Monolithic ceramic body and assembly

Patent metadata

Field	Value
Publication number	US-2020339481-A1
Application number	US-202016862245-A
Country	US
Kind code	A1
Filing date	Apr 29, 2020
Priority date	Apr 29, 2019
Publication date	Oct 29, 2020
Grant date	—

Abstract

In another embodiment, a porous ceramic assembly can comprise at least two of the monolithic ceramic bodies which are coupled to each other by a first complementary engagement structure and a second complementary engagement structure.

First claim

What is claimed is:

1 . A monolithic ceramic body comprising:
a first portion comprising a plurality of pores defining an interconnected network of pores extending through a portion of the monolithic ceramic body; a second portion integrally formed with the first portion and defining at least a portion of a perimeter surface of the monolithic ceramic body, wherein the second portion includes at least one complementary engagement structure.

2 . The monolithic ceramic body of claim 1 , wherein the plurality of pores of the first portion has an average pore size of at least 30 microns, and a total porosity of the first portion is at least 50 vol %.

3 . The monolithic ceramic body of claim 2 , wherein the plurality of pores of the first portion has an average pore size of at least 500 microns.

4 . The monolithic ceramic body of claim 1 , wherein an average pore size of the second portion is smaller than an average pore size of the first portion.

5 . The monolithic ceramic body of claim 1 , wherein the second portion has a porosity of less than 50 vol %.

6 . The monolithic ceramic body of claim 1 , wherein the plurality of pores defining an interconnected network comprises at least 80% of the total porosity.

7 . The monolithic ceramic body of claim 1 , wherein the plurality of pores of the first portion comprises a size gradient of the average pore size from a first outer surface of the first portion to a second outer surface of the first portion, wherein the size gradient reduces the average pore size from the first exterior surface to the second exterior surface by at least 20 percent.

8 . The monolithic ceramic body of claim 1 , wherein the ceramic comprises an oxide, a carbide, nitride, boride, or any combination thereof.

9 . The monolithic ceramic body of claim 8 , wherein the ceramic comprises alumina, silica, cordierite, silicon carbide, zirconia, zircon, tungsten carbide, silicon nitride, hexagonal boron nitride, cubic boron nitride, SiAlON, or any combination thereof.

10 . The monolithic ceramic body of claim 1 , wherein the ceramic body is a filter, a catalyst carrier, an insulation material, an electrode material, a guard bed for a reactor, a scaffold for a battery, a material for a fuel cell, or a bio scaffold.

11 . The monolithic ceramic body of claim 1 , wherein the at least one complementary engagement structure comprises at least one first complementary engagement structure and at least one second complementary engagement structure.

12 . The monolithic ceramic body of claim 11 , wherein the at least one first complementary engagement structure includes a depression and the at least one second complementary engagement structure includes a protrusion.

13 . The monolithic ceramic body of claim 11 , wherein a shape of the at least one first complementary engagement structure is non-polygonal, and a shape of the at least one second complementary engagement structure is complementary to the shape of the first complementary engagement structure.

14 . The monolithic ceramic body of claim 1 , wherein the monolithic ceramic body comprises a rectangular structure, and the at least one complementary engagement structure is positioned in a center of a side surface of the monolithic ceramic body throughout a thickness of the body.

15 . The monolithic ceramic body of claim 1 , wherein the monolithic ceramic body comprises a rectangular structure, and each of two side surfaces comprises one complementary engagement structure throughout a thickness of the body.

16 . A porous ceramic assembly comprising:
at least one first monolithic ceramic body comprising: a first portion comprising a plurality of pores defining an interconnected network of pores extending through a portion of the monolithic ceramic body; and a second portion integrally formed with the first portion and defining at least a portion of a perimeter surface of the monolithic ceramic body, wherein the second portion includes at least one first complementary engagement structure; and at least one second monolithic ceramic body comprising: at least one second complementary engagement structure, wherein the at least one first monolithic ceramic body and the at least one second monolithic ceramic body are coupled to each other via the at least one first complementary engagement structure and the at least one second complementary engagement structure.

17 . The porous ceramic assembly of claim 16 , wherein the second monolithic ceramic body comprises a first portion comprising a plurality of pores defining an interconnected network which has a same structure as the plurality of pores of the first portion of the first monolithic ceramic body.

18 . The porous ceramic assembly of claim 16 , wherein the second monolithic ceramic body comprises a first portion comprising a plurality of pores defining an interconnected network which has a different structure as the plurality of pores of the first portion of the first monolithic ceramic body.

19 . A process for preparing a monolithic ceramic body, comprising:
forming a monolithic green body by an additive manufacturing process, wherein the green body comprises ceramic particles and a binder; removing the binder of the green body by heat treatment; and sintering the green body at a temperature of at least 700° C. to obtain the ceramic body, wherein the ceramic body comprises a first portion comprising a plurality of pores defining an interconnected network of pores; a second portion integrally formed with the first portion and defining at least a portion of a perimeter surface of the monolithic ceramic body, wherein the second portion includes at least one complementary engagement structure.

20 . The process of claim 19 , wherein the ceramic particles comprise alumina, silica, cordierite, silicon carbide, zirconia, zircon, tungsten carbide, silicon nitride, hexagonal boron nitride, cubic boron nitride, SiAlON, or any combination thereof.

Assignees

• Saint Gobain Ceramics

Inventors

• Hampden-Smith Mark
• Mirri Francesca
• Mcgahan Michael
• Lante Bojana
• Simadiris Emmanuel
• Sender Michael
• Rehrig Paul W
• Nguyen Patrick Van Nuoi
• Dahar Stephen Lee

Classifications

• C04B2235/665

  Local sintering, e.g. laser sintering · CPC title

• C04B2235/6026

  Computer aided shaping, e.g. rapid prototyping · CPC title

• C04B2111/00793

  as filters or diaphragms · CPC title

• C04B38/06 Primary

  by burning-out added substances {by burning natural expanding materials or by sublimating or melting out added substances} · CPC title

• C04B38/0074

  expressed as porosity percentage · CPC title