Porous article and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-11229902-B2
Application number	US-201716304853-A
Country	US
Kind code	B2
Filing date	May 31, 2017
Priority date	May 31, 2016
Publication date	Jan 25, 2022
Grant date	Jan 25, 2022

Abstract

The present disclosure relates to porous ceramic articles and a method of making the same. The porous ceramic articles have a porosity (P) as a fraction in a range of about 0.3 to about 0.7; a permeability factor PQ>0.025, wherein PQ is (K bulk )/(P·d 50 2 ), K bulk being bulk permeability in Darcy, and d 50 being the mean pore size in micrometers (μm); a tortuosity in a range of about 1.8 to 3; and a median pore size diameter d 50 in a range of about 10 μm to about 35 μm. The porous ceramic articles can have an interconnected bead microstructure comprising beads and bead connections, PQ is directly proportional to bead size, and wherein in a random cross section through the body, the beads appear as globular portions.

First claim

What is claimed is:

1. A porous ceramic body, comprising:
an interconnected bead microstructure comprising bead portions and bead connection portions, wherein adjacent bead portions are connected by the bead connection portions;
a porosity (P) as a fraction in a range of about 0.3 to about 0.7;
a permeability factor PQ>0.025, wherein PQ is (K bulk )/(P·d 50 2 ), K bulk being bulk permeability in Darcy, and d 50 being the mean pore size in micrometers (μm);
a tortuosity in a range of about 1.8 to 3; and
a median pore size diameter d 50 in a range of about 10 μm to about 25 μm;
wherein PQ is directly proportional to bead size, and
wherein in a random cross section through the body, the bead portions appear as globular.

2. The body of claim 1 , wherein PQ>0.05.

3. The body of claim 1 , wherein a median bead portion diameter (D bead ) of the bead portions is in a range of about 14 μm<D bead ≤50 μm.

4. The body of claim 1 , comprising at least one of aluminum titanate, pseudobrookite, cordierite, feldspar, glass, and mullite.

5. The ceramic body of claim 1 , comprising: a plurality of porous ceramic channel walls extending axially from opposing first and second end faces defining channels therebetween; and an outer peripheral surface extending axially.

6. The body of claim 5 , further comprising plugs disposed in a portion of the cell channels forming at least one of a particulate filter and a partial particulate filter.

7. The body of claim 5 , further comprising at least one of a catalyst coating disposed in channel walls and a catalyst coating disposed on channel walls.

8. A porous ceramic body comprising:
an interconnected bead microstructure comprising bead portions and bead connection portions wherein adjacent bead portions are connected by the bead connection portions;
a porosity (P) as a fraction in a range of about 0.3 to about 0.7;
a permeability factor PQ>0.025, wherein PQ is (K bulk )/(P·d 50 2 ), K bulk being bulk permeability in Darcy, and d 50 being the mean pore size in micrometers (μm);
a tortuosity in a range of about 1.8 to 3; and
a median pore size diameter d 50 in a range of about 10 μm to about 25 μm;
wherein PQ is inversely proportional to bead overlap, bead overlap being fraction of radial interference between adjacent connected bead portions,
wherein in a random cross section through the body, the bead portions appear as globular.

9. A porous ceramic body comprising:
a porosity (P) as a fraction in a range of about 0.3 to about 0.7;
a permeability factor PQ>0.025, wherein PQ is (K bulk )/(P·d 50 2 ), K bulk being bulk permeability in Darcy, and d 50 being the mean pore size in micrometers (μm);
a tortuosity in a range of about 1.8 to 3; and

a median pore size diameter d 50 in a range of about 10 μm to about 25 μm;
wherein a ratio of through-wall permeability K TW to bulk permeability K bulk is greater than 0.9 (K TW /K bulk >0.9).

10. The body of claim 9 , wherein K TW /K bulk >0.99.

11. A porous ceramic body comprising:
an interconnected bead microstructure, comprising:
bead portions;
bead connection portions, wherein adjacent bead portions are connected by the bead connection portions;

a porosity (P) as a fraction in a range of about 0.3 to about 0.7;
a permeability factor PQ>0.025, wherein PQ is (K bulk )/(P·d 50 2 ), K bulk being bulk permeability in Darcy, and d 50 being the mean pore size in micrometers (μm);
a tortuosity in a range of about 1.8 to 3; and
a median pore size diameter d 50 in a range of about 10 μm to about 25 μm; and
a bead overlap of less than about 0.5, the bead overlap being a fraction of radial interference between adjacent connected bead portions,
wherein the bead portions comprise inorganic, reaction-sintered spheres, and
wherein in a random cross section through the body, the bead portions appear as globular.

12. The body of claim 11 , wherein the inorganic, reaction-sintered spheres comprise oxides comprised of at least one crystalline phase and a glassy phase.

13. The body of claim 12 , wherein the crystalline phase comprises at least one of pseudobrookite, cordierite, mullite, spinel, strontium, aluminum feldspar, beta-spodumene, and beta-eucryptite.

14. The body of claim 11 , wherein the inorganic, reaction-sintered spheres are comprised of at least one of alumina, titania, silica, rare earth, SiC, SiN, and alkaline earth oxides.

15. The body of claim 11 , wherein each bead connection portion comprises binder on less than 50% of surfaces of the bead portions and the bead microstructure further comprises pores.

16. The body of claim 11 , wherein the bead microstructure further comprises pores between surfaces of the bead portions.

17. The body of claim 11 , wherein the bead overlap is less than about 0.2.

18. The body of claim 11 , wherein the bead overlap is less than about 0.05.

19. A porous body, comprising:
a porosity (P) as a fraction in a range of about 0.3 to about 0.4;
a permeability (K) greater than or equal to about 0.017·P·d 50 2 , where d 50 is the mean pore size;
a tortuosity in a range of about 2 to 5; and
a median pore size diameter d 50 as measured by mercury porosimetry in a range of about 10 μm to about 35 μm.

Assignees

• Corning Inc

Inventors

• Backhaus-Ricoult Monika
• Tsvetkov Boris Nikolayevich

Classifications

• B01D46/2429 Primary

  of the honeycomb walls or cells · CPC title

• B01J35/57

  Honeycombs · CPC title

• B01D46/24491

  Porosity · CPC title

• B01D46/2425

  characterized by parameters related to the physical properties of the honeycomb structure material · CPC title

• B01D46/24492

  Pore diameter · CPC title