Fast firing method for high porosity ceramics

Patent metadata

Field	Value
Publication number	US-9452578-B2
Application number	US-201313951840-A
Country	US
Kind code	B2
Filing date	Jul 26, 2013
Priority date	Jul 26, 2013
Publication date	Sep 27, 2016
Grant date	Sep 27, 2016

Abstract

A method for firing a green honeycomb ceramic body including heating the green honeycomb ceramic body from room temperature to a first temperature of less than or equal to about 350° C. with at least one heating rate of greater than or equal to about 80° C./hr. The green honeycomb ceramic body may be heated from the first temperature to a second temperature of greater than or equal to about 800° C. at a heating rate of greater than or equal to about 90° C./hr. The green honeycomb ceramic body may be heated from the second temperature to a third temperature of greater than or equal to about 1000° C. The green honeycomb ceramic body may include aluminum raw materials for forming an aluminum titanate ceramic body.

First claim

What is claimed is:

1. A method for firing a green honeycomb ceramic body, the method comprising:
heating the green honeycomb ceramic body from room temperature to a first temperature of less than or equal to about 350° C., wherein heating the green honeycomb ceramic body from room temperature to the first temperature comprises a heating rate of greater than or equal to about 80° C./hr;
heating the green honeycomb ceramic body from the first temperature to a second temperature of greater than or equal to about 800° C., wherein heating the green honeycomb ceramic body from the first temperature to the second temperature comprises a heating rate of greater than or equal to about 90° C./hr; and
heating the green honeycomb ceramic body from the second temperature to a third temperature of greater than or equal to about 1000° C.,
wherein the green honeycomb ceramic body has a diameter of from greater than or equal to about 4.0 inches to less than or equal to about 9.0 inches,
wherein the green honeycomb ceramic body comprises a carbon-based pore former in a concentration of from greater than or equal to about 10% to less than or equal to about 48% by weight,
wherein the green honeycomb ceramic body comprises aluminum raw materials for forming an aluminum titanate ceramic body, and
wherein heating the green honeycomb ceramic body from room temperature to the first temperature comprises at least one heating rate that is different from a heating rate during heating of the green honeycomb ceramic body from the first temperature to the second temperature.

2. The method of claim 1 , wherein heating the green honeycomb ceramic body from room temperature to the first temperature comprises:
heating the green honeycomb ceramic body to a temperature of from about 245° C. to about 265° C. at a heating rate of from about 180° C./hr to about 220° C./hr; and
heating the green honeycomb ceramic body from the temperature of about 245° C. to about 265° C. to the first temperature at a heating rate less than or equal to about 15° C./hr.

3. The method of claim 2 , wherein heating the green honeycomb ceramic body from the first temperature to the second temperature comprises heating the green honeycomb ceramic body at a heating rate of from about 180° C./hr to about 220° C./hr.

4. The method of claim 3 , wherein heating the green honeycomb ceramic body from the second temperature to the third temperature comprises heating the green honeycomb ceramic body at a heating rate of less than or equal to about 15° C./hr.

5. The method of claim 2 , wherein the green honeycomb ceramic body has a diameter of from greater than or equal to about 6.3 inches to less than or equal to about 7.5 inches.

6. The method of claim 2 , wherein the green honeycomb ceramic body comprises a carbon-based pore former in a concentration of from greater than or equal to about 34% to less than or equal to about 48% by weight by superaddition.

7. The method of claim 2 , the raw materials for forming the green honeycomb ceramic body comprise magnesium-containing material.

8. The method of claim 2 , wherein an atmosphere of a kiln comprises from about 3% to about 15% by volume of oxygen during the firing.

9. The method of claim 1 , wherein heating the green honeycomb ceramic body from room temperature to the first temperature comprises:
heating the green honeycomb ceramic body from room temperature to a temperature of from about 90° C. to about 200° C. at a heating rate of from about 130° C./hr to about 170° C./hr; and
heating the green honeycomb ceramic body from the temperature of from about 90° C. to about 200° C. to the first temperature at a heating rate less than or equal to about 15° C./hr.

10. The method of claim 9 , wherein heating the green honeycomb ceramic body from the first temperature to the second temperature comprises heating the green honeycomb ceramic body at a heating rate of from about 180° C./hr to about 220° C./hr.

11. The method of claim 9 , wherein heating the green honeycomb ceramic body from the second temperature to the third temperature comprises heating the green honeycomb ceramic body at a heating rate of less than or equal to about 15° C./hr.

12. The method of claim 9 , wherein the green honeycomb ceramic body has a diameter of about 6.3 inches.

13. The method of claim 9 , wherein the green honeycomb ceramic body comprises a carbon-based pore former in a concentration of from greater than or equal to about 34% to less than or equal to about 45% by weight by superaddition.

14. The method of claim 9 , wherein the raw materials for forming the green honeycomb ceramic body comprises magnesium-containing material.

15. The method of claim 9 , wherein heating the green honeycomb ceramic body from room temperature to the first temperature comprises:
heating the green honeycomb ceramic body from room temperature to a temperature of from about 90° C. to about 110° C. at a heating rate of from about 130° C./hr to about 170° C./hr; and
heating the green honeycomb ceramic body from the temperature of from about 90° C. to about 110° C. to the first temperature at a heating rate of less than or equal to about 15° C./hr.

16. The method of claim 9 , wherein heating the green honeycomb ceramic body from room temperature to the first temperature comprises:
heating the green honeycomb ceramic body from room temperature to a temperature of from about 180° C. to about 200° C. at a heating rate of from about 130° C./hr to about 170° C./hr;
heating the green honeycomb ceramic body from the temperature of from about 180° C. to about 200° C. to a temperature of from about 200° C. to about 220° C. at a heating rate of less than or equal to about 15° C./hr; and
heating the green honeycomb ceramic body from the temperature of from about 200° C. to about 220° C. to the first temperature at a heating rate of less than or equal to about 5° C./hr.

17. The method of claim 9 , wherein an atmosphere of a kiln comprises from about 3% to about 15% by volume of oxygen during the firing.

18. The method of claim 1 , wherein heating the green honeycomb ceramic body from room temperature to the first temperature comprises:
heating the green honeycomb ceramic body from room temperature to a temperature of from about 90° C. to about 110° C. at a heating rate of from about 70° C./hr to about 90° C./hr;
heating the green honeycomb ceramic body from the temperature of from about 90° C. to about 110° C. to a temperature of from about 140° C. to about 160° C. at a heating rate of from about 40° C./hr to about 60° C./hr;
heating the green honeycomb ceramic body from the temperature of from about 140° C. to about 160° C. to a temperature of from about 190° C. to about 210° C. at a heating rate of from about 15° C./hr to about 35° C./hr; and
heating the green honeycomb ceramic body from the temperature of from about 190° C. to about 210° C. to the first temperature at a heating rate of less than or equal to about 15° C./hr.

19. The method of claim 18 , wherein heating the green honeycomb ceramic body from the second temperature to the third temperature comprises heating the green honeycomb ceramic body at a heating rate of greater than or equal to about 90° C./hr.

20. The method of claim 19 , wherein the green honeycomb ceramic body is further heated from the third temperature to a temperature of from about 1100° C. to about 1200° C. at a heating rate of from about 7° C./hr to about 12° C./hr.

21. The method of claim 18 , wherein the green honeycomb ceramic

Assignees

• Corning Inc

Inventors

• Bronfenbrenner David Jack
• Nguyen Luan Trong
• Vileno Elizabeth Marie

Classifications

• C04B2235/6562

  Heating rate · CPC title

• C04B35/64

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title

• C04B2235/3206

  Magnesium oxides or oxide-forming salts thereof · CPC title

• C04B2235/6584

  at an oxygen percentage below that of air · CPC title

• C04B38/0006

  Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083) · CPC title