# US 11,078,121 B2 · High cordierite-to-mullite ratio cordierite-mullite-aluminum magnesium titanate compositions and ceramic articles comprising same

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- Number: US 11,078,121 B2
- Document ID: US11078121B2
- Status: Granted
- Kind: B2
- Application number: 15/834,839
- Filed: 2017-12-07
- Published: 2018-04-26
- Granted: 2021-08-03
- Earliest claimed: 2013-09-23
- Assignees: Corning Incorporated
- Applicants: Corning Incorporated
- Inventors: Monika Backhaus-Ricoult; Patrick David Tepesch; Bryan Ray Wheaton
- Web page: https://patentgrep.com/patent/US11078121B2

## CPC

- C04B 35/1015: {containing refractory metal compounds other than those covered by C04B35/103 - C04B35/106}
- B01D 39/2068: {Other inorganic materials, e.g. ceramics}
- C04B 35/478: based on aluminium titanates
- C04B 35/64: Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F})
- C04B 38/0006: {Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083)}
- F01N 3/08: for rendering innocuous (using electric or electrostatic separators F01N3/01; chemical aspects B01D53/92)
- 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 2235/3208: Calcium oxide or oxide-forming salts thereof, e.g. lime
- C04B 2235/3213: Strontium oxides or oxide-forming salts thereof
- C04B 2235/3218: Aluminium (oxy)hydroxides, e.g. boehmite, gibbsite, alumina sol
- 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 2235/3232: Titanium oxides or titanates, e.g. rutile or anatase
- 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 2235/3445: Magnesium silicates, e.g. forsterite
- C04B 2235/3463: Alumino-silicates other than clay, e.g. mullite
- 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 2235/5436: micrometer sized, i.e. from 1 to 100 micron
- C04B 2235/5463: Particle size distributions
- C04B 2235/786: Micrometer sized grains, i.e. from 1 to 100 micron
- 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: 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)
- F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16)

## Abstract

Disclosed are ceramic bodies comprised of composite cordierite-mullite-aluminum magnesium titanate (CMAT) ceramic compositions having high cordierite-to-mullite ratio and methods for the manufacture of same.

## Claims

### Claim 1

A method of manufacturing a ceramic article, comprising:
providing an inorganic batch composition comprising a magnesia source, a silica source, an alumina source, a titania source, and at least one sintering aid;
mixing the inorganic batch composition together with one or more processing aids comprising at least one of a plasticizer, lubricant, binder, pore former, and solvent to form a ceramic precursor batch composition;
shaping the ceramic precursor batch composition into a green body; and
firing the green body under conditions effective to convert the green body into a ceramic article comprising a pseudobrookite phase comprising alumina, magnesia, and titania, a second phase comprising cordierite, and a third phase comprising mullite,
wherein the cordierite-to-mullite phase ratio is greater than or equal to 1.3 and less than or equal to 2.5.

### Claim 2 (depends on 1)

The method of claim 1, wherein the cordierite-to-mullite phase ratio is greater than or equal to 1.8 and less than or equal to 2.2.

### Claim 3 (depends on 1)

The method of claim 1, wherein the ceramic precursor batch composition is shaped by extrusion.

### Claim 4 (depends on 1)

The method of claim 1, wherein the firing conditions effective to convert the green body into a ceramic article comprise heating the green body at a hold temperature in the range of 1250° C. to 1450° C. and maintaining the hold temperature for a hold time sufficient to convert the green body into the ceramic article.

### Claim 5

A method of manufacturing a ceramic article, comprising:
providing an inorganic batch composition comprising a magnesia source, a silica source, an alumina source, a titania source, and at least one sintering aid;
mixing the inorganic batch composition together with one or more processing aids comprising at least one of a plasticizer, lubricant, binder, pore former, and solvent to form a ceramic precursor batch composition;
shaping the ceramic precursor batch composition into a green body; and
firing the green body under conditions effective to convert the green body into a ceramic article comprising a pseudobrookite phase comprising alumina, magnesia, and titania, a second phase comprising cordierite, and a third phase comprising mullite,
wherein the cordierite-to-mullite phase ratio is greater than or equal to 1.3 and less than or equal to 7.

### Claim 6

A method of manufacturing a ceramic article, comprising:
providing an inorganic batch composition comprising a magnesia source, a silica source, an alumina source, a titania source, and at least one sintering aid;
mixing the inorganic batch composition together with one or more processing aids comprising at least one of a plasticizer, lubricant, binder, pore former, and solvent to form a ceramic precursor batch composition;
shaping the ceramic precursor batch composition into a green body; and
firing the green body under conditions effective to convert the green body into a ceramic article comprising a pseudobrookite phase comprising alumina, magnesia, and titania, a second phase comprising cordierite, and a third phase comprising mullite,
wherein the cordierite-to-mullite phase ratio is greater than or equal to 1.3 and less than or equal to 4.