# US 2014/0150389 A1 · Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same

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- Number: US 2014/0150389 A1
- Document ID: US20140150389A1
- Status: Published application
- Kind: A1
- Application number: 13/690,096
- Filed: 2012-11-30
- Published: 2014-06-05
- Earliest claimed: 2012-11-30
- Assignees: Corning Incorporated
- Inventors: Adriane Marie Divens-Dutcher; Patrick David Tepesch; Elizabeth Marie Vileno
- Web page: https://patentgrep.com/patent/US20140150389A1

## CPC

- C04B 35/478: based on aluminium titanates
- B01D 46/2429: {of the honeycomb walls or cells}
- B01D 46/24491: {Porosity}
- B01D 46/24492: {Pore diameter}
- B01D 46/24494: {Thermal expansion coefficient, heat capacity or thermal conductivity}
- C04B 35/195: Alkaline earth aluminosilicates, e.g. cordierite {or anorthite}
- C04B 38/0006: {Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083)}
- C04B 2111/00793: {as filters or diaphragms}
- 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 2235/3217: Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
- 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 2235/3236: Alkaline earth titanates
- 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 2235/3463: 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 2235/349: Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
- C04B 2235/422: Carbon
- C04B 2235/425: Graphite
- C04B 2235/6567: Treatment time
- C04B 2235/77: Density
- 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)

## Abstract

Disclosed are ceramic bodies comprised of composite cordierite aluminum magnesium titanate ceramic compositions and methods for the manufacture of same.

## Claims

### Claim 1

A ceramic article comprising a first crystalline phase comprised predominantly of a solid solution of aluminum titanate and magnesium dititanate and a second crystalline phase comprising cordierite, the article having a composition, as expressed in weight percent on an oxide basis of from 4 to 10% MgO; from 40 to 55% Al2O3; from 25 to 44% TiO2; from 5 to 25% SiO2, and a sintering aid, the sintering aid comprising at least one of calcium oxide and strontium oxide.

### Claim 2 (depends on 1)

The ceramic article of claim 1, wherein the sintering aid comprises a cerium oxide.

### Claim 3 (depends on 2)

The ceramic article of claim 2, wherein the sintering aid further comprises at least one of a yttrium oxide and a lanthanum oxide.

### Claim 4 (depends on 1)

The ceramic article of claim 1 having a composition expressed on an oxide basis of: a(Al2TiO5)+b(MgTi2O5)+c(2MgO.2Al2O3.5SiO2)+d(3Al2O3.2SiO2)+e(MgO.Al2O3)+f(2MgO.TiO2)+g(CaO)+h(SrO)+i(X)+j(Fe2O3.TiO2)+k(TiO2)+l(Al2O3), wherein X is at least one of CeO2, Y2O3, and La2O3, and a, b, c, d, e, f, g, h, i, j, k, and l are weight fractions of each component such that (a+b+c+d+e+f+g+h+i+j+k+l)=1.00, and wherein 0.3≦a≦0.75, 0.075≦b≦0.3, 0.02≦c≦0.5, 0.0≦d≦0.4, 0.0≦e≦0.25, 0.0≦f≦0.1, 0.0≦g≦0.01, 0.0≦h≦0.02, 0.0015≦(g+h), 0.0≦i≦0.05, 0.0≦j≦0.05, 0.0≦k≦0.2, and 0.0≦l≦0.1.

### Claim 5 (depends on 4)

The ceramic article of claim 4, wherein 0.0025≦g≦0.0075.

### Claim 6 (depends on 4)

The ceramic article of claim 4, wherein 0.005≦h≦0.015.

### Claim 7 (depends on 4)

The ceramic article of claim 4, wherein the sintering aid further comprises a cerium oxide.

### Claim 8 (depends on 6)

The ceramic article of claim 6, wherein the sintering aid further comprises at least one of yttrium oxide and a lanthanum oxide.

### Claim 9 (depends on 1)

The ceramic article of claim 1, wherein the ceramic article comprises a total porosity % P greater than 40% by volume.

### Claim 10 (depends on 9)

The ceramic article of claim 9, wherein the ceramic article comprises a coefficient of thermal expansion, as measured between 25-1000° C., of less than or equal to 14×10−7/° C.

### Claim 11 (depends on 1)

The ceramic article of claim 1, wherein the sintering aid is present, on a weight percent oxide basis, in an amount in a range of 0.15 to 2 weight % relative to the total weight of the inorganic batch composition.

### Claim 12 (depends on 1)

The ceramic article of claim 1 having a composition, as expressed in weight percent on an oxide basis: of 5 to 10% MgO; 40 to 50% Al2O3; 30 to 35% TiO2; and 10 to 20% SiO2.

### Claim 13 (depends on 1)

The ceramic article of claim 1, comprising a median pore size d50 in a range of 10 μm to 30 μm.

### Claim 14 (depends on 13)

The ceramic article of claim 13, comprising a median pore size d50 in the range of from 15 μm to 25 μm.

### Claim 15 (depends on 1)

A diesel particulate filter comprising the ceramic article of claim 1, wherein said diesel particulate filter comprises a honeycomb structure having a plurality of axially extending end-plugged inlet and outlet cells.

### Claim 16

A ceramic article, comprising:
a pseudobrookite phase comprising predominately alumina, magnesia, and titania;
a second phase comprising cordierite; and
a sintering aid, comprising at least one of a calcium oxide and strontium oxide.

### Claim 17 (depends on 16)

The ceramic article of claim 16, further comprising at least one of a lanthanide oxide and yttrium oxide.

### Claim 18 (depends on 17)

The ceramic article of claim 17, wherein the lanthanide oxide comprises a cerium oxide.

### Claim 19 (depends on 17)

The ceramic article of claim 17, wherein the sintering aid comprises cerium oxide and at least one of yttrium oxide and a lanthanum oxide.

### Claim 20

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 aid selected from the group consisting of a plasticizer, lubricant, binder, pore former, and solvent, to form a plasticized ceramic precursor batch composition;
shaping the plasticized 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 predominately alumina, magnesia, and titania and a second phase comprising cordierite,
wherein the sintering aid comprises at least one of calcium oxide and strontium oxide.

### Claim 21 (depends on 20)

The method of claim 20, wherein the sintering aid comprises at least one of a lanthanide oxide and yttrium oxide.

### Claim 22 (depends on 21)

The method of claim 21, wherein the lanthanide oxide comprises a cerium oxide.

### Claim 23 (depends on 22)

The method of claim 22, wherein the sintering aid comprises cerium oxide and at least one of yttrium oxide and a lanthanum oxide.

### Claim 24 (depends on 20)

The method of claim 20, wherein at least one sintering aid is present, on a weight percent oxide basis, in an amount in a range of 0.15 to 2 weight % relative to the total weight of the inorganic batch composition.

### Claim 25 (depends on 24)

The method of claim 24, wherein the plasticized ceramic precursor batch composition is shaped by extrusion.

### Claim 26 (depends on 20)

The method of claim 20, wherein the firing conditions effective to convert the green body into a ceramic article comprise heating the green body at a first hold temperature in the range of 1250° C. to 1450° C. and maintaining the first hold temperature for a first hold time sufficient to convert the green body into a ceramic article.

### Claim 27 (depends on 26)

The method of claim 26, wherein the first hold temperature is in the range of 1330° C. to 1380° C. and wherein the first hold time is in the range of from 2 to 24 hours.

### Claim 28 (depends on 26)

The method of claim 26, wherein the firing conditions further comprise:
cooling the fired ceramic body to a second hold temperature less than the first hold temperature for a second hold time;
heating the ceramic body to a third hold temperature greater than a threshold temperature and less than the first hold temperature for a third hold time, wherein the third hold temperature is greater than the second hold temperature; and
cooling the ceramic body to room temperature (RT).

### Claim 29 (depends on 28)

The method of claim 28, wherein the second hold temperature is in a range of 25° C. to 500° C., the second hold time is in a range of 1 hour to 48 hours, the third hold temperature is in a range of 850° C. to 1350° C., and the third hold time is in a range of 1 hour to 24 hours.