Porous article and method of manufacturing the same
AssigneeCorning Incorporated
InventorsMonika Backhaus-Ricoult, Boris Nikolayevich Tsvetkov
Life of this patent
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Abstract
The present disclosure relates to porous ceramic articles and a method of making the same. The porous ceramic articles have a porosity (P) as a fraction in a range of about 0.3 to about 0.7; a permeability factor PQ>0.025, wherein PQ is (Kbulk)/(P·d502), Kbulk being bulk permeability in Darcy, and d50 being the mean pore size in micrometers (μm); a tortuosity in a range of about 1.8 to 3; and a median pore size diameter d50 in a range of about 10 μm to about 35 μm. The porous ceramic articles can have an interconnected bead microstructure comprising beads and bead connections, PQ is directly proportional to bead size, and wherein in a random cross section through the body, the beads appear as globular portions.
Claims19
A porous ceramic body, comprising:
- an interconnected bead microstructure comprising bead portions and bead connection portions, wherein adjacent bead portions are connected by the bead connection portions;
- a porosity (P) as a fraction in a range of about 0.3 to about 0.7;
- a permeability factor PQ>0.025, wherein PQ is (Kbulk)/(P·d502), Kbulk being bulk permeability in Darcy, and d50 being the mean pore size in micrometers (μm);
- a tortuosity in a range of about 1.8 to 3;
- and
- a median pore size diameter d50 in a range of about 10 μm to about 25 μm;
- wherein PQ is directly proportional to bead size, and
- wherein in a random cross section through the body, the bead portions appear as globular.
A porous ceramic body comprising:
- an interconnected bead microstructure comprising bead portions and bead connection portions wherein adjacent bead portions are connected by the bead connection portions;
- a porosity (P) as a fraction in a range of about 0.3 to about 0.7;
- a permeability factor PQ>0.025, wherein PQ is (Kbulk)/(P·d502), Kbulk being bulk permeability in Darcy, and d50 being the mean pore size in micrometers (μm);
- a tortuosity in a range of about 1.8 to 3;
- and
- a median pore size diameter d50 in a range of about 10 μm to about 25 μm;
- wherein PQ is inversely proportional to bead overlap, bead overlap being fraction of radial interference between adjacent connected bead portions,
- wherein in a random cross section through the body, the bead portions appear as globular.
A porous ceramic body comprising:
- a porosity (P) as a fraction in a range of about 0.3 to about 0.7;
- a permeability factor PQ>0.025, wherein PQ is (Kbulk)/(P·d502), Kbulk being bulk permeability in Darcy, and d50 being the mean pore size in micrometers (μm);
- a tortuosity in a range of about 1.8 to 3;
- and
- a median pore size diameter d50 in a range of about 10 μm to about 25 μm;
- wherein a ratio of through-wall permeability KTW to bulk permeability Kbulk is greater than 0.9 (KTW/Kbulk>0.9).
A porous ceramic body comprising:
- an interconnected bead microstructure, comprising:
- bead portions;
- bead connection portions, wherein adjacent bead portions are connected by the bead connection portions;
- a porosity (P) as a fraction in a range of about 0.3 to about 0.7;
- a permeability factor PQ>0.025, wherein PQ is (Kbulk)/(P·d502), Kbulk being bulk permeability in Darcy, and d50 being the mean pore size in micrometers (μm);
- a tortuosity in a range of about 1.8 to 3;
- and
- a median pore size diameter d50 in a range of about 10 μm to about 25 μm;
- and
- a bead overlap of less than about 0.5, the bead overlap being a fraction of radial interference between adjacent connected bead portions,
- wherein the bead portions comprise inorganic, reaction-sintered spheres, and
- wherein in a random cross section through the body, the bead portions appear as globular.
A porous body, comprising:
- a porosity (P) as a fraction in a range of about 0.3 to about 0.4;
- a permeability (K) greater than or equal to about 0.017·P·d502, where d50 is the mean pore size;
- a tortuosity in a range of about 2 to 5;
- and
- a median pore size diameter d50 as measured by mercury porosimetry in a range of about 10 μm to about 35 μm.
Dependencies are inferred from the claim text.