Cordierite-indialite-pseudobrookite structured ceramic bodies, batch composition mixtures, and methods of manufacturing ceramic bodies therefrom

Patent metadata

Field	Value
Publication number	US-11891339-B2
Application number	US-201917271988-A
Country	US
Kind code	B2
Filing date	Aug 29, 2019
Priority date	Aug 31, 2018
Publication date	Feb 6, 2024
Grant date	Feb 6, 2024

Abstract

A ceramic body exhibiting % P≥50%, df≤0.36, and a combined weight percentage of crystalline phases containing cordierite and indialite of at least 85 wt %, and up to 10 wt % of a crystalline pseudobrookite structured phase, such as armalcolite. The ceramic body contains, as expressed on an oxide basis, either: 1% wt % to 11% wt % titania and 89% wt % to 99% wt % MgO, Al 2 O 3 , and SiO 2 that have relative weight ratios of MgO:Al 2 O 3 :SiO 2 within the field defined by 15.6:34.0:50.4, 12.6:34.0:53.4, 13.9:30.7:55.4, and 16.9:30.7:52.4, or 2.5% to 11% titania and 89% wt % to 97.5% wt % MgO, Al 2 O 3 , and SiO 2 that have relative weight ratios of MgO:Al 2 O 3 :SiO 2 within the field defined by 15.6:34.0:50.4, 12.6:34.0:53.4, 12.0:35.7:52.3, and 15.0:35.7:49.3. Batch composition mixtures and methods of manufacturing ceramic bodies using the batch compositions are provided, as are other aspects.

First claim

What is claimed is:

1. A ceramic body, comprising:
% P≥50%, wherein % P is average bulk porosity by volume;
df≤0.36, wherein df is (d 50 -d 10 )/d 50 ;
a combined weight percentage of crystalline phases containing cordierite and indialite of at least 85 wt %;
up to 10 wt % of a crystalline phase comprising a pseudobrookite structure,
wherein the ceramic body contains, as expressed in weight percent on an oxide basis, either:
1% wt % to 11% wt % titania and 89% wt % to 99% wt % MgO, Al 2 O 3 , and SiO 2 that have relative weight ratios of MgO:Al 2 O 3 :SiO 2 within the field defined by 15.6:34.0:50.4, 12.6:34.0:53.4, 13.9:30.7:55.4, and 16.9:30.7:52.4, or
2.5% to 11% titania and 89% wt % to 97.5% wt % MgO, Al 2 O 3 , and SiO2 that have relative weight ratios of MgO:Al 2 O 3 :SiO 2 within the field defined by 15.6:34.0:50.4, 12.6:34.0:53.4, 12.0:35.7:52.3, and 15.0:35.7:49.3.

2. The ceramic body of claim 1 , comprising 50%≤% P≤72%.

3. The ceramic body of claim 1 , comprising 65%≤% P≤72%.

4. The ceramic body of claim 1 , comprising df≤0.22.

5. The ceramic body of claim 1 , comprising 0.16≤df≤0.20.

6. The ceramic body of claim 1 , comprising 7 μm≤d 50 ≤20 μm, wherein d 50 is a median pore size of the ceramic article.

7. The ceramic body of claim 6 , comprising 10 μm≤d 50 ≤20 μm, wherein d 50 is a median pore size of the ceramic article.

8. The ceramic body of claim 6 , comprising 12 μm≤d 50 ≤20 μm, wherein d 50 is a median pore size of the ceramic article.

9. The ceramic body of claim 1 , comprising CTE≤14×10 −7 /° C., wherein CTE is a coefficient of thermal expansion, as measured between 25° C.-800° C.

10. The ceramic body of claim 1 , comprising:
50%≤% P≤72%;
7 μm≤d 50 ≤20 μm, wherein d 50 is a median pore size;
0.16≤df≤0.36; and
3×10 −7 /K≤CTE≤14×10 −7 /K.

11. The ceramic body of claim 1 , comprising:
60%≥% P≥72%;
10 μm≤d 50 ≤20 μm, wherein d 50 is a median pore size;
0.16≤df≤0.25; and
3×10 −7 /° C.≤CTE≤13×10 −7 ° C., wherein CTE is a coefficient of thermal expansion of the ceramic body as measured between 25° C. and 800° C.

12. The ceramic body of claim 1 , comprising:
60%≤% P≤72%;
12 μm≤d 50 ≤20 μm, wherein d 50 is a median pore size of the ceramic body;
0.16≤df≤0.20; and
3×10 −7 /K≤CTE≤12×10 −7 /K, wherein CTE is a coefficient of thermal expansion of the ceramic body as measured between 25° C. and 800° C.

13. The ceramic body of claim 1 , comprising:
60%≤% P≤72%;
13 μm≤d 50 ≤20 μm, wherein d 50 is a median pore size of the ceramic body;
0.16≤df≤0.18; and
3×10 −7 /K≤CTE≤12×10 −7 /K, wherein CTE is a coefficient of thermal expansion of the ceramic body as measured between 25° C. and 800° C.

14. The ceramic body of claim 1 , wherein the combined weight percentage of the crystalline phases of cordierite and indialite range from 85 wt % to 92 wt %.

15. The ceramic body of claim 1 , wherein the pseudobrookite structure comprises a crystalline phase of armalcolite.

16. The ceramic body of claim 15 , wherein the crystalline phase of armalcolite ranges from 2 wt % to 8 wt %.

17. The ceramic body of claim 1 , comprising an amorphous phase of less than 7 wt %.

18. The ceramic body of claim 1 , comprising 2% wt % to 6 wt % titania and 94% wt % to 98% wt % MgO, Al 2 O 3 , and SiO 2 that have relative weight ratios of MgO:Al2O3:SiO2 within the field defined by 14.3:34.9:50.8; 13.3:34.9:51.8; 14.3:32.3:53.4; and 15.3:32.3:52.4.

19. A ceramic body, comprising:
crystalline phases comprising cordierite and indialite with a combined weight percentage ranging between 85 wt % to 92 wt %, and a second crystalline phase of up to 10 wt % of a pseudobrookite structure comprising armalcolite,
wherein the ceramic body contains, as expressed in weight percent on an oxide basis, 1% wt % to 11% wt % titania, and 89% wt % to 99% wt % MgO, Al 2 O 3 , and SiO 2 that have relative weight ratios of MgO:Al 2 O 3 :SiO 2 within the field defined by 15.6:34.0:50.4, 12.6:34.0:53.4, 13.9:30.7:55.4, and 16.9:30.7:52.4;
55%≤% P≤72%;
8 μm≤d 50 ≤20 μm, wherein d 50 is a median pore size;
0.16≤df≤0.32, wherein df is (d 50 -d 10 )/d 50 ; and
3×10 −7 /° C.≤CTE≤14×10 −7 /° C. from 25° C. to 800° C.

20. A ceramic body, comprising:
crystalline phases comprising cordierite and indialite with a combined weight percentage ranging between 85 wt % to 92 wt %, and a second crystalline phase of up to 10 wt % pseudobrookite structure comprising armalcolite, wherein the ceramic body contains, as expressed in weight percent on an oxide basis, 2.5% to 11% titania and 89% wt % to 97.5% wt % MgO, Al 2 O 3 , and SiO 2 that have relative weight ratios of MgO:Al 2 O 3 :SiO 2 within the field defined by 15.6:34.0:50.4, 12.6:34.0:53.4, 12.0:35.7:52.3, and 15.0:35.7:49.3;
55%≤% P≤72%;
8 μm≤d 50 ≤20 μm, wherein d 50 is a median pore size;
0.16≤df≤0.32, wherein df is (d 50 -d 10 )/d 50 ; and
3×10 −7 /° C.≤CTE≤14×10 −7 /° C. from 25° C. to 800° C.

Assignees

• Corning Inc

Inventors

• Sarma Huthavahana Kuchibhotla
• Tanner Cameron Wayne

Classifications

• C04B35/195 Primary

  Alkaline earth aluminosilicates, e.g. cordierite {or anorthite} · CPC title

• C04B38/0012

  characterised by the material used for sealing or plugging (some of) the channels of the honeycombs · CPC title

• C04B38/068

  Carbonaceous materials, e.g. coal, carbon, graphite, hydrocarbons · CPC title

• C04B2235/3232

  Titanium oxides or titanates, e.g. rutile or anatase · CPC title

• 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