Percolated mullite and a method of forming same

Patent metadata

Field	Value
Publication number	US-2015344371-A1
Application number	US-201214362351-A
Country	US
Kind code	A1
Filing date	Dec 7, 2012
Priority date	Dec 9, 2011
Publication date	Dec 3, 2015
Grant date	—

Abstract

A method of producing percolated mullite in a body of material, the method including the step of heating the body of material, wherein the body of material has a composition that includes alumina and silica, and the weight ratio of alumina:silica is from approximately 10:90 to approximately 77:23. The percolated mullite produced extends continuously and/or substantially throughout the entire body of material.

First claim

1 . A method of producing percolated mullite in a body of material, the method including the step of heating the body of material, wherein the body of material has a composition that includes alumina and silica, and the weight ratio of alumina:silica is from approximately 10:90 to approximately 65:35.

2 . A method as claimed in claim 1 , wherein the percolated mullite produced extends continuously and substantially throughout the entire body of material.

3 . A method as claimed in claim 1 , wherein the percolated mullite is produced in the body of material such that a 3-3 composite material is formed wherein the percolated mullite is formed of direct-bonded mullite grains, and the percolated mullite and residual glass form mutually interpenetrating and substantially continuous three-dimensional networks.

4 . A method as claimed in claim 3 , wherein the body of material has a mullite volume content of less than about 95%.

5 . (canceled)

6 . A method as claimed in claim 1 , wherein the percolated mullite is produced in the body of material such that a 0-3 composite material is formed wherein the percolated mullite is formed of direct-bonded mullite grains that form a three-dimensional network.

7 . A method as claimed in claim 6 , wherein the body of material has a mullite volume content of greater than or equal to about 90%.

8 - 9 . (canceled)

10 . A method as claimed in claim 1 , wherein the composition includes an alumina:silica weight ratio of from approximately 24:76 to approximately 48:52.

11 . A method as claimed in claim 1 , wherein the body includes pre-existing mullite, and/or a pre-existing glass component.

12 - 13 . (canceled)

14 . A method as claimed in claim 1 , wherein glass is added.

15 - 16 . (canceled)

17 . A method as claimed in claim 1 , wherein the composition includes at least one flux.

18 . A method as claimed in claim 17 , wherein the at least one flux is an oxide and/or salt of an alkali, alkaline earth, transition metal or lanthanide, or a semimetal, metalloid, or a halogen.

19 - 23 . (canceled)

24 . A method as claimed in claim 1 , wherein the composition of the body includes a naturally occurring raw material and/or a synthetic raw material capable of forming mullite when heated.

25 . A method as claimed in claim 1 , wherein the body is comprised principally of fly ash, bottom ash, municipal ash, bagasse ash or rice husk ash, or mixtures thereof.

26 - 27 . (canceled)

28 . A method as claimed in claim 1 , wherein the composition of the body includes one or more materials selected from the group consisting of fly ash, bottom ash, municipal ash, bagasse ash, rice hush ash, mullite, kyanite, sillimanite, andalusite, topaz, pyrophyllite, clays, phyllite-schist, saprolite clay, kyanite-staurolite, anorthosite, syenite, emery rock, other aluminosilicates, bauxite, alumina, aluminium hydrates, and red mud.

29 - 30 . (canceled)

31 . A method as claimed in claim 1 , wherein the body is heated at a temperature of between approximately 1400° C. and approximately 1600° C. for a period of time.

32 . A method as claimed in claim 31 , wherein the body is heated at a temperature of at least 1500° C.

33 - 42 . (canceled)

43 . Percolated mullite produced in accordance with the method of claim 1 .

44 . (canceled)

45 . A body of material including a percolated mullite microstructure formed of direct-bonded mullite grains, the percolated mullite microstructure extending continuously and substantially throughout the entire body.

46 . A body of material as claimed in claim 45 , wherein the material is a 3-3 composite.

47 . A body of material as claimed in claim 45 , wherein the material is a 0-3 composite.

Assignees

• Newsouth Innovations Pty Ltd
• Vecor Ip Holdings Ltd
• Newsouthinnovations Pty Ltd
• Vecor Ip Holdingds Ltd

Inventors

• Sorrell Charles Christopher
• Koshy Pramod
• Koszo Sandor

Classifications

• C04B35/62204

  using waste materials or refuse (clay-wares containing waste materials C04B33/132) · CPC title

• C04B35/653

  Processes involving a melting step · CPC title

• C04B35/107

  Refractories by fusion casting · CPC title

• C04B2235/444

  Halide containing anions, e.g. bromide, iodate, chlorite · CPC title

• Y10T428/249921

  Web or sheet containing structurally defined element or component · CPC title