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US 8,709,577 B2Granted
High porosity ceramic honeycomb article containing rare earth oxide and method of manufacturing same
AssigneeCorning Incorporated
InventorsDouglas Munroe Beall, Yves Andre Henri Brocheton, Gregory Albert Merkel
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Abstract
The present invention describes a high porosity (% P≧45%), refractory, ceramic article comprising a cordierite ceramic phase and at least about 0.1 wt. % of a rare earth oxide, such as yttrium oxide or lanthanum oxide. When compared to typical high-porosity cordierite articles, the articles of the present invention may exhibit relatively high strength, relatively low microcracking, relatively high strain tolerance (MOR/E), and/or relatively high thermal shock resistance (TSP).
Claims35
A ceramic honeycomb article, comprising:
- a predominant cordierite ceramic phase and at least about 0.1 wt. % of a rare earth oxide containing within the microstructure of the ceramic;
- a total porosity (% P) wherein % P≧45%;
- ERatio 1000≦1.05, wherein ERatio 1000=E1000° C./ERT;
- and
- CTE≦15×10−7/° C. from 25° C.-800° C.;
- and
- Δαmc less than 2.5,
- wherein at least a portion of the rare earth oxide is contained in an intercrystalline glass phase.
5 more elements
A ceramic honeycomb article, comprising:
- a total porosity (% P) wherein 50%≦% P≦70%,
- a median pore size of 3-30 microns,
- the article containing a cordierite-type phase including a compound having a formula [A]x[M]y[T]ZO18, where A is selected from a group consisting of alkali elements, alkaline earth elements, rare earth elements, CO2, H2O, and combinations thereof;
- M is selected from a group consisting of Mg, Fe, Mn, Co, and combinations thereof;
- T is selected from a group consisting of Al, Si, Ga, Ge, and combinations thereof;
- 0≦x≦1.0;
- 1.9≦y≦2.1;
- and 8.9≦z≦9.1;
- and 0.1-5.0 wt. % of a rare earth oxide,
- ERatio 1000≦1.05, wherein ERatio 1000=E1000° C./ERT;
- CTE≦15×10−7/° C. from 25° C.-800° C.;
- and
- Δαmc less than 2.5,
- wherein at least a portion of the rare earth oxide is contained in an intercrystalline glass phase.
11 more elements
Dependencies are inferred from the claim text.