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US 11,535,563 B2Granted
Methods of making cordierite ceramic bodies using chlorite raw material
AssigneeCorning Incorporated
InventorGregory Albert Merkel
Life of this patent
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Abstract
A method of making a porous cordierite ceramic article using chlorite raw material is described herein. The method includes mixing materials to form a cordierite-forming mixture. The cordierite-forming mixture includes a chlorite raw material in an amount of about 5% to about 60% by weight and a platy aluminum silicate raw material in an amount of 0% to about 30% by weight of the total inorganic content of the cordierite-forming mixture. The cordierite-forming mixture is then formed into a green body and fired to form the porous cordierite ceramic article. In some cases, the porous cordierite ceramic article exhibits a low coefficient of thermal expansion (CTE), which provides the article with high thermal shock resistance.
Claims21
A method of making a porous ceramic article comprising cordierite, the method comprising:
- mixing a plurality of materials to form a cordierite-forming mixture, wherein the cordierite-forming mixture comprises:
- a chlorite raw material in an amount of about 5% to about 60% by weight of a total inorganic content of the cordierite-forming mixture,
- (ii) a silica source material, and
- (iii) an aluminum-containing source material, wherein the aluminum-containing source material comprises a platy aluminum silicate raw material in an amount of 0% to about 30% by weight of the total inorganic content of the cordierite-forming mixture;
- forming the cordierite-forming mixture into a green body;
- and
- firing the green body to form the porous ceramic article comprising cordierite,
- wherein the composition of the porous ceramic article further satisfies the following relationship:
- A+AE+RE<0.5,
- where A is a sum of weight percentages of alkali metal oxides, AE is a sum of weight percentages of alkaline earth metal oxides excluding MgO, and RE is a sum of weight percentages of rare earth metal oxides;
- wherein the porous ceramic article comprises a coefficient of thermal expansion of less than or equal to about 14×10−7 ° C−1 from 25 to 800° C.
8 more elements
A method of making a porous ceramic article comprising cordierite, the method comprising:
- mixing a plurality of materials to form a cordierite-forming mixture, wherein the cordierite-forming mixture comprises:
- (i) a chlorite raw material in an amount of about 5% to about 60% by weight of a total inorganic content of the cordierite-forming mixture,
- (ii) a silica source material,
- (iii) an alumina source material in an amount of 0% to about 40% by weight of the total inorganic content of the cordierite-forming mixture;
- (iv) a platy aluminum silicate raw material in an amount of 0% to about 30% by weight of the total inorganic content of the cordierite-forming mixture;
- (v) an Al2SiO5 raw material in an amount of 0% to about 45% by weight of the total inorganic content of the cordierite-forming mixture;
- (vi) a mullite raw material in an amount of 0% to about 35% by weight of the total inorganic content of the cordierite-forming mixture,
- wherein the cordierite-forming mixture satisfies the following relationship:
- WM(0.477−0.0095D50,M)+WS(0.469−0.019D50,S)+WP(0.721−0.075D50,P)+0.055(WA)(D50,A)≤13,
- wherein WM is a percentage by weight of mullite raw material, WS is a percentage by weight of Al2SiO5 raw material, WP is a percentage by weight of the platy aluminum silicate raw material, and WA is a percentage by weight of the alumina source material, D50,M is a median particle diameter of the mullite raw material in microns, D50,S is a median particle diameter of the Al2SiO5 raw material in microns, D50,P is a median particle diameter of the platy aluminum silicate raw material in microns, and D50,A is a median particle diameter of the alumina source material in microns;
- forming the cordierite-forming mixture into a green body;
- and
- firing the green body to form the porous ceramic article comprising cordierite.
10 more elements
A method of making a porous ceramic article comprising cordierite, the method comprising:
- mixing a plurality of materials to form a cordierite-forming mixture, wherein the cordierite-forming mixture comprises:
- (iv) a chlorite raw material in an amount of about 5% to about 60% by weight of a total inorganic content of the cordierite-forming mixture,
- (v) a silica source material, and
- (vi) an aluminum-containing source material, wherein the aluminum-containing source material comprises a platy aluminum silicate raw material in an amount of 0% to about 30% by weight of the total inorganic content of the cordierite-forming mixture;
- forming the cordierite-forming mixture into a green body;
- and
- firing the green body to form the porous ceramic article comprising cordierite, wherein the composition of the porous ceramic article further satisfies the following relationship:
- A+AE+RE<0.5,
- where A is a sum of weight percentages of alkali metal oxides, AE is a sum of weight percentages of alkaline earth metal oxides excluding MgO, and RE is a sum of weight percentages of rare earth metal oxides;
- wherein the porous ceramic article comprises an E8000c/E250c ratio of at least about 1.00.
7 more elements
A method of making a porous ceramic article comprising cordierite, the method comprising:
- mixing a plurality of materials to form a cordierite-forming mixture, wherein the cordierite-forming mixture comprises:
- (vii) a chlorite raw material in an amount of about 5% to about 60% by weight of a total inorganic content of the cordierite-forming mixture,
- (viii) a silica source material, and
- (ix) an aluminum-containing source material, wherein the aluminum-containing source material comprises a platy aluminum silicate raw material in an amount of 0% to about 30% by weight of the total inorganic content of the cordierite-forming mixture;
- forming the cordierite-forming mixture into a green body;
- and
- firing the green body to form the porous ceramic article comprising cordierite,
- wherein the composition of the porous ceramic article further satisfies the following relationship:
- A+AE+RE<0.5,
- where A is a sum of weight percentages of alkali metal oxides, AE is a sum of weight percentages of alkaline earth metal oxides excluding MgO, and RE is a sum of weight percentages of rare earth metal oxides;
- wherein the aluminum-containing source material comprises:
- an alumina source material in an amount of 0% to about 40% by weight of the total inorganic content of the cordierite-forming mixture;
- an Al2SiO5 raw material in an amount of 0% to about 45% by weight of the total inorganic content of the cordierite-forming mixture;
- and
- a mullite raw material in an amount of 0% to about 35% by weight of the total inorganic content of the cordierite-forming mixture,
- wherein the cordierite-forming mixture satisfies the following relationship:
- WM(0.477−0.0095D50,M)+WS(0.469−0.019D50,S)+WP(0.721−0.075D50,P)+0.055(WA)(D50,A)≤13,
- wherein WM is a percentage by weight of mullite raw material, WS is a percentage by weight of Al2SiO5 raw material, WP is a percentage by weight of the platy aluminum silicate raw material, and WA is a percentage by weight of the alumina source material, D50,M is a median particle diameter of the mullite raw material in microns, D50,S is a median particle diameter of the Al2SiO5 raw material in microns, D50,P is a median particle diameter of the platy aluminum silicate raw material in microns, and D50,A is a median particle diameter of the alumina source material in microns.
15 more elements
Dependencies are inferred from the claim text.