Beta-spodumene-cordierite composition, article, and method
AssigneeCorning Incorporated
InventorsGregory Albert Merkel, Cameron Wayne Tanner
Life of this patent
Estimating the term…
Abstract
Porous spodumene-cordierite honeycomb bodies of high strength but low volumetric density, useful for the manufacture of close-coupled engine exhaust converters, gasoline engine particulate exhaust filters, and NOx integrated engine exhaust filters, are provided through the reactive sintering of batches comprising sources of magnesia, alumina and silica together with a lithia source, such as a spodumene or petalite ore.
Claims21
A method for making a porous ceramic article comprising the steps of:
- mixing inorganic batch ingredients with a liquid and an organic binder to form a plasticized batch mixture, the inorganic batch ingredients comprising sources of magnesia, silica, alumina and lithia, wherein the lithia source comprises one or more lithium-containing compounds, wherein the magnesia source comprises one or more magnesium-containing compounds, and wherein the magnesia source constitutes less than 25 wt % of the inorganic batch ingredients;
- forming the plasticized batch mixture into a green body;
- and
- heating the green body to a top temperature of 1180 to 1260° C. for a time sufficient to convert the green body into the porous ceramic article, the article being comprised of a principal phase of beta-spodumene and a minor phase of cordierite.
A porous spodumene-cordierite honeycomb body having a honeycomb volumetric density of less than 0.3 g/cm3.
A combustion engine exhaust emissions control device selected from the group consisting of close-coupled engine exhaust converters, gasoline engine particulate exhaust filters, and NOx integrated engine exhaust filters, wherein the device comprises a composite spodumene-cordierite honeycomb body having a honeycomb volumetric density of less than 0.3 g/cm3.
Dependencies are inferred from the claim text.