High cordierite-to-mullite ratio cordierite-mullite-aluminum magnesium titanate compositions and ceramic articles comprising same

Patent metadata

Field	Value
Publication number	US-11078121-B2
Application number	US-201715834839-A
Country	US
Kind code	B2
Filing date	Dec 7, 2017
Priority date	Sep 23, 2013
Publication date	Aug 3, 2021
Grant date	Aug 3, 2021

Abstract

Disclosed are ceramic bodies comprised of composite cordierite-mullite-aluminum magnesium titanate (CMAT) ceramic compositions having high cordierite-to-mullite ratio and methods for the manufacture of same.

First claim

What is claimed is:

1. A method of manufacturing a ceramic article, comprising:
providing an inorganic batch composition comprising a magnesia source, a silica source, an alumina source, a titania source, and at least one sintering aid;
mixing the inorganic batch composition together with one or more processing aids comprising at least one of a plasticizer, lubricant, binder, pore former, and solvent to form a ceramic precursor batch composition;
shaping the 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 alumina, magnesia, and titania, a second phase comprising cordierite, and a third phase comprising mullite,
wherein the cordierite-to-mullite phase ratio is greater than or equal to 1.3 and less than or equal to 2.5.

2. The method of claim 1 , wherein the cordierite-to-mullite phase ratio is greater than or equal to 1.8 and less than or equal to 2.2.

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

4. 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 hold temperature in the range of 1250° C. to 1450° C. and maintaining the hold temperature for a hold time sufficient to convert the green body into the ceramic article.

5. A method of manufacturing a ceramic article, comprising:
providing an inorganic batch composition comprising a magnesia source, a silica source, an alumina source, a titania source, and at least one sintering aid;
mixing the inorganic batch composition together with one or more processing aids comprising at least one of a plasticizer, lubricant, binder, pore former, and solvent to form a ceramic precursor batch composition;
shaping the 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 alumina, magnesia, and titania, a second phase comprising cordierite, and a third phase comprising mullite,
wherein the cordierite-to-mullite phase ratio is greater than or equal to 1.3 and less than or equal to 7.

6. A method of manufacturing a ceramic article, comprising:
providing an inorganic batch composition comprising a magnesia source, a silica source, an alumina source, a titania source, and at least one sintering aid;
mixing the inorganic batch composition together with one or more processing aids comprising at least one of a plasticizer, lubricant, binder, pore former, and solvent to form a ceramic precursor batch composition;
shaping the 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 alumina, magnesia, and titania, a second phase comprising cordierite, and a third phase comprising mullite,
wherein the cordierite-to-mullite phase ratio is greater than or equal to 1.3 and less than or equal to 4.

Assignees

• Corning Inc

Inventors

• Backhaus-Ricoult Monika
• Tepesch Patrick David
• Wheaton Bryan Ray

Classifications

• C04B35/478 Primary

  based on aluminium 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

• C04B2235/5436

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

• C04B2235/3229

  Cerium oxides or oxide-forming salts thereof · CPC title

• F01N3/08

  for rendering innocuous (using electric or electrostatic separators F01N3/01; chemical aspects B01D53/92) · CPC title