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US 9,957,200 B2Granted
Composition for improved manufacture of substrates
AssigneeCorning Incorporated
InventorsDouglas Munroe Beall, Gregg William Crume, James Anthony Feldman, Christopher John Malarkey, Elizabeth Marie Vileno
Life of this patent
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Abstract
A ceramic precursor batch composition, green ware formed thereof, porous ceramic honeycomb article formed thereof, and methods of making same.
Claims19
A ceramic precursor batch composition, comprising:
- inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition;
- and
- a temperature gelling cellulose ether,
- wherein the batch composition comprises a soluble ion concentration of less than 0.75 molar,
- wherein, in a wet state, the batch composition comprises a dielectric loss tangent at 915 MHz of less than 0.6, and
- wherein the dielectric loss tangent (tan δ) equals the ratio of the relative dielectric loss to the relative dielectric constant (∈″/∈′).
3 more elements
A ceramic precursor batch composition, comprising:
- inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition;
- and
- a temperature gelling cellulose ether,
- wherein the batch composition comprises a soluble ion concentration of less than 0.75 molar, and
- wherein the inorganic oxide composition comprises less than 1 wt % SO3.
2 more elements
A ceramic precursor batch composition, comprising:
- inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition;
- and
- a temperature gelling cellulose ether,
- wherein the batch composition comprises a soluble ion concentration of less than 0.75 molar, and
- wherein the batch composition comprises at least 0.1 wt % a catalytically active functional group.
2 more elements
A ceramic precursor batch composition, comprising:
- inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition;
- and
- a temperature gelling cellulose ether,
- wherein the batch composition comprises a soluble ion concentration of less than 0.75 molar, and
- wherein, in a wet state, a relative dielectric loss of the wet batch composition at 915 MHz is less than 25.
2 more elements
A ceramic green ware body, comprising:
- a plurality of channels;
- inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition;
- and
- a temperature gelling cellulose ether,
- wherein the ceramic green ware body comprises a soluble ion concentration of less than 0.75 molar,
- wherein, in a wet state, the ceramic green ware body comprises a dielectric loss tangent at 915 MHz of less than 0.6*CFA (closed frontal area fraction) in an axial direction, and
- wherein the dielectric loss tangent (tan δ) is equal to the ratio of the relative dielectric loss to the relative dielectric constant (∈″body/∈′body)=(∈″bulk CFA)/((1−CFA)+∈′bulk CFA).
4 more elements
A ceramic green ware body, comprising:
- a plurality of channels;
- inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition;
- and
- a temperature gelling cellulose ether,
- wherein the ceramic green ware body comprises a soluble ion concentration of less than 0.75 molar, and
- wherein the ceramic green ware body comprises at least 0.1 wt % a catalytically active functional group.
3 more elements
A ceramic green ware body, comprising:
- a plurality of channels;
- inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition;
- and
- a temperature gelling cellulose ether,
- wherein the ceramic green ware body comprises a soluble ion concentration of less than 0.75 molar, and
- wherein the ceramic green ware body comprises a wet bulk material with a relative dielectric loss at 915 MHz of less than 25, and a wet relative dielectric loss of the ceramic green body at 915 MHz that is less than 25*CFA (25 multiplied by the fraction of closed frontal area).
3 more elements
A method of making a ceramic green ware body, comprising:
- mixing a temperature gelling cellulose ether and inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition with a liquid vehicle to form a precursor batch;
- forming the precursor batch into a structure comprising a plurality of channels to form a wet ceramic green ware body,
- wherein the wet ceramic green ware body comprises a soluble ion concentration of less than 0.75 molar,
- wherein the wet ceramic green ware body comprises a dielectric loss tangent at 915 MHz in the wet ceramic green ware body of less than 0.6*CFA (closed frontal area fraction) in the axial direction,
- wherein the dielectric loss tangent (tan δ) equals the ratio of the relative dielectric loss to the relative dielectric constant (∈″/∈′),
- wherein the wet ceramic green ware body comprises a microwave penetration depth “D1/2P” in the axial direction of at least 2 cm, and
- wherein D1/2P is a function of the green ware CFA (closed frontal area fraction);
- and
- drying the wet ceramic green ware body to form the ceramic green ware body.
6 more elements
A method of making a ceramic green ware body, comprising:
- mixing a temperature gelling cellulose ether and inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition with a liquid vehicle to form a precursor batch,
- mixing at least 0.1 wt % a catalytically active functional group with the temperature gelling cellulose ether, the inorganic ceramic-forming ingredients and the liquid vehicle to form the precursor batch;
- forming the precursor batch into a structure comprising a plurality of channels to form a wet ceramic green ware body, wherein the wet ceramic green ware body comprises a soluble ion concentration of less than 0.75 molar;
- and
- drying the wet ceramic green ware body to form the ceramic green ware body.
2 more elements
A method of making a ceramic green ware body, comprising:
- mixing a temperature gelling cellulose ether and inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition with a liquid vehicle to form a precursor batch;
- forming the precursor batch into a structure comprising a plurality of channels to form a wet ceramic green ware body,
- wherein the wet ceramic green ware body comprises a soluble ion concentration of less than 0.75 molar,
- wherein the wet ceramic green ware body comprises a wet bulk material with a relative dielectric loss at 915 MHz of less than 25, and the wet ceramic green ware body has a relative dielectric loss at 915 MHz that is less than 25*CFA (25 multiplied by the fraction of closed frontal area),
- wherein the wet ceramic green ware body comprises a microwave penetration depth “D1/2P” that is greater than 20% of the diameter of the ware in the radial direction perpendicular to the channels, and
- wherein D1/2P is a function of the green ware CFA (closed frontal area fraction);
- and
- drying the wet ceramic green ware body to form the ceramic green ware body.
5 more elements
A ceramic green ware body, comprising:
- a plurality of channels;
- inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition;
- and
- a temperature gelling cellulose ether,
- wherein the ceramic green ware body comprises a soluble ion concentration of less than 0.75 molar, and
- wherein the ceramic green ware body comprises less than 1 wt % SO3.
3 more elements
A method of making a ceramic green ware body, comprising:
- mixing a temperature gelling cellulose ether and inorganic ceramic-forming ingredients comprising 50-98.9 wt % an inorganic oxide composition with a liquid vehicle to form a precursor batch, wherein the inorganic oxide composition comprises less than 1 wt % SO3;
- forming the precursor batch into a structure comprising a plurality of channels to form a wet ceramic green ware body, wherein the wet ceramic green ware body comprises a soluble ion concentration of less than 0.75 molar;
- and
- drying the wet ceramic green ware body to form the ceramic green ware body.
1 more element
Dependencies are inferred from the claim text.