Ceramic composite beads and methods for making same

Patent metadata

Field	Value
Publication number	US-10029939-B2
Application number	US-201514633695-A
Country	US
Kind code	B2
Filing date	Feb 27, 2015
Priority date	Feb 27, 2015
Publication date	Jul 24, 2018
Grant date	Jul 24, 2018

Abstract

Methods for making a ceramic or glass-ceramic include spray-drying a mixture comprising batch materials to form agglomerated particles; bringing the agglomerated particles into contact with a plasma for a residence time sufficient to form fused particles; and annealing the fused particles at a temperature and for a time sufficient to form ceramic or glass-ceramic particles. The methods can be used to produce fused glass particles, ceramic or glass-ceramic particles, and ceramic or glass-ceramic articles, such as ceramic honeycombs.

First claim

What is claimed is:

1. A fused glass particle having an average particle size ranging from about 10 microns to about 50 microns, comprising silica and alumina in a combined amount of greater than about 45 wt %, and comprising less than about 5% crystalline phase, wherein the fused glass particle is substantially homogeneous, and wherein the fused glass particle has a T g of at least about 1600° C.

2. A ceramic or glass-ceramic article made from at least one fused glass particle of claim 1 and comprising less than 5% residual glass phase.

3. The ceramic or glass-ceramic article of claim 2 , wherein the ceramic or glass-ceramic article has a porosity of at least about 40%.

4. The ceramic or glass-ceramic article of claim 2 , wherein the CTE of the ceramic or glass-ceramic article is less than about 20×10 −7 K −1 at a temperature ranging from 20° C. to 800° C.

5. The ceramic or glass-ceramic article of claim 2 , wherein the ceramic or glass-ceramic article has a microcrack factor ranging from about 0.1 to about 8.

6. The ceramic or glass-ceramic article of claim 2 , wherein the ceramic or glass-ceramic article comprises less than about 1% residual glass phase.

7. The ceramic or glass-ceramic article of claim 2 , wherein the ceramic or glass-ceramic article is a honeycomb.

Assignees

• Corning Inc

Inventors

• Backhaus-Ricoult Monika
• Boughton Daniel Robert
• Heine Jennifer Anella

Classifications

• C04B35/185

  Mullite {3Al2O3-2SiO2} · CPC title

• C04B35/443 Primary

  Magnesium aluminate spinel · CPC title

• C01G23/003 Primary

  Titanates (C01G23/001 takes precedence) · CPC title

• C04B35/62655

  Drying, e.g. freeze-drying, spray-drying, microwave or supercritical drying · CPC title

• C04B35/62675

  characterised by the treatment temperature · CPC title