Fused silica based cellular structures

Patent metadata

Field	Value
Publication number	US-10370304-B2
Application number	US-201314073020-A
Country	US
Kind code	B2
Filing date	Nov 6, 2013
Priority date	Nov 29, 2012
Publication date	Aug 6, 2019
Grant date	Aug 6, 2019

Abstract

A porous cellular body comprising primarily a porous sintered glass material is disclosed. The porous sintered glass material primarily includes a first phase and a second phase, the first phase primarily comprising amorphous fused silica and the second phase comprising amorphous fused silica and a sintering aid.

First claim

What is claimed is:

1. An exhaust aftertreatment component comprising:
a porous honeycomb body comprising a plurality of cells, where the porous honeycomb body comprises primarily a porous sintered glass material having a total porosity of at least 20%, the porous sintered glass material primarily comprising a first phase and a second phase,
wherein the first phase comprises at least 97% by weight of bonded amorphous silica particles and the second phase comprises at least 50% by weight of amorphous silica and at least 6% by weight of a sintering aid material, wherein the sintering aid material is a boron-containing compound, and
wherein the first phase and the second phase collectively comprise at least 85% by weight of amorphous silica; and
wherein the exhaust aftertreatment component comprises at least one of a particulate filter and a substrate for supporting a catalyst.

2. The exhaust aftertreatment component of claim 1 , wherein the weight ratio of the first phase to the second phase is at least 1.5:1.

3. The exhaust aftertreatment component of claim 1 , wherein the porous sintered glass material has a median pore diameter (d 50 ) of at least 0.5 microns.

4. The exhaust aftertreatment component of claim 1 , wherein the porous cellular body has a CTE (25-800° C.) of less than 8.0×10 −7 /° C. and a modulus of rupture (MOR) of at least 1,000 psi.

5. The exhaust aftertreatment component of claim 1 , wherein the porous sintered glass material comprises less than 0.1% by weight of Na 2 O.

6. The exhaust aftertreatment component of claim 1 , wherein the second phase contains at least 15% by weight of the sintering aid material.

7. The exhaust aftertreatment component of claim 1 , wherein the second phase contains 10% to 25% by weight of the sintering aid material.

8. The exhaust aftertreatment component of claim 1 , wherein the second phase comprises 50% to 92% by weight of amorphous silica.

9. The exhaust aftertreatment component of claim 1 , wherein the second phase comprises at least 65% by weight of amorphous silica.

10. The exhaust aftertreatment component of claim 1 , wherein the first phase comprises less than 3% by weight of sintering aid material.

11. An exhaust aftertreatment component made by a process comprising:
compounding a plurality of batch constituents to form a precursor batch composition, the batch constituents comprising amorphous fused silica powder and a sintering aid selected from the group consisting of B 2 O 3 and H 3 BO 3 ;
forming the precursor batch composition into a cellular green body comprising a porous honeycomb body comprising a plurality of cells; and
subjecting the cellular green body to a heat treatment to make a porous cellular body;
wherein the porous cellular body comprises primarily a porous sintered glass material comprising primarily a first phase and a second phase,
wherein the first phase comprises at least 97% by weight of amorphous silica and the second phase comprises at least 50% by weight of amorphous silica and at least 6% by weight of a sintering aid;
wherein the first phase and the second phase collectively comprise at least 85% by weight of amorphous silica;
wherein the porous sintered glass material has a total porosity of at least 20%; and
wherein the exhaust aftertreatment component comprises at least one of a particulate filter and a substrate for supporting a catalyst.

12. The exhaust aftertreatment component of claim 11 , wherein the porous sintered glass material has a median pore diameter (d 50 ) of at least 0.5 microns.

13. The exhaust aftertreatment component of claim 11 , wherein the amorphous fused silica of the batch constituents has a median particle size of from 0.5 to 200 microns.

14. The exhaust aftertreatment component of claim 11 , wherein the porous cellular body has a CTE (25-800° C.) of less than 8.0×10 −7 /° C. and a modulus of rupture (MOR) of at least 1,000 psi.

15. The exhaust aftertreatment component of claim 11 , wherein the heat treatment is a single heat treatment having a total duration of less than 20 hours.

16. The exhaust aftertreatment component of claim 11 , wherein the second phase comprises 50% to 92% by weight of amorphous silica.

17. The exhaust aftertreatment component of claim 11 , wherein the second phase comprises at least 65% by weight of amorphous silica.

Assignees

• Corning Inc

Inventors

• Beall Douglas Munroe
• Tanner Cameron Wayne

Classifications

• Y10T428/24157

  Filled honeycomb cells [e.g., solid substance in cavities, etc.] · CPC title

• C03B19/066

  for the production of quartz or fused silica articles (other processes specially adapted for the production of quartz or fused silica articles C03B20/00) · CPC title

• C04B38/0006

  Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083) · CPC title

• C03B19/08

  by foaming · CPC title

• B01D39/2003

  Glass or glassy material · CPC title