Cordierite-Forming Batch Materials And Methods Of Using The Same
AssigneeCorning Incorporated
InventorsChris Maxwell, Martin Joseph Murtagh
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Abstract
The present disclosure relates to cordierite-forming batch materials and methods of using the same, and in particular batch materials for forming porous cordierite bodies suitable for treating engine emissions. The batch materials include sources of magnesium, alumina, silica, and high BET specific surface area raw kaolin clay. In some embodiments, the BET specific surface area of the raw kaolin clay is greater than 22 m2/g. In other embodiments, the BET specific surface area of the raw kaolin clay is greater than 13 m2/g, and the source of magnesium oxide and the source of non-kaolin clay source of silica both have relatively coarse particle size.
Claims22
A cordierite-forming batch material comprised of inorganic batch components comprising:
- at least one source of magnesium oxide;
- at least one non-kaolin clay source of alumina;
- at least one non-kaolin clay source of silica;
- and
- at least one kaolin clay;
- wherein the at least one kaolin clay comprises at least one raw kaolin clay having a BET surface area greater than 22 m2/g;
- and
- wherein the cordierite-forming batch material has an overall composition comprising, in weight percent on an oxide basis, 5-25% MgO, 35-60 wt % SiO2, and 25-50 wt % Al2O3.
A method of making a cordierite-containing ceramic body comprising:
- forming a green body from a batch material comprising inorganic batch components comprising:
- at least one source of magnesium oxide;
- at least one non-kaolin clay source of alumina;
- at least one non-kaolin clay source of silica;
- and
- at least one kaolin clay;
- wherein the at least one kaolin clay comprises at least one raw kaolin clay having a BET surface area greater than 22 m2/g;
- and
- wherein the cordierite-forming batch material has an overall composition comprising, in weight percent on an oxide basis, 5-25% MgO, 35-60 wt % SiO2, and 25-50 wt % Al2O3;
- and
- firing the green body to obtain the cordierite-containing ceramic body.
A cordierite-forming batch material comprised of inorganic batch components comprising:
- at least one source of magnesium oxide having a median particle diameter greater than 10 μm;
- at least one non-kaolin clay source of alumina;
- at least one non-kaolin clay source of silica having a median particle diameter greater than 10 μm;
- and
- at least one kaolin clay;
- wherein the at least one kaolin clay comprises at least one raw kaolin clay having a BET surface area greater than 13 m2/g;
- and
- wherein the cordierite-forming batch material has an overall composition comprising, in weight percent on an oxide basis, 5-25% MgO, 35-60 wt % SiO2, and 25-50 wt % Al203.
A method of making a cordierite-containing ceramic body comprising:
- forming a green body from a batch material comprising inorganic batch components comprising:
- at least one source of magnesium oxide having a median particle diameter greater than 10 μm;
- at least one non-kaolin clay source of alumina;
- at least one non-kaolin clay source of silica having a median particle diameter greater than 10 μm;
- and
- at least one kaolin clay;
- wherein the at least one kaolin clay comprises at least one raw kaolin clay having a BET surface area greater than 13 m2/g;
- and
- wherein the cordierite-forming batch material has an overall composition comprising, in weight percent on an oxide basis, 5-25% MgO, 35-60 wt % SiO2, and 25-50 wt % Al2O3;
- and
- firing the green body to obtain the cordierite-containing ceramic body.
Dependencies are inferred from the claim text.