Porous structure such as for filters, and making the same
AssigneeCorning Incorporated
InventorsGuohua Chen, Weimin Hou, He Jing, Jia Liu, Yiting Qin, John Forrest Wight, Jr., Qing Zhou
Life of this patent
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Abstract
A method of making a porous structure configured for use in a particulate filter includes bonding a plurality of glass bubbles to one another, and breaching the plurality of glass bubbles. Voids within individual breached glass bubbles open into one another to form cavities that extend through the porous structure.
Claims35
A porous structure, comprising:
- a plurality of glass bubbles comprising at least 7.3 wt % Na2O;
- wherein the glass bubbles are sintered to one another such that adjoining glass bubbles are physically bonded directly to one another;
- wherein more than 50% of the glass bubbles are breached;
- wherein voids defined within individual breached glass bubbles open into one another to form cavities that extend through the porous structure and to surfaces thereof;
- and
- wherein the porous structure has at least 50% porosity in terms of volume and comprises at least 10 vol % MgO.
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A method of making a porous structure configured for use in a particulate filter, comprising:
- adding a source Mg to a plurality of glass bubbles comprising Na2O;
- heating and bonding the plurality of glass bubbles to one another, wherein the glass bubbles have a D50 particle size of at least 1 micrometer but no more than 100 micrometers, and wherein the plurality comprises at least 1000 of the glass bubbles;
- and
- breaching at least some of the glass bubbles at a temperature between 500° C. and 800° C.;
- wherein, in aggregate, the bonded, breached glass bubbles form the porous structure, the porous structure comprising at least 7.3 wt % Na2O and at least 10 wt % MgO, and wherein voids within individual breached glass bubbles open into one another to form cavities that extend through the porous structure and to surfaces thereof.
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Dependencies are inferred from the claim text.