CORDIERITE ALUMINUM MAGNESIUM TITANATE COMPOSITIONS AND CERAMIC ARTICLES COMPRISING SAME

• US 20160229750A1
• Filed: 02/05/2015
• Published: 08/11/2016
• 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
• Granted Patent: US 10,501,375 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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:

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

a second phase comprising cordierite.

2. The ceramic article of claim 1, further comprising a sintering aid.

3. The ceramic article of claim 2, 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.

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

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

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

7. The ceramic article of claim 6, 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.

8. The ceramic article of claim 6, further comprising a washcoat.

9. The ceramic article of claim 1 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; and

from 5 to 25% SiO₂.

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

m to 30 μ

m.

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

12. The diesel particulate filter of claim 11, further comprising a washcoat.

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

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

15. A method of manufacturing a ceramic article, comprising:

mixing an inorganic batch composition comprising a magnesia source, a silica source, an alumina source, and a titania source together with one or more processing aid selected from the group consisting of a plasticizer, lubricant, binder, pore former, and solvent, to form a plasticized ceramic precursor batch composition;

shaping the plasticized ceramic precursor batch composition into a green body; and

firing the green body under conditions effective to convert the green body into a ceramic article comprising a pseudobrookite phase comprising predominately alumina, magnesia, and titania and a second phase comprising cordierite.

16. The method of claim 15, further comprising, adding at least one sintering aid to the inorganic batch composition.

17. The method of claim 16, wherein the sintering aid comprises at least one of a lanthanide oxide and yttrium oxide.

18. The method of claim 17, wherein the lanthanide oxide comprises at least one of lanthanum oxide and cerium oxide.

19. The method of claim 16, wherein the at least one 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.

20. The method of claim 15, wherein the plasticized ceramic precursor batch composition is shaped by extrusion.

21. The method of claim 15, wherein the firing conditions effective to convert the green body into a ceramic article comprise heating the green body at a maximum soak temperature in the range of from 1250°

C. to 1450°

C. and maintaining the maximum soak temperature for a hold time sufficient to convert the green body into a ceramic article.

22. The method of claim 15, further comprising at least one of end-plugging and washcoating the ceramic article.

23. A method of treating exhaust gas, comprising:

flowing exhaust gas through a ceramic article, the ceramic article comprising;

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

a second phase comprising cordierite.