Dimensional control of ceramic structures via composition

Patent metadata

Field	Value
Publication number	US-9878958-B2
Application number	US-201313770119-A
Country	US
Kind code	B2
Filing date	Feb 19, 2013
Priority date	Feb 29, 2012
Publication date	Jan 30, 2018
Grant date	Jan 30, 2018

Abstract

Disclosed herein are methods for controlling and/or predicting the shrinkage and/or growth of a ceramic honeycomb structure between a green body state and a fired state by adjusting the hydrated alumina content of the batch composition. Also disclosed herein is substantially clay-free cordierite honeycombs produced in accordance with such methods.

First claim

What is claimed is:

1. A method of controlling the shrinkage and/or growth of a ceramic honeycomb structure between a green body state and a fired state, the method comprising:
(a) providing a substantially clay-free cordierite batch composition comprising a hydrated alumina content and suitable for making a ceramic honeycomb structure;
(b) extruding the batch composition into a green honeycomb structure;
(c) measuring the dimensions of the green honeycomb structure;
(d) firing the green honeycomb structure;
(e) measuring the dimensions of the fired honeycomb structure;
(f) determining the shrinkage or growth of the fired honeycomb structure as compared to the green honeycomb structure and selecting a desired hydrated alumina content of the batch composition based on a correlation between the shrinkage or growth and the hydrated alumina content of the batch composition;
(g) adjusting the hydrated alumina content of the composition to the desired hydrated alumina content by the addition of a selected amount of at least one hydrated alumina to the batch composition; and
(h) repeating steps (a)-(g) as necessary to obtain a desired level of shrinkage or growth between the green body and fired states.

2. The method of claim 1 , wherein the batch composition comprises at least one source of silica, alumina, magnesium, or combinations thereof.

3. The method of claim 2 , wherein the batch composition further comprises at least one glass forming metal oxide source.

4. The method of claim 3 , wherein the at least one glass forming metal oxide source comprises an yttrium source, a lanthanum source, or a combination thereof.

5. The method of claim 4 , wherein the at least one glass forming metal oxide source comprises at least one source of calcium, potassium, sodium, lithium, iron, or combinations thereof.

6. The method of claim 1 , wherein the at least one hydrated alumina is chosen from boehmite and aluminum tri-hydrate.

7. The method of claim 1 , wherein the at least one hydrated alumina is added to the batch composition in an amount ranging up to about 50% by weight relative to the total weight of the batch composition.

8. A method of controlling the shrinkage and/or growth of a ceramic honeycomb structure between a green body state and a fired state, the method comprising:
(a) providing a substantially clay-free cordierite batch composition comprising a hydrated alumina content and suitable for making a ceramic honeycomb structure;
(b) analyzing the hydrated alumina content of the batch composition;
(c) adjusting the hydrated alumina content of the batch composition to a desired hydrated alumina content by the addition of a predetermined amount of at least one hydrated alumina to the batch composition;
(d) extruding the adjusted batch composition into a green honeycomb structure;
(e) measuring the dimensions of the green honeycomb structure;
(f) firing the green honeycomb structure;
(g) measuring the dimensions of the fired honeycomb structure;
(h) determining the shrinkage or growth of the fired honeycomb structure as compared to the green honeycomb structure and selecting the desired hydrated alumina content of the batch composition based on a correlation between the shrinkage or growth and the hydrated alumina content of the batch composition; and
(i) repeating steps (b)-(h) as necessary to obtain a desired level of shrinkage or growth between the green body and fired states.

9. The method of claim 8 , wherein the batch composition comprises at least one source of silica, alumina, magnesium, or combinations thereof.

10. The method of claim 8 , wherein the batch composition further comprises at least one glass forming metal oxide source.

11. The method of claim 10 , wherein the at least one glass forming metal oxide source comprises an yttrium source, a lanthanum source, or a combination thereof.

12. The method of claim 11 , wherein the at least one glass forming metal oxide source comprises at least one source of calcium, potassium, sodium, lithium, iron, or combinations thereof.

13. The method of claim 8 , wherein the hydrated alumina is chosen from boehmite and aluminum tri-hydrate.

14. The method of claim 8 , wherein the at least one hydrated alumina is added to the batch composition in an amount ranging up to about 50% by weight relative to the total weight of the batch composition.

Assignees

• Corning Inc

Inventors

• Bronfenbrenner David J
• Lehman Michael James

Classifications

• Y10T428/24149

  Honeycomb-like · CPC title

• C04B2235/34

  Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides · CPC title

• C04B2235/3203

  Lithium oxide or oxide-forming salts thereof · CPC title

• B28B17/0072

  Product control or inspection · CPC title

• C04B2235/3418

  Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint · CPC title