Inorganic membrane filtration articles and methods thereof

Patent metadata

Field	Value
Publication number	US-2021107838-A1
Application number	US-202017129040-A
Country	US
Kind code	A1
Filing date	Dec 21, 2020
Priority date	Oct 30, 2015
Publication date	Apr 15, 2021
Grant date	—

Abstract

An inorganic membrane filtration article and methods for making the same. The membrane filtration article includes a sintered flow-through ceramic honeycomb with a plurality of partition walls defining a plurality of open channels from an inlet end of the honeycomb to an outlet end of the honeycomb. The honeycomb is formed from a cordierite composition with low-sodium and/or low-potassium content for enhanced filtration performance.

First claim

What is claimed is:

1 . A method of making a ceramic article, the method comprising:
applying a green membrane layer onto at least a portion of porous partition walls of a ceramic honeycomb, wherein the walls of the ceramic honeycomb comprise 0.001≤Na 2 O≤0.10 wt. % (weight percent), or 0.001≤K 2 O≤0.03 wt. %, or 0.001≤Na 2 O+K 2 O≤0.13 wt. %; and firing the green membrane layer on the ceramic honeycomb walls to form a porous membrane layer, wherein the green membrane layer comprises 0.001≤Na 2 O ≤0.10 wt. %, or 0.001≤K 2 O≤0.03 wt. %, or 0.001≤Na 2 O≤+K 2 O≤0.13 wt. %.

2 . The method of claim 1 wherein the porous partition walls comprise CaO 0.01-0.15 wt. %; Fe 2 O 3 0.4-1.0 wt. %; NiO 0.001-0.01 wt. %; and TiO 2 0.1-0.5 wt. %.

3 . The method of claim 1 wherein at least 50 wt. % of the porous membrane layer is comprised of: Al 2 O 3 31-37 wt. %; SiO 2 45-51 wt. %; MgO 10-16 wt. %; and (Na 2 O+K 2 O) 0.01-0.10 wt. %.

4 . The method of claim 1 wherein the porous membrane layer comprises: CaO 0.05-0.15 wt. %; Fe 2 O 3 0.3-1.0 wt. %; NiO 0.001-0.1 wt. %; and TiO 2 0.2-0.8 wt. %.

5 . The method of claim 1 wherein the porous membrane layer comprises Na 2 O 0.01-0.7 wt. % and K 2 O 0.01-0.03 wt. %.

6 . The method of claim 1 wherein the porous membrane layer has a median thickness from about 5 microns to about 25 microns.

7 . The method of claim 1 wherein the porous membrane layer comprises pore diameters from about 0.1 micron to about 5 microns.

8 . The method of claim 1 wherein the porous membrane layer comprises a median pore diameter D50 from about 0.2 microns to about 3 microns.

9 . The method of claim 1 wherein the porous membrane layer has a porosity from about 40% to about 60%.

10 . The method of claim 1 wherein the porous membrane layer comprises alumina.

11 . The method of claim 1 wherein the porous membrane layer comprises cordierite.

12 . The method of claim 1 wherein the porous membrane layer is comprises a cordierite-alumina composite.

13 . The method of claim 1 wherein the porous membrane layer comprises 1 wt. % to 50 wt. % alumina.

14 . The method of claim 1 wherein the green membrane layer is fired at from about 1100° C. to about 1300° C.

Assignees

• Corning Inc

Inventors

• Fekety Curtis Robert
• Gu Yunfeng
• Lu Yanxia Ann
• Song Zhen

Classifications

• B01D46/2474

  of the walls along the length of the honeycomb · CPC title

• B01D46/2484

  Cell density, area or aspect ratio · CPC title

• B01D46/2482

  Thickness, height, width, length or diameter · CPC title

• B01D46/247

  of the cells · CPC title

• B01D46/24491

  Porosity · CPC title