Ceramic composite beads and methods for making same

Patent metadata

Field	Value
Publication number	US-2016251249-A1
Application number	US-201514633695-A
Country	US
Kind code	A1
Filing date	Feb 27, 2015
Priority date	Feb 27, 2015
Publication date	Sep 1, 2016
Grant date	—

Abstract

The disclosure relates to methods for making a ceramic or glass-ceramic, the methods comprising spray-drying a mixture comprising batch materials to form agglomerated particles; bringing the agglomerated particles into contact with a plasma for a residence time sufficient to form fused particles; and annealing the fused particles at a temperature and for a time sufficient to form ceramic or glass-ceramic particles. Fused glass particles, ceramic or glass-ceramic particles, and ceramic or glass-ceramic articles, such as ceramic honeycombs, made by these methods are also disclosed herein.

First claim

What is claimed is:

1 . A method for making a ceramic or glass-ceramic, comprising:
spray-drying a mixture comprising batch materials to form agglomerated particles; bringing the agglomerated particles into contact with a plasma for a residence time sufficient to react and melt the agglomerated particles to form fused particles; and annealing the fused particles at a temperature and for a time sufficient to form ceramic or glass-ceramic particles.

2 . The method of claim 1 , wherein the mixture is a slurry comprising inorganic batch materials, at least one solvent, and optionally at least one additive chosen from binders, surfactants, dispersants, and anti-foaming agents.

3 . The method of claim 1 , the batch materials comprise metal oxides, carbides, nitrides, or borides, and combinations thereof.

4 . The method of claim 1 , wherein the plasma has a temperature ranging from about 9,000K to about 11,000K.

5 . The method of claim 1 , wherein the agglomerated particles are heated to a temperature of at least about 2000° C., and wherein the residence time is less than about 10 seconds.

6 . The method of claim 1 , wherein the fused particles are annealed at a temperature ranging from about 700° C. to about 1650° C., for a time ranging from about 1 hour to about 100 hours.

7 . The method of claim 1 , wherein the batch composition has a T g greater than about 1600° C.

8 . The method of claim 1 , further comprising forming a glass-ceramic article from the glass-ceramic particles.

9 . The method of claim 1 , further comprising forming a green article from the fused particles, wherein the annealing step comprises annealing the green article comprising the fused particles.

10 . A ceramic or glass-ceramic article made according to the method of claim 1 .

11 . A ceramic or glass-ceramic particle having an average particle size ranging from about 10 microns to about 50 microns and comprising less than about 5% residual glass phase, wherein the ceramic or glass-ceramic particle has a substantially homogeneous fine microstructure.

12 . The ceramic or glass-ceramic particle of claim 11 , wherein the ceramic or glass-ceramic particle comprises cordierite, aluminum titanate, spinel, mullite, and composites thereof.

13 . The ceramic or glass-ceramic particle of claim 11 , wherein the ceramic or glass-ceramic particle is substantially spherical in shape.

14 . A fused glass particle having an average particle size ranging from about 10 microns to about 50 microns and comprising less than about 5% crystalline phase, wherein the fused glass particle is substantially homogeneous, and wherein the fused glass particle has a T g of at least about 1600° C.

15 . A ceramic or glass-ceramic article made from at least one fused glass particle of claim 14 .

16 . The ceramic or glass-ceramic article of claim 15 , wherein the ceramic or glass-ceramic article has a porosity of at least about 40%.

17 . The ceramic or glass-ceramic article of claim 15 , wherein the CTE of the ceramic or glass-ceramic article is less than about 20×10 −7 K −1 at a temperature ranging from 20° C. to 800° C.

18 . The ceramic or glass-ceramic article of claim 15 , wherein the ceramic or glass-ceramic article has a microcrack factor ranging from about 0.1 to about 8.

19 . The ceramic or glass-ceramic article of claim 15 , wherein the ceramic or glass-ceramic article comprises less than about 5% residual glass phase.

20 . The ceramic or glass-ceramic article of claim 15 , wherein the ceramic or glass-ceramic article is a honeycomb.

Assignees

• Corning Inc

Inventors

• Backhaus-Ricoult Monika
• Boughton Daniel Robert
• Heine Jennifer Anella

Classifications

• C04B35/62655

  Drying, e.g. freeze-drying, spray-drying, microwave or supercritical drying · CPC title

• C04B2235/3229

  Cerium oxides or oxide-forming salts thereof · CPC title

• C04B35/185

  Mullite {3Al2O3-2SiO2} · CPC title

• C01F7/025

  Granulation or agglomeration · CPC title

• C04B35/195

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