Porous ceramic article and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-9623360-B2
Application number	US-201414250655-A
Country	US
Kind code	B2
Filing date	Apr 11, 2014
Priority date	May 20, 2013
Publication date	Apr 18, 2017
Grant date	Apr 18, 2017

Abstract

The present disclosure relates to porous ceramic articles and a method of making the same. The porous ceramic articles have microstructure of sinter bonded or reaction bonded large pre-reacted particles and pore network structure exhibiting large pore necks. The method of making the porous ceramic articles involves using pre-reacted particles having one or more phases. A plastic ceramic precursor composition is also disclosed. The composition includes a mixture of at least one of dense, porous, or hollow spheroidal pre-reacted particles and a liquid vehicle.

First claim

What is claimed is:

1. A porous ceramic body, comprising:
a microstructure of solid matter and a network of contiguous pores;
a permeability of greater than or equal to 1000;
a porosity greater than or equal to 45%;
a median pore size (d50) greater than 10 μm;
a coefficient of thermal expansion (CTE) in a range of 2×10 −7 K −1 to 20×10 −7 K −1 from room temperature (20° C.) to 800° C.;
a strain tolerance greater than 0.10%; and
an MOR greater than 170 psi for a honeycomb geometry (300/14) or equivalent,
wherein a permeability factor of (permeability in Darcy)/((porosity as a fraction) * (median pore diameter, d50 in microns) 2 is in a range of about 4-6×10 −3 Darcy/μm 2 .

2. The porous ceramic body of claim 1 , wherein the microstructure of solid matter and network of pores comprises inverse porosity.

3. The porous ceramic body of claim 1 , wherein the microstructure of solid matter and network of pores comprises regular porosity.

4. The porous ceramic body of claim 1 , wherein the porosity is greater than or equal to 57%.

5. The porous ceramic body of claim 1 , wherein the porosity is greater than or equal to 60%.

6. The porous ceramic body of claim 1 , wherein the median pore size (d50) is greater than 14 μm.

7. The porous ceramic body of claim 1 , wherein the median pore size (d50) is greater than 14 μm.

8. The porous ceramic body of claim 1 , wherein the median pore size (d50) is in a range of 15 μm to 25 μm.

9. The porous ceramic body of claim 1 , wherein the median pore size (d50) is in a range of 20 μm to 30 μm.

10. The porous ceramic body of claim 1 , wherein the coefficient of thermal expansion (CTE) is in a range of 2×10 −7 K −1 to 15×10 −7 K −1 from room temperature (20° C.) to 800° C.

11. The porous ceramic body of claim 1 , wherein the coefficient of thermal expansion (CTE) is in a range of 2×10 −7 K −1 to 10×10 −7 K −1 from room temperature (20° C.) to 800° C.

12. The porous ceramic body of claim 1 , wherein the solid matter comprises a primary phase (greater than 50 vol %) of cordierite.

13. The porous ceramic body of claim 12 , wherein the solid matter further comprises a secondary phase (less than 50 vol %) of at least one of feldspar, mullite, spinel, and strontium titanate.

14. The porous ceramic body of claim 1 , wherein the solid matter comprises a primary phase (greater than 50 vol %) of pseudobrookite aluminum-titanate solid solution.

15. The porous ceramic body of claim 14 , wherein the solid matter further comprises a secondary phase (less than 50 vol %) of at least one of feldspar, cordierite, mullite, spinel, glass, and strontium titanate.

16. The porous ceramic body of claim 1 , further comprising at least one of a catalyst substrate, a partial wall-flow filter and a wall-flow filter.

17. The porous ceramic body of claim 1 , wherein the microstructure comprises microcracks.

18. The porous ceramic body of claim 1 , wherein the contiguous pores comprise pore necks substantially the size of the bulk pores.

Assignees

• Corning Inc

Inventors

• Backhaus-Ricoult Monika
• Glose Christopher Raymond

Classifications

• C04B2235/5436

  micrometer sized, i.e. from 1 to 100 micron · CPC title

• C04B2235/3222

  Aluminates other than alumino-silicates, e.g. spinel (MgAl2O4) · CPC title

• C04B2235/3236

  Alkaline earth titanates · CPC title

• C04B38/0051

  characterised by the pore size, pore shape or kind of porosity · CPC title

• C04B2235/3463

  Alumino-silicates other than clay, e.g. mullite · CPC title