Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same

Patent metadata

Field	Value
Publication number	US-10450233-B2
Application number	US-201514614910-A
Country	US
Kind code	B2
Filing date	Feb 5, 2015
Priority date	Jun 30, 2006
Publication date	Oct 22, 2019
Grant date	Oct 22, 2019

Abstract

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

First claim

The invention claimed is:

1. A method of manufacturing a ceramic article, comprising:
mixing an inorganic batch composition comprising, as expressed in weight percent on an oxide basis, from 4% to 10% of a magnesia source, from 5% to 25% of a silica source, from 40% to 55% of an alumina source, and from 25% to 35% of 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.

2. The method of claim 1 , further comprising, adding at least one sintering aid to the inorganic batch composition.

3. The method of claim 2 , wherein the sintering aid comprises at least one of a lanthanide oxide and yttrium oxide.

4. The method of claim 3 , wherein the lanthanide oxide comprises at least one of lanthanum oxide and cerium oxide.

5. The method of claim 2 , 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.

6. The method of claim 1 , wherein the plasticized ceramic precursor batch composition is shaped by extrusion.

7. The method of claim 1 , 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.

8. The method of claim 1 , further comprising at least one of end-plugging and washcoating the ceramic article.

9. The method of claim 1 , wherein the ceramic article comprises a honeycomb structure having an inlet end and an outlet end, and a multiplicity of cells extending from the inlet end to the outlet end, and wherein the honeycomb structure comprises the pseudobrookite phase and the second phase comprising cordierite.

10. The method of claim 1 , wherein the ceramic article comprises a total porosity greater than 40% by volume and a coefficient of thermal expansion of less than or equal to 15×10 −7 /° C. as measured between 25° C. and 1000° C.

11. The method of claim 1 , wherein the ceramic article comprises at least about 50 wt % of the pseudobrookite phase comprising predominately alumina, magnesia, and titania.

Assignees

• Corning Inc

Inventors

• Divens-Dutcher Adriane Marie
• Merkel Gregory Albert
• Tepesch Patrick David
• Vileno Elizabeth Marie
• Wusirika Raja Rao

Classifications

• C04B2235/3481

  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 title

• C04B2235/5436

  micrometer sized, i.e. from 1 to 100 micron · CPC title

• C04B2235/3236

  Alkaline earth titanates · CPC title

• C04B2235/3418

  Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint · CPC title

• C04B35/44 Primary

  based on aluminates · CPC title