Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same

• US 10,501,375 B2
• Filed: 02/05/2015
• Issued: 12/10/2019
• Est. Priority Date: 06/30/2006
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Divens-Dutcher, Adriane Marie, Merkel, Gregory Albert, Tepesch, Patrick David, Vileno, Elizabeth Marie, Wusirika, Raja Rao
• Primary Examiner(s): Orlando, Amber R
• Application Number:
  US14/614,945
• Publication Number:
  US 20160229750A1
• Time in Patent Office: 1,769 Days
• CPC Class Codes: B01D 2239/1208 Porosity apparatus incorporating such gas filtering material B01D2275/30 - B01D2275/307
• CPC Class Codes: B01D 2255/40 Mixed oxides
• CPC Class Codes: B01D 2258/012 Diesel engines and lean burn gasoline engines
• CPC Class Codes: B01D 39/2075 sintered or bonded by inorganic agents
• CPC Class Codes: B01D 53/94 by catalytic processes
• CPC Class Codes: B01D 53/944 Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts three-way-catalysts [TWC] B01D53/9445
• CPC Class Codes: B01J 21/10 Magnesium; Oxides or hydroxides thereof
• CPC Class Codes: B01J 23/02 of the alkali- or alkaline earth metals or beryllium
• CPC Class Codes: B01J 23/10 of rare earths
• CPC Class Codes: B01J 2523/00 Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/22 Magnesium
• CPC Class Codes: B01J 2523/31 Aluminium
• CPC Class Codes: B01J 2523/36 Yttrium
• CPC Class Codes: B01J 2523/3706 Lanthanum
• CPC Class Codes: B01J 2523/3712 Cerium
• CPC Class Codes: B01J 2523/41 Silicon
• CPC Class Codes: B01J 2523/47 Titanium
• CPC Class Codes: B01J 35/19 Catalysts containing parts with different compositions
• CPC Class Codes: B01J 35/30 characterised by their physical properties
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 35/60 : characterised by their surface properties or porosity
• CPC Class Codes: B01J 37/0018 : Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)
• CPC Class Codes: B01J 37/04 : Mixing B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: B01J 37/08 : Heat treatment B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: B01J 37/082 : Decomposition and pyrolysis
• CPC Class Codes: C04B 2111/00793 : as filters or diaphragms
• CPC Class Codes: C04B 2111/0081 : as catalysts or catalyst carriers
• CPC Class Codes: C04B 2235/3206 : Magnesium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3224 : Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
• 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 2235/3236 : 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 2235/3481 : 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 2235/80 : 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 2235/9615 : Linear firing shrinkage
• 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
• 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: C04B 38/068 : Carbonaceous materials, e.g. coal, carbon, graphite, hydrocarbons

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 honeycomb monolith structure having an inlet end and an outlet end, and a multiplicity of cells formed by walls extending from the inlet end to the outlet end, wherein each of the walls of the honeycomb monolith structure comprises;

at least about 50 wt % of a pseudobrookite phase comprising predominately alumina, magnesia, and titania;

a second phase comprising cordierite; and

a sintering aid;

wherein the article has 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; and

from 5% to 25% SiO₂, and

wherein the honeycomb monolith structure further comprises;

median pore diameter d₅₀ of at least 10 μ

m, and

d_f that does not exceed 0.50.

2. The ceramic article of claim 1, wherein the sintering aid is present, on a weight percent oxide basis, in an amount in the range of from greater than 0.1 to 5 weight % relative to the total weight of the inorganic batch composition.

3. The ceramic article of claim 1, further comprising a sintering aid, comprising at least one of a lanthanide oxide and yttrium oxide.

4. The ceramic article of claim 3, wherein the lanthanide oxide comprises a cerium oxide.

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

6. The ceramic article of claim 5, wherein the ceramic article comprises a coefficient of thermal expansion, as measured between 25-1000°

C., less than or equal to 14×

10<sup>−

7</sup>/°

C.

7. The ceramic article of claim 5, further comprising a washcoat.

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

m to 30 μ

m.

9. A diesel particulate filter comprising the ceramic article of claim 1.

10. The diesel particulate filter of claim 9, further comprising a washcoat.

11. A flow through substrate comprising the ceramic article of claim 1.

12. A catalytic flow through substrate comprising the ceramic article of claim 1.

13. The ceramic article of claim 1, wherein the article has a composition, as expressed in weight percent on an oxide basis, of from 0 to 3% Fe₂O₃.

14. The ceramic article of claim 1, wherein the walls of the honeycomb monolith structure have a composition, as expressed in weight percent on an oxide basis, of:

a(Al₂TiO₅)+b(MgTi₂O₅)+c(2MgO.2Al₂O₃.5SiO₂)+d(3Al₂O₃.2SiO₂)+e(MgO.Al₂O₃)+f(2MgO.TiO₂)+g(Y₂O₃)+h(La₂O₃)+i(Fe₂O₃.TiO₂)+j(TiO₂);

wherein a, b, c, d, e, f, g, h, i, and j are weight fractions of each component such that (a+b+c+d+e+f+g+h+i+j)=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≤

0.05, 0.0≤

h≤

0.05, 0.0≤

i≤

0.05, and 0.0≤

j≤

0.20.

15. The ceramic article of claim 1, wherein the Al₂O₃ component of the composition, as expressed in weight percent on an oxide basis, is from 42% to 55%.

16. The ceramic article of claim 1, comprising:

CTE (25°

C.-1000°

C.) not exceeding 12×

10<sup>−

7</sup>/°

C.;

total porosity % P of at least 45% by volume;

the median pore diameter d₅₀ is at least 14 μ

m; and

the d_f is not more than 0.35.

17. The ceramic article of claim 1, comprising:

CTE (25°

C.-1000°

C.) does not exceed 18×

10<sup>−

7</sup>/°

C.; and

the total porosity % P is at least 60% by volume.

18. The ceramic article of claim 1, comprising:

CTE (25°

C.-1000°

C.) does not exceed 12×

10<sup>−

7</sup>/°

C.; and

total porosity % P is at least 60% by volume.

19. The ceramic article of claim 1, wherein d_b does not exceed 1.0.

20. The ceramic article of claim 1, wherein the ceramic article is a particulate filter comprising:

CTE (25°

C.-1000°

C.) from 6×

10<sup>−

7</sup>/°

C. to 20×

10<sup>−

7</sup>/°

C.);

total porosity % P of from 44% to 52% by volume;

the median pore diameter d₅₀ ranges from 15 μ

m to 27 μ

m; and

the d_f ranges from 0.24 to 0.45.

21. The ceramic article of claim 1, comprising:

CTE (25°

C.-1000°

C.) of from 10×

10<sup>−

7</sup>/°

C. to 14×

10<sup>−

7</sup>/°

C.;

the median pore diameter d₅₀ ranges from 16 μ

m to 22 μ

m; and

the d_f ranges from 0.17 to 0.31.

22. The ceramic article of claim 1, comprising a third phase of mullite.

23. The ceramic article of claim 1, comprising a third phase of mullite and another phase of sapphirine.

24. A ceramic article, comprising:

a honeycomb monolith structure having an inlet end and an outlet end, and a multiplicity of cells formed by porous walls extending from the inlet end to the outlet end, wherein the porous walls of the honeycomb monolith structure further comprise;

at least about 50 wt % of a pseudobrookite phase comprising predominately alumina, magnesia, and titania and including 15 wt % to 35 wt % of MgTiO₅;

a second phase comprising cordierite;

a third phase comprising mullite, and

wherein the porous walls of the honeycomb monolith structure comprise 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; and

from 5% to 25% SiO₂, and

wherein the honeycomb monolith structure further comprises;

a coefficient of thermal expansion, as measured between 25°

C.-1000°

C., of less than or equal to 14×

10<sup>−

7</sup>/°

C.;

total porosity % P of at least 40% by volume;

median pore diameter d₅₀ of at least 10 μ

m; and

d_f that does not exceed 0.50.