Composition for improved manufacture of substrates

Patent metadata

Field	Value
Publication number	US-2016376200-A1
Application number	US-201415038971-A
Country	US
Kind code	A1
Filing date	Nov 26, 2014
Priority date	Nov 27, 2013
Publication date	Dec 29, 2016
Grant date	—

Abstract

A ceramic precursor batch composition, green ware formed thereof, porous ceramic honeycomb article formed thereof, and methods of making same.

First claim

1 . A ceramic precursor batch composition, comprising:
inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition; and a temperature gelling cellulose ether, wherein the batch composition comprises a soluble ion concentration of less than 0.75 molar.

2 - 3 . (canceled)

4 . The composition of claim 1 , wherein the soluble ions comprise any of water soluble alkali and alkaline earth species, ammonia, phosphates, sulfates, organic acid, halides, and combinations thereof.

5 . The composition of claim 1 , wherein the inorganic oxide composition comprises less than 1 wt % SO 3 .

6 . The composition of claim 1 , wherein the inorganic oxide composition comprises at least one of titania, titanium hydroxide, zirconia, zirconium hydroxide, zeolite, and combinations thereof.

7 . The composition of claim 1 , further comprising at least 0.1 wt % a catalytically active functional group.

8 - 9 . (canceled)

10 . The composition of claim 1 , wherein the temperature gelling cellulose ether is present in 1 to 10 parts by weight and the sum of the inorganic ceramic-forming ingredients is present in 100 parts by weight.

11 . The composition any one of any one of claim 1 , further comprising a relative dielectric loss of the wet composition at 915 MHz of less than 25.

12 . The composition of claim 1 , further comprising a
dielectric loss tangent of the wet composition at 915 MHz less than 0.6, wherein the dielectric loss tangent (tan δ) equals the ratio of the relative dielectric loss to the relative dielectric constant (∈″/∈′).

13 . The composition of claim 1 , further comprising a rheology capable of being extruded into a cellular product.

14 . A ceramic green ware body, comprising:
a plurality of channels; inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition; and a temperature gelling cellulose ether, wherein the ceramic green ware body comprises a soluble ion concentration of less than 0.75 molar.

15 . (canceled)

16 . The ceramic green ware body of claim 14 , wherein the soluble ions comprise any of water soluble alkali and alkaline earth species, ammonia, phosphates, sulfates, organic acid, halides, and combinations thereof.

17 . (canceled)

18 . The ceramic green ware body of claim 14 , further comprising at least 0.1 wt % a catalytically active functional group.

19 . The ceramic green ware body of claim 14 , wherein the catalytically active functional group comprises at least one of V, Ru, W, Mo, zeolite, Pt, Pd, Mn, Cu, Ni, and promoted titanium.

20 . (canceled)

21 . The ceramic green ware body of claim 14 , further comprising a wet bulk material with a relative dielectric loss at 915 MHz of less than 25, and a wet relative dielectric loss of the ceramic green body at 915 MHz that is less than 25*CFA (25 multiplied by the fraction of closed frontal area).

22 . The ceramic green ware body of claim 14 , further comprising a dielectric loss tangent at 915 MHz in the wet ceramic green ware body of less than 0.6*CFA (closed frontal area fraction), in the axial direction,
wherein the dielectric loss tangent (tan δ)=∈″ body /∈′ body =(∈″ bulk CFA)/((1−CFA)+∈′ bulk CFA), the ratio of the relative dielectric loss to the relative dielectric constant.

23 . (canceled)

24 . A method of making a ceramic green ware body, comprising:
mixing a temperature gelling cellulose ether and inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition with a liquid vehicle to form a precursor batch; forming the precursor batch into a structure comprising a plurality of channels to form a wet ceramic green ware body, wherein the wet ceramic green ware body comprises a soluble ion concentration of less than 0.75 molar; and drying the wet ceramic green ware body to form the ceramic green ware body.

25 . (canceled)

26 . The method of claim 24 , further comprising mixing at least 0.1 wt % a catalytically active functional group with the temperature gelling cellulose ether, the inorganic ceramic-forming ingredients and the liquid vehicle to form the precursor batch.

27 . (canceled)

28 . A method of making a porous ceramic honeycomb body, comprising firing the ceramic green ware body of claim 24 , to produce the porous ceramic honeycomb body.

29 . The method of claim 24 , wherein the wet ceramic green ware body comprises a wet bulk material with a relative dielectric loss at 915 MHz of less than 25, and the wet ceramic green ware body has a relative dielectric loss at 915 MHz that is less than 25*CFA (25 multiplied by the fraction of closed frontal area),
wherein microwave penetration depth “D 1/2P ” is greater than 20% of the diameter of the ware in the radial direction perpendicular to the channels, and wherein D 1/2P is a function of the green ware CFA (closed frontal area fraction).

30 . The method of claim 24 , wherein the wet ceramic green ware body comprises a dielectric loss tangent at 915 MHz in the wet ceramic green ware body of less than 0.6*CFA (closed frontal area fraction), in the axial direction,
wherein the dielectric loss tangent (tan δ)=∈″/∈′, the ratio of the relative dielectric loss to the relative dielectric constant, wherein microwave penetration depth “D 1/2P ” in the axial direction of at least 2 cm, and wherein D 1/2P is a function of the green ware CFA (closed frontal area fraction).

Assignees

• Corning Inc

Inventors

• Beall Douglas Munroe
• Crume Gregg William
• Feldman James Anthony
• Malarkey Christopher John
• Vileno Elizabeth Marie

Classifications

• B01J35/57

  Honeycombs · CPC title

• B01J21/063

  Titanium; Oxides or hydroxides thereof · CPC title

• C04B2235/5216

  Inorganic · CPC title

• C04B35/82

  Asbestos; Glass; Fused silica · CPC title

• B01D53/94

  by catalytic processes · CPC title