# US 10,501,375 B2 · Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same

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- Number: US 10,501,375 B2
- Document ID: US10501375B2
- Status: Granted
- Kind: B2
- Application number: 14/614,945
- Filed: 2015-02-05
- Published: 2016-08-11
- Granted: 2019-12-10
- Earliest claimed: 2006-06-30
- Assignees: Corning Incorporated
- Applicants: Corning Incorporated
- Inventors: Adriane Marie Divens-Dutcher; Gregory Albert Merkel; Patrick David Tepesch; Elizabeth Marie Vileno; Raja Rao Wusirika
- Web page: https://patentgrep.com/patent/US10501375B2

## CPC

- C04B 35/478: based on aluminium titanates
- B01D 39/2075: {sintered or bonded by inorganic agents}
- B01D 53/94: by catalytic processes
- B01J 21/10: Magnesium; Oxides or hydroxides thereof
- B01J 23/02: of the alkali- or alkaline earth metals or beryllium
- B01J 23/10: of rare earths
- B01J 35/57: Honeycombs
- B01J 37/0018: {Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)}
- B01J 37/04: Mixing {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 37/082: {Decomposition and pyrolysis}
- C04B 38/0006: {Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083)}
- B01D 53/944: {Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts (three-way-catalysts [TWC] B01D53/9445)}
- B01D 2239/1208: Porosity
- B01D 2255/40: Mixed oxides
- B01D 2258/012: Diesel engines and lean burn gasoline engines
- B01J 35/19: {Catalysts containing parts with different compositions}
- B01J 35/30: characterised by their physical properties
- B01J 35/60: characterised by their surface properties or porosity
- B01J 37/08: Heat treatment {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 2235/15: X-ray diffraction
- B01J 2523/00: Constitutive chemical elements of heterogeneous catalysts
- C04B 2111/00793: {as filters or diaphragms}
- C04B 2111/0081: {as catalysts or catalyst carriers}
- C04B 2235/3206: Magnesium oxides or oxide-forming salts thereof
- C04B 2235/3224: Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
- C04B 2235/3225: Yttrium oxide or oxide-forming salts thereof
- C04B 2235/3227: Lanthanum oxide or oxide-forming salts thereof
- C04B 2235/3229: Cerium oxides or oxide-forming salts thereof
- C04B 2235/3236: Alkaline earth titanates
- C04B 2235/3418: Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
- C04B 2235/3481: Alkaline earth metal alumino-silicates other than clay, e.g. cordierite, beryl, micas such as margarite, plagioclase feldspars such as anorthite, zeolites such as chabazite
- C04B 2235/349: Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
- C04B 2235/80: Phases present in the sintered or melt-cast ceramic products other than the main phase
- C04B 2235/9607: Thermal properties, e.g. thermal expansion coefficient
- C04B 2235/9615: Linear firing shrinkage
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS

## Abstract

Disclosed are ceramic bodies comprised of composite cordierite aluminum magnesium titanate ceramic compositions and methods for the manufacture of same.

## Claims

### Claim 1

A ceramic article, comprising:
a honeycomb monolith structure having an inlet end and an outlet end, and a multiplicity of cells formed by walls extending from the inlet end to the outlet end, wherein each of the walls of the honeycomb monolith structure comprises:
at least about 50 wt % of a pseudobrookite phase comprising predominately alumina, magnesia, and titania;
a second phase comprising cordierite; and
a sintering aid;
wherein the article has a composition, as expressed in weight percent on an oxide basis, of from 4% to 10% MgO; from 40% to 55% Al2O3; from 25% to 44% TiO2; and from 5% to 25% SiO2, and
wherein the honeycomb monolith structure further comprises:
median pore diameter d50 of at least 10 μm, and
df that does not exceed 0.50.

### Claim 2 (depends on 1)

The ceramic article of claim 1, wherein the sintering aid is present, on a weight percent oxide basis, in an amount in the range of from greater than 0.1 to 5 weight % relative to the total weight of the inorganic batch composition.

### Claim 3 (depends on 1)

The ceramic article of claim 1, further comprising a sintering aid, comprising at least one of a lanthanide oxide and yttrium oxide.

### Claim 4 (depends on 3)

The ceramic article of claim 3, wherein the lanthanide oxide comprises a cerium oxide.

### Claim 5 (depends on 1)

The ceramic article of claim 1, wherein the ceramic article comprises a total porosity % P greater than 40% by volume.

### Claim 6 (depends on 5)

The ceramic article of claim 5, wherein the ceramic article comprises a coefficient of thermal expansion, as measured between 25-1000° C., less than or equal to 14×10−7/° C.

### Claim 7 (depends on 5)

The ceramic article of claim 5, further comprising a washcoat.

### Claim 8 (depends on 1)

The ceramic article of claim 1, comprising a median pore size d50 in the range of from 10 μm to 30 μm.

### Claim 9 (depends on 1)

A diesel particulate filter comprising the ceramic article of claim 1.

### Claim 10 (depends on 9)

The diesel particulate filter of claim 9, further comprising a washcoat.

### Claim 11 (depends on 1)

A flow through substrate comprising the ceramic article of claim 1.

### Claim 12 (depends on 1)

A catalytic flow through substrate comprising the ceramic article of claim 1.

### Claim 13 (depends on 1)

The ceramic article of claim 1, wherein the article has a composition, as expressed in weight percent on an oxide basis, of from 0 to 3% Fe2O3.

### Claim 14 (depends on 1)

The ceramic article of claim 1, wherein the walls of the honeycomb monolith structure have a composition, as expressed in weight percent on an oxide basis, of: a(Al2TiO5)+b(MgTi2O5)+c(2MgO.2Al2O3.5SiO2)+d(3Al2O3.2SiO2)+e(MgO.Al2O3)+f(2MgO.TiO2)+g(Y2O3)+h(La2O3)+i(Fe2O3.TiO2)+j(TiO2);
wherein a, b, c, d, e, f, g, h, i, and j are weight fractions of each component such that (a+b+c+d+e+f+g+h+i+j)=1.00; and
wherein 0.3≤a≤0.75, 0.075≤b≤0.3, 0.02≤c≤0.5, 0.0≤d≤0.4, 0.0≤e≤0.25, 0.0≤f≤0.1, 0.0≤g≤0.05, 0.0≤h≤0.05, 0.0≤i≤0.05, and 0.0≤j≤0.20.

### Claim 15 (depends on 1)

The ceramic article of claim 1, wherein the Al2O3 component of the composition, as expressed in weight percent on an oxide basis, is from 42% to 55%.

### Claim 16 (depends on 1)

The ceramic article of claim 1, comprising:
CTE (25° C.-1000° C.) not exceeding 12×10−7/° C.;
total porosity % P of at least 45% by volume;
the median pore diameter d50 is at least 14 μm; and
the df is not more than 0.35.

### Claim 17 (depends on 1)

The ceramic article of claim 1, comprising:
CTE (25° C.-1000° C.) does not exceed 18×10−7/° C.; and
the total porosity % P is at least 60% by volume.

### Claim 18 (depends on 1)

The ceramic article of claim 1, comprising:
CTE (25° C.-1000° C.) does not exceed 12×10−7/° C.; and
total porosity % P is at least 60% by volume.

### Claim 19 (depends on 1)

The ceramic article of claim 1, wherein db does not exceed 1.0.

### Claim 20 (depends on 1)

The ceramic article of claim 1, wherein the ceramic article is a particulate filter comprising:
CTE (25° C.-1000° C.) from 6×10−7/° C. to 20×10−7/° C.);
total porosity % P of from 44% to 52% by volume;
the median pore diameter d50 ranges from 15 μm to 27 μm; and
the df ranges from 0.24 to 0.45.

### Claim 21 (depends on 1)

The ceramic article of claim 1, comprising:
CTE (25° C.-1000° C.) of from 10×10−7/° C. to 14×10−7/° C.;
the median pore diameter d50 ranges from 16 μm to 22 μm; and
the df ranges from 0.17 to 0.31.

### Claim 22 (depends on 1)

The ceramic article of claim 1, comprising a third phase of mullite.

### Claim 23 (depends on 1)

The ceramic article of claim 1, comprising a third phase of mullite and another phase of sapphirine.

### Claim 24

A ceramic article, comprising:
a honeycomb monolith structure having an inlet end and an outlet end, and a multiplicity of cells formed by porous walls extending from the inlet end to the outlet end, wherein the porous walls of the honeycomb monolith structure further comprise:
at least about 50 wt % of a pseudobrookite phase comprising predominately alumina, magnesia, and titania and including 15 wt % to 35 wt % of MgTiO5;
a second phase comprising cordierite;
a third phase comprising mullite, and
wherein the porous walls of the honeycomb monolith structure comprise a composition, as expressed in weight percent on an oxide basis, of from 4% to 10% MgO; from 40% to 55% Al2O3; from 25% to 44% TiO2; and from 5% to 25% SiO2, and
wherein the honeycomb monolith structure further comprises:
a coefficient of thermal expansion, as measured between 25° C.-1000° C., of less than or equal to 14×10−7/° C.;
total porosity % P of at least 40% by volume;
median pore diameter d50 of at least 10 μm; and
df that does not exceed 0.50.