Ceramic filter process
AssigneePolyCeramics, Inc.
InventorsKevin G. Hayes, Peter A. Roberts
Life of this patent
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Abstract
A process for preparing a porous ceramic material, is disclosed. The process uses an organic sponge material, and a ceramic slurry. The ceramic slurry contains liquid, gluten, and ceramic material. In the first step of the process, the ceramic slurry is applied to the sponge in order to substantially saturate it with slurry. Thereafter, the saturated sponge is dehydrated until it contains less than about 5.0 weight percent of liquid. The dehydrated sponge is then fired at a temperature of from about 1,100 to about 3,500 degrees Fahrenheit.
Claims17
A process for preparing a porous ceramic material, comprising the steps of sequentially:
- (a) providing an organic sponge material which, after being heated to a temperature of 800 degrees Celsius for at least 60 minutes, will have at least 95 weight percent of its content of solid material converted to gas;
- (b) providing a slurry comprised of liquid, gluten, and ceramic material, wherein said slurry is comprised of at least about 60 weight percent of said ceramic material and from about 1 to about 40 weight percent of glutent, by combined weight of ceramic material and gluten, and from about 45 to about 75 weight percent of liquid, by combined weight of liquid, ceramic material, and gluten;
- (c) applying said slurry to said organic sponge so that said organic sponge contains from about 95 to about 100 weight percent of the maximum amount of said slurry it is capable of holding, thereby providing a substantially saturated organic sponge;
- (d) dehydrating said substantially saturated organic sponge so that said sponge contains less than about 5.0 weight percent of said liquid, thereby providing a dehydrated organic sponge;
- and
- (e) subjecting said dehydrated organic sponge to a temperature of from about 1,100 to about 3,500 degrees Fahrenheit.
Dependencies are inferred from the claim text.