthanum oxide.

9. The ceramic article of claim 1, wherein the ceramic article comprises a total porosity % P greater than 40% by volume.

10. The ceramic article of claim 9, wherein the ceramic article comprises a coefficient of thermal expansion, as measured between 25-1000°

C., of less than or equal to 14×

10<sup>−

7</sup>/°

C.

11. The ceramic article of claim 1, wherein the sintering aid is present, on a weight percent oxide basis, in an amount in a range of 0.15 to 2 weight % relative to the total weight of the inorganic batch composition.

12. The ceramic article of claim 1 having a composition, as expressed in weight percent on an oxide basis:

of 5 to 10% MgO;

40 to 50% Al₂O₃;

30 to 35% TiO₂; and

10 to 20% SiO₂.

13. The ceramic article of claim 1, comprising a median pore size d₅₀ in a range of 10 μ

m to 30 μ

m.

14. The ceramic article of claim 13, comprising a median pore size d₅₀ in the range of from 15 μ

m to 25 μ

m.

15. A diesel particulate filter comprising the ceramic article of claim 1, wherein said diesel particulate filter comprises a honeycomb structure having a plurality of axially extending end-plugged inlet and outlet cells.