CN104995154A - Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same - Google Patents
Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same Download PDFInfo
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- CN104995154A CN104995154A CN201380051106.8A CN201380051106A CN104995154A CN 104995154 A CN104995154 A CN 104995154A CN 201380051106 A CN201380051106 A CN 201380051106A CN 104995154 A CN104995154 A CN 104995154A
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- 239000000203 mixture Substances 0.000 title claims abstract description 98
- 239000000919 ceramic Substances 0.000 title claims abstract description 95
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 title abstract description 9
- SNAAJJQQZSMGQD-UHFFFAOYSA-N aluminum magnesium Chemical compound [Mg].[Al] SNAAJJQQZSMGQD-UHFFFAOYSA-N 0.000 title abstract description 9
- 229910052878 cordierite Inorganic materials 0.000 title abstract description 9
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 title abstract description 9
- 238000000034 method Methods 0.000 claims abstract description 26
- 238000004519 manufacturing process Methods 0.000 claims abstract description 6
- 239000011148 porous material Substances 0.000 claims description 43
- 238000005245 sintering Methods 0.000 claims description 41
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 claims description 30
- 229910000420 cerium oxide Inorganic materials 0.000 claims description 29
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 claims description 29
- 229910052782 aluminium Inorganic materials 0.000 claims description 26
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 22
- 239000004411 aluminium Substances 0.000 claims description 21
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 21
- 239000013078 crystal Substances 0.000 claims description 21
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 20
- 239000011777 magnesium Substances 0.000 claims description 20
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 19
- 238000010304 firing Methods 0.000 claims description 19
- 150000001875 compounds Chemical class 0.000 claims description 17
- MRELNEQAGSRDBK-UHFFFAOYSA-N lanthanum(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[La+3].[La+3] MRELNEQAGSRDBK-UHFFFAOYSA-N 0.000 claims description 17
- 239000000395 magnesium oxide Substances 0.000 claims description 16
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 14
- 229910052749 magnesium Inorganic materials 0.000 claims description 14
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 13
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 12
- 229910000311 lanthanide oxide Inorganic materials 0.000 claims description 11
- 239000012700 ceramic precursor Substances 0.000 claims description 10
- 238000010411 cooking Methods 0.000 claims description 10
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 10
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 9
- 229910017682 MgTi Inorganic materials 0.000 claims description 8
- 239000006057 Non-nutritive feed additive Substances 0.000 claims description 8
- 229910010413 TiO 2 Inorganic materials 0.000 claims description 8
- 239000000377 silicon dioxide Substances 0.000 claims description 8
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 claims description 7
- 230000000903 blocking effect Effects 0.000 claims description 5
- 239000003795 chemical substances by application Substances 0.000 claims description 5
- 239000000314 lubricant Substances 0.000 claims description 5
- 239000004902 Softening Agent Substances 0.000 claims description 4
- 239000002904 solvent Substances 0.000 claims description 4
- 239000002131 composite material Substances 0.000 abstract description 19
- 239000000654 additive Substances 0.000 description 23
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 21
- 239000000463 material Substances 0.000 description 19
- 229910044991 metal oxide Inorganic materials 0.000 description 18
- 150000004706 metal oxides Chemical class 0.000 description 18
- 230000000996 additive effect Effects 0.000 description 14
- 238000000354 decomposition reaction Methods 0.000 description 13
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 13
- 238000009826 distribution Methods 0.000 description 13
- 229910052863 mullite Inorganic materials 0.000 description 13
- 230000008859 change Effects 0.000 description 12
- 239000007788 liquid Substances 0.000 description 8
- 239000002245 particle Substances 0.000 description 8
- 239000000843 powder Substances 0.000 description 8
- 238000007493 shaping process Methods 0.000 description 8
- 229910000505 Al2TiO5 Inorganic materials 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 7
- 230000008569 process Effects 0.000 description 7
- AABBHSMFGKYLKE-SNAWJCMRSA-N propan-2-yl (e)-but-2-enoate Chemical compound C\C=C\C(=O)OC(C)C AABBHSMFGKYLKE-SNAWJCMRSA-N 0.000 description 7
- 229910052761 rare earth metal Inorganic materials 0.000 description 7
- 150000002910 rare earth metals Chemical class 0.000 description 7
- 239000002994 raw material Substances 0.000 description 7
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 6
- 229910052753 mercury Inorganic materials 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- 229920002472 Starch Polymers 0.000 description 5
- 239000013543 active substance Substances 0.000 description 5
- 239000002585 base Substances 0.000 description 5
- 229910052799 carbon Inorganic materials 0.000 description 5
- 238000001914 filtration Methods 0.000 description 5
- 230000008439 repair process Effects 0.000 description 5
- 239000006104 solid solution Substances 0.000 description 5
- 229910052596 spinel Inorganic materials 0.000 description 5
- 239000011029 spinel Substances 0.000 description 5
- 239000008107 starch Substances 0.000 description 5
- 235000019698 starch Nutrition 0.000 description 5
- 239000000454 talc Substances 0.000 description 5
- 235000012222 talc Nutrition 0.000 description 5
- 229910052623 talc Inorganic materials 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 229910052727 yttrium Inorganic materials 0.000 description 5
- 229910020068 MgAl Inorganic materials 0.000 description 4
- 235000021355 Stearic acid Nutrition 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 238000001816 cooling Methods 0.000 description 4
- 238000007571 dilatometry Methods 0.000 description 4
- POULHZVOKOAJMA-UHFFFAOYSA-N dodecanoic acid Chemical compound CCCCCCCCCCCC(O)=O POULHZVOKOAJMA-UHFFFAOYSA-N 0.000 description 4
- 239000010439 graphite Substances 0.000 description 4
- 229910002804 graphite Inorganic materials 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
- 239000010687 lubricating oil Substances 0.000 description 4
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical group CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 4
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 4
- 230000001590 oxidative effect Effects 0.000 description 4
- -1 peridotites Chemical compound 0.000 description 4
- 239000002243 precursor Substances 0.000 description 4
- 239000004071 soot Substances 0.000 description 4
- 239000008117 stearic acid Substances 0.000 description 4
- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 3
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 3
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 3
- 208000035126 Facies Diseases 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 239000005642 Oleic acid Substances 0.000 description 3
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 description 3
- 238000002441 X-ray diffraction Methods 0.000 description 3
- 239000012298 atmosphere Substances 0.000 description 3
- 239000011230 binding agent Substances 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 230000008602 contraction Effects 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 3
- 229920000609 methyl cellulose Polymers 0.000 description 3
- 239000001923 methylcellulose Substances 0.000 description 3
- 235000010981 methylcellulose Nutrition 0.000 description 3
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 3
- 239000005995 Aluminium silicate Substances 0.000 description 2
- 239000005639 Lauric acid Substances 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- 235000012211 aluminium silicate Nutrition 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000003197 catalytic effect Effects 0.000 description 2
- 229910001919 chlorite Inorganic materials 0.000 description 2
- 229910052619 chlorite group Inorganic materials 0.000 description 2
- QBWCMBCROVPCKQ-UHFFFAOYSA-N chlorous acid Chemical compound OCl=O QBWCMBCROVPCKQ-UHFFFAOYSA-N 0.000 description 2
- 229910052593 corundum Inorganic materials 0.000 description 2
- 239000010431 corundum Substances 0.000 description 2
- 230000001186 cumulative effect Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000005496 eutectics Effects 0.000 description 2
- 235000019580 granularity Nutrition 0.000 description 2
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 2
- 229940059904 light mineral oil Drugs 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 210000000582 semen Anatomy 0.000 description 2
- RYYKJJJTJZKILX-UHFFFAOYSA-M sodium octadecanoate Chemical compound [Na+].CCCCCCCCCCCCCCCCCC([O-])=O RYYKJJJTJZKILX-UHFFFAOYSA-M 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 238000005382 thermal cycling Methods 0.000 description 2
- 239000003981 vehicle Substances 0.000 description 2
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 1
- 244000068988 Glycine max Species 0.000 description 1
- 235000010469 Glycine max Nutrition 0.000 description 1
- OYHQOLUKZRVURQ-HZJYTTRNSA-N Linoleic acid Chemical compound CCCCC\C=C/C\C=C/CCCCCCCC(O)=O OYHQOLUKZRVURQ-HZJYTTRNSA-N 0.000 description 1
- 229910017625 MgSiO Inorganic materials 0.000 description 1
- TUNFSRHWOTWDNC-UHFFFAOYSA-N Myristic acid Natural products CCCCCCCCCCCCCC(O)=O TUNFSRHWOTWDNC-UHFFFAOYSA-N 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 229910052650 alkali feldspar Inorganic materials 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 229910001413 alkali metal ion Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- 229910001420 alkaline earth metal ion Inorganic materials 0.000 description 1
- WYTGDNHDOZPMIW-RCBQFDQVSA-N alstonine Natural products C1=CC2=C3C=CC=CC3=NC2=C2N1C[C@H]1[C@H](C)OC=C(C(=O)OC)[C@H]1C2 WYTGDNHDOZPMIW-RCBQFDQVSA-N 0.000 description 1
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 description 1
- BTBJBAZGXNKLQC-UHFFFAOYSA-N ammonium lauryl sulfate Chemical compound [NH4+].CCCCCCCCCCCCOS([O-])(=O)=O BTBJBAZGXNKLQC-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 239000006105 batch ingredient Substances 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910001593 boehmite Inorganic materials 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 229920003086 cellulose ether Polymers 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000008367 deionised water Substances 0.000 description 1
- 229910021641 deionized water Inorganic materials 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 229910001648 diaspore Inorganic materials 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000013213 extrapolation Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 229910052839 forsterite Inorganic materials 0.000 description 1
- 239000005350 fused silica glass Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000012010 growth Effects 0.000 description 1
- IPCSVZSSVZVIGE-UHFFFAOYSA-N hexadecanoic acid Chemical compound CCCCCCCCCCCCCCCC(O)=O IPCSVZSSVZVIGE-UHFFFAOYSA-N 0.000 description 1
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 1
- 239000010443 kyanite Substances 0.000 description 1
- 229910052850 kyanite Inorganic materials 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- 229960004232 linoleic acid Drugs 0.000 description 1
- 150000002632 lipids Chemical class 0.000 description 1
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 1
- 239000012184 mineral wax Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- NDLPOXTZKUMGOV-UHFFFAOYSA-N oxo(oxoferriooxy)iron hydrate Chemical compound O.O=[Fe]O[Fe]=O NDLPOXTZKUMGOV-UHFFFAOYSA-N 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 238000002161 passivation Methods 0.000 description 1
- 239000000546 pharmaceutical excipient Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920001083 polybutene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 229910052903 pyrophyllite Inorganic materials 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 229910001753 sapphirine Inorganic materials 0.000 description 1
- 238000007569 slipcasting Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000001228 spectrum Methods 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 239000003784 tall oil Substances 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 230000001052 transient effect Effects 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
- 230000008016 vaporization Effects 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
- 239000002912 waste gas Substances 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
- C04B35/462—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates based on titanates
- C04B35/478—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates based on titanates based on aluminium titanates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/632—Organic additives
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/007—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores
- C04B38/0074—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores expressed as porosity percentage
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
- C04B2235/3206—Magnesium oxides or oxide-forming salts thereof
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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Abstract
Disclosed are ceramic bodies comprised of composite cordierite aluminum magnesium titanate ceramic compositions and methods for the manufacture of same.
Description
The cross reference of related application
The application is the U.S. Patent Application No. 13/676 submitted on November 14th, 2012, the continuation application of 567 also requires the right of priority of this application, this application is the U.S. Patent Application No. 13/584 submitted on August 14th, 2012, the part continuation application of 993, the full content of above two literary compositions is included in herein by reference, just as describing in detail in full in this article.
Invention field
The present invention relates to ceramic composition, more specifically, relate to the composite ceramic compositions comprising cordierite aluminum magnesium titanate.
Technical background
The refractory materials that the little thus resistance to sudden heating of thermal expansion is high is used to the application that such as substrate for catalytic converters and diesel particulate filter and so in use produce high thermal gradient.One of best materials for these application is trichroite, because its thermal expansion is little, fusing point is high, cost is low.In diesel particulate filter field, it has been recognized that, higher thermal capacity is conducive to improving the weather resistance of strainer in regenerative process (Hickman SAE).In order to reduce the volume of the material needed for the given heat of absorption, wish the material using volumetric heat capacity amount high.Wish that the volume of material is less, because this can reduce the pressure drop of evacuation circuit and increase for storing grey open volume.But, still require low-thermal-expansion.Aluminium titanates is that a few can be made into little and one of the material that volumetric heat capacity amount is higher than trichroite of thermal expansion.
Aluminium titanates (AT) and the matrix material containing vast scale aluminium titanates have several shortcoming.The first, pure aluminium titanates is lower than being metastable state when about 1200 DEG C.The thermal expansion of the second, AT is only just lower when particle size is larger, and forms tiny crack when cooling in kiln.These macrobeads and tiny crack easily make the physical strength of material lower.3rd, it is very large delayed that tiny crack causes thermal dilatometry to have, and causes transient thermal growths value very high, particularly when cooling.The firing temperature of the four, AT based composites is usually higher, is generally greater than 1400 DEG C.Finally, AT display has very high thermal cycling and increases, and the existence of alkali metal expands this thermal cycling and increases.
In order to reduce decomposition rate, additive can be added in aluminium titanates, such as mullite, MgTi
2o
5and Fe
2tiO
5.MgTi
2o
5be easy to reduce decomposition rate under the reducing conditions, only just make decomposition rate slow down under oxidative conditions when high-content (>10%).Fe
2tiO
5be easy to reduce decomposition rate under oxidative conditions, increase decomposition rate (United States Patent (USP) 5153153,1992) under the reducing conditions.
Second-phase (second phase) is added if mullite is to improve the intensity of complex body, because usually crack splitting can not be there is between mullite crystal in AT.Mullite is also a kind of well selection, because it also has quite high volumetric heat capacity.Other second-phase also in AT matrix material, comprises alkali and alkaline earth metal ions feldspar.But the thermal expansion of mullite and alkali feldspars is greater than optimal heat and expands.
Providing the intensity with improvement to keep in the effort of the composite AT ceramic body of low CTE simultaneously, be selection more better than mullite using trichroite as second-phase, because the thermal expansivity of trichroite is less than mullite.But trichroite and pure aluminium titanates all can not reach thermodynamic equilibrium at any temperature.The composite ceramics based on trichroite and AT with low CTE, high strength and excellent thermostability is provided to represent a much progress of this area.The invention provides this object.
Summary of the invention
Show and describe the embodiment of the composite ceramic compositions comprising cordierite aluminum magnesium titanate herein.In one aspect, the invention provides a kind of ceramic comprising first crystal phase and the second crystal phase, described first crystal forms primarily of the sosoloid of aluminium titanates and two magnesium titanates, and described second crystal comprises trichroite mutually.In one embodiment, the solid solution phase of aluminium titanates and two magnesium titanates demonstrates pseudobrookite (pseudobrookite) crystalline structure.In another embodiment, the overall porosity %P of ceramic is greater than 40 volume %.
In another aspect, the present invention includes a kind of diesel particulate filter, it comprises foregoing invention ceramic composition.In one embodiment, described diesel particulate filter comprises polynuclear plane, and this structure has inlet chamber and the downstream chamber of multiple axially extended end blocking.
Again in one aspect of the method, the invention provides a kind of method manufacturing invention composite cordierite aluminum magnesium titanate ceramic of the present invention.The method generally includes, and first providing package is containing the inorganic batch composition of magnesium oxide source, silica source, alumina source and titania source.Then, this inorganic batch composition mixed with one or more processing aids, described processing aid is selected from lower group: softening agent, lubricant, tackiness agent, pore former and solvent, so that the ceramic precursor batch composition forming plasticising.The ceramic precursor batch composition of this plasticising is shaped or otherwise forms green compact, optionally dry, then fire under described green being effectively converted into the condition of ceramic.
A kind of example embodiment discloses a kind of goods, and described goods comprise composite composition, and this composite composition comprises the sosoloid of aluminium titanates and two magnesium titanates and comprises the second crystal phase of trichroite.Take oxide weight percent as benchmark, consisting of of described goods: 4-10%MgO; 40-55%Al
2o
3; 25-35%TiO
2; 5-25%SiO
2; And metal oxide sintering aid, this metal oxide sintering aid comprises lanthanide oxide.
A kind of example embodiment also discloses a kind of diesel particulate filter, and described diesel particulate filter comprises composite composition, and this composite composition comprises the sosoloid of aluminium titanates and two magnesium titanates and comprises the second crystal phase of trichroite.Take oxide weight percent as benchmark, consisting of of described particulate filter: 4-10%MgO; 40-55%Al
2o
3; 25-35%TiO
2; 5-25%SiO
2; And metal oxide sintering aid, this metal oxide sintering aid comprises lanthanide oxide.In an example embodiment, described diesel particulate filter comprises polynuclear plane, and this structure has inlet chamber and the downstream chamber of multiple axially extended end blocking.
A kind of example embodiment also discloses the method for the manufacture of composite cordierite aluminum magnesium titanate ceramic.Described method comprises composite inorganic batch composition, and it comprises magnesium oxide source, silica source, alumina source and titania source, and at least one metal oxide sintering aid, and wherein said metal oxide sintering aid comprises lanthanide oxide.By this inorganic batch composition and one or more processing aids admixed together, described processing aid is selected from lower group: softening agent, lubricant, tackiness agent, pore former and solvent, so that the ceramic precursor batch composition forming plasticising.The ceramic precursor batch composition of plasticising is configured as green.Described method fires green under being included in and green being changed into effectively the condition of ceramic, this ceramic comprises first crystal phase and the second crystal phase, described first crystal forms primarily of the sosoloid of aluminium titanates and two magnesium titanates, and described second crystal comprises trichroite mutually.
A kind of example embodiment also discloses a kind of goods, and described goods comprise the pseudobrookite phase mainly comprising aluminum oxide, magnesium oxide and titanium oxide, comprise the second-phase of trichroite, and sintering aid.Sintering aid comprises at least one in lanthanide oxide and yttrium oxide.
Should be understood that foregoing general description and the following detailed description are all example and illustrative, be intended to be further expalined claimed the present invention.
Accompanying drawing explanation
The present invention is further described see the following drawings, wherein:
Fig. 1 illustrates stable combined along aluminium titanates (Al
2tiO
5) and trichroite (Mg
2al
4si
5o
18) between pseudo-binary juncture (pseudo-binary join) with the change of temperature and composition.
Quaternary MgO-Al when Fig. 2 illustrates 1300 DEG C
2o
3-TiO
2-SiO
2with the facies relationship of two magnesium titanates, aluminium titanates and the trichroite ternary section that is end points in system.
Fig. 3 illustrate at 1100 DEG C for contrast aluminum titanate ceramic compositions and phasor trichroite/mullite/pseudobrookite district in composition length variations over time.
After Fig. 4 illustrates and keeps 100 hours for contrast aluminum titanate ceramic compositions and the trichroite/mullite/pseudobrookite composition of table 1 at the temperature of 950-1250 DEG C, the change of its thermal expansivity within the scope of 25-1000 DEG C.
Fig. 5 shows the change of representative pressure drop data with soot load amount of the ceramic wall flow filter of trichroite/mullite/pseudobrookite constructed in accordance.
Fig. 6 illustrates the microstructure of the invention object with about 55 grams per liter aluminum oxide washcoat (washcoat).
Fig. 7 shows the thermal expansivity (CTE) of example embodiment of the present invention with relative rare earth cost (1%Y
2o
3=1) change.
Embodiment
As above summarize, in one embodiment, the invention provides a kind of composite ceramic body comprising first crystal phase and the second crystal phase, described first crystal is primarily of the sosoloid (MgTi of aluminium titanates and two magnesium titanates
2o
5-Al
2tiO
5) form, described second crystal comprises trichroite mutually.Take oxide weight percent as benchmark, the feature of the composition of this ceramic body comprises following component: 4-10%MgO; 40-55%Al
2o
3; 25-44%TiO
2; 5-25%SiO
2, 0-5%Y
2o
3, 0-5%La
2o
3and 0-3%Fe
2o
3.In these or other embodiment, the composition of ceramic body of the present invention is that the oxide compound of benchmark and the weight fraction of combination of oxides comprise when representing: a (Al with oxide compound
2tiO
5)+b (MgTi
2o
5)+c (2MgO2Al
2o
35SiO
2)+d (3Al
2o
32SiO
2)+e (MgOAl
2o
3)+f (2MgOTiO
2)+g (Y
2o
3)+h (La
2o
3)+i (Fe
2o
3tiO
2)+j (TiO
2), wherein a, b, c, d, e, f, g, h, i and j are the weight fractions of each component, meet (a+b+c+d+e+f+g+h+i+j)=1.00.For this purpose, the scope of the weight fraction of each component is as follows respectively: 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≤0.05,0.0≤h≤0.05,0.0≤i≤0.05, and 0.0≤j≤0.20.Can think, the oxide compound for the oxide compound composition defining these potteries does not need to be present in ceramic articles mutually with corresponding free oxide or crystal with combination of oxides, unless particularly pointing out these crystal is herein the feature of these potteries mutually.Although also will be appreciated that a, b, c, d, e, f, g, h, and i sum is 1.00, the ratio of what this expressed is oxide compound and combination of oxides.That is, beyond the oxide compound processing described ratio and combination of oxides, composite ceramic body can comprise other impurity.With reference to embodiment as described below, this will become apparent.
The solid solution phase of aluminium titanates and two magnesium titanates preferably presents pseudobrookite crystalline structure.For this reason, the composition of pseudobrookite phase can be depending on the main assembly (bulkcomposition) of technological temperature and pottery, therefore can be decided by equilibrium conditions.But in one embodiment, the composition of pseudobrookite phase comprises the MgTi of about 15 % by weight to 35 % by weight
2o
5.And although the cumulative volume of pseudobrookite phase also can change, in another embodiment, cumulative volume is preferably 50 volume % to 95 volume % of total ceramic composition.
Optionally, composite ceramic body also can comprise the phase that one or more are selected from lower group: mullite, sapphirine, titania polymorph are as rutile or anatase octahedrite, corundum and spinel solid solution (MgAl
2o
4-Mg
2tiO
4).When there is Spinel, its composition also can depend on technological temperature and main assembly.But in one embodiment, Spinel can comprise at least about 95%MgAl
2o
4.
And ceramic composition also optionally can contain one or more metal oxide sintering aid or additive, thus reduce firing temperature and expand to be formed and fire window needed for ceramic composition.The amount of the sintering aid existed can be the 0-5 % by weight of total composition, and sintering aid can comprise such as one or more metal oxides, as Fe
2tiO
5, Y
2o
3and La
2o
3.In one embodiment, find as yttrium oxide (Y
2o
3) and/or lanthanum trioxide (La
2o
3) add fashionable with 0.5-4.0 % by weight, the more preferably amount of 1.0-2.0 % by weight, be sinter additives excellent especially.For this reason, yttrium oxide or lanthanide oxide can exist mutually as oxide compound, or form new phase with one or more other metal oxide component of ceramic body.Similarly, in some embodiments, from suitable source of iron ferriferous oxide with iron protoxide or ferric oxide or with the combination of other oxide compound (as Fe
2tiO
5) when existing, by Fe
2tiO
5calculate, ferriferous oxide amount can be 0 % by weight to 3 % by weight Fe
2tiO
5.Fe
2tiO
5have the decomposition rate being beneficial to and slowing down in oxidizing atmosphere.Work as Fe
2tiO
5when being all present in ceramic body with Spinel, spinel solid solution still can be included in the iron of ferrous iron in sosoloid and/or trivalent.
According to particular implementation of the present invention, ceramic body comprises about 10 % by weight to 25 % by weight trichroites, about 10 % by weight to 30 % by weight mullites, about 50 % by weight to 70 % by weight primarily of Al
2tiO
5-MgTi
2o
5the pseudobrookite phase of sosoloid composition and about 0.5 % by weight to 3.0 % by weight Y
2o
3additive.
In some cases, ceramic body of the present invention can comprise the overall porosity of higher level.Such as, the present invention can provide overall porosity %P be at least 40%, at least 45%, at least 50% or even at least 60% ceramic body, porosity is measured by mercury porosimeter.
Except higher overall porosity, ceramic body of the present invention also comprises the pore size distribution of relative narrower, is proved by the percentage ratio of minimum less and/or larger aperture.Therefore, relative aperture distribution can by hole fraction representation, and hole used herein mark is that the volume of voids measured by mercury porosimeter is removed in the percentage ratio of 100.Such as, d
50numerical value be mean pore sizes based on pore volume, measure by micron; Therefore, d
50it is bore dia when infiltrating mercury in the perforate of in ceramics sample 50%.D
90numerical value be 90% pore volume be less than d by its diameter
90the bore dia when hole of numerical value is formed; Therefore, d
90also equal bore dia when infiltrating mercury in the perforate of 10 volume % in pottery.In addition, d
10numerical value be 10% pore volume be less than d by its diameter
10the bore dia when hole of numerical value is formed, therefore, d
10equal bore dia when infiltrating mercury in pottery in 90 volume % perforates.D
10and d
90value also represents with units of micrometers.
In one embodiment, the mean pore sizes d in the hole existed in ceramic of the present invention
50for at least 10 μm, more preferably at least 14 μm, or more preferably at least 16 μm.In another embodiment, the mean pore sizes d in the hole existed in ceramic of the present invention
50be no more than 30 μm, be more preferably no more than 25 μm, be more preferably no more than 20 μm.In another embodiment, the mean pore sizes d in the hole existed in ceramic of the present invention
50be 10 μm to 30 μm, more preferably 18 μm to 25 μm is even more preferably 14 μm to 25 μm, more preferably 16 μm to 20 μm.For this reason, when ceramic body of the present invention is used to diesel exhaust filtration application, above-mentioned porosity value and mean pore sizes value be combined in the filtration efficiency remaining useful while, low idle voltage drop and soot-loaded pressure drop can be provided.
In one embodiment, the narrower pore size distribution of ceramic of the present invention is expressed as than mean pore sizes d
50the Tile Width in little aperture, and the mark being quantitatively hole further.As used herein, mean pore sizes d is less than
50the Tile Width " d in aperture
the factor" or " d
f" value represents, it is expressed as (d
50-d
10)/d
50value.For this reason, the d of ceramic articles of the present invention
the factorvalue is no more than 0.50,0.40,0.35 or not even more than 0.30.Some preferred embodiment in, the d of ceramic body of the present invention
the factorvalue is no more than 0.25 or even 0.20.For this reason, lower d
fvalue represents low aperture mark, when ceramic body of the present invention being used for diesel filter application, and low d
fvalue is conducive to guaranteeing low soot-loaded pressure drop.
In another embodiment, the narrower pore size distribution of ceramic of the present invention also can by than mean pore sizes d
50the Tile Width in little or large aperture represents, and is quantitatively the mark in hole further.As used herein, than mean pore sizes d
50tile Width " the d in little or large aperture
width" or " d
b" value representative, it is expressed as (d
90-d
10)/d
50value.For this reason, in one embodiment, the d of ceramic structure of the present invention
bvalue is less than 1.50,1.25,1.10 or even 1.00.In some particularly preferred embodiments, d
bvalue is not more than 0.8, is more preferably not more than 0.7, is even more preferably not more than 0.6.Lower d
bvalue can provide higher filtration efficiency and higher intensity for diesel filter application.
In another embodiment, ceramic body of the present invention can show the low thermal expansivity causing excellent resistance to sudden heating (TSR).As those skilled in the art are accessible, TSR and thermal expansivity (CTE) are inversely proportional to.That is, the ceramic body that thermal expansion is little has high resistance to sudden heating usually, and can tolerate the temperature fluctuation of the wide region such as met with in diesel exhaust filtration application.Therefore, in one embodiment, the feature of ceramic of the present invention has the lower thermal expansivity (CTE) along at least one direction, and measure with dilatometry, described CTE is less than or equal to about 25.0 × 10 in the temperature range of 25 to 1000 DEG C
-7/ DEG C, be less than or equal to about 20.0 × 10
-7/ DEG C, be less than or equal to about 15.0 × 10
-7/ DEG C, be less than or equal to about 10.0 × 10
-7/ DEG C, or be even less than or equal to about 8.0 × 10
-7/ DEG C.
And should be appreciated that, embodiments of the present invention can show the combination of the above-mentioned character of any needs.Such as, in one embodiment, preferred CTE (25-1000 DEG C) is no more than 12.0 × 10
-7/ DEG C (and be preferably not more than 10.0 × 10
-7/ DEG C), porosity %P is at least 45%, and mean pore sizes is at least 14 microns (more preferably at least 18 microns), d
fvalue was not more than for 0.35 (being more preferably not more than 0.30).More preferably, the d of the ceramic body of these examples
bvalue is no more than 1.0, is more preferably no more than 0.85, is more preferably no more than 0.75.In another kind of example embodiment, CTE (25-1000 DEG C) is no more than 18x10
-7/ DEG C and porosity %P is at least 40%.Such as, CTE (25-1000 DEG C) is no more than 18x10
-7/ DEG C and porosity %P is at least 60%.In another kind of embodiment, CTE (25-1000 DEG C) is no more than 12x10
-7/ DEG C and porosity %P is at least 40%.In another kind of embodiment, CTE (25-1000 DEG C) is no more than 12x10
-7/ DEG C and porosity %P is at least 60%.
Ceramic body of the present invention can have arbitrary shape or the geometry of applicable application-specific.In the particularly suitable high temperature filtration applications of ceramic body of the present invention as in diesel particulate filter, preferably ceramic body has vesicular structure, structure as unitarily formed in honeycomb.Such as, in an exemplary embodiment, ceramic body comprises the honeycomb body structure with entrance end and exit end or inlet end face and exit end face, and multiple hole extending to exit end from entrance end, and this some holes has the wall of porous.The hole density of honeycomb body structure can be 70 hole/inches further
2(10.9 holes/centimetre
2) to 400 hole/inches
2(62 holes/centimetre
2).In one embodiment, a part for this some holes can block with the same or similar thickener of composition of composition with this polynuclear plane at entrance end or inlet end face, and as described in No. 4329162nd, United States Patent (USP), this patent is incorporated herein by reference.Only block in the end in hole, plug depth is about 5-20 millimeter usually, but can change plug depth.The hole of a part blocks at exit end, but this some holes does not correspond to those holes in inlet end plugged.Therefore, each hole only at one end blocks.Preferred arrangement mode blocks every a hole with halma board pattern at designated surface.
This blocking configuration makes exhaust flow have closer contact with the porous wall of base material.Exhaust flow flows into base material by the perforate at entrance end, then by the hole wall of porous, then is discharged from this structure by the perforate of exit end.The strainer describing type at this is called " wall stream " strainer, because the flowing-path that alternately blocking duct produces requires that processed waste gas passes through from the hole wall of porous ceramics, then discharges from strainer.
The present invention also provides a kind of precursor batch of the formation pottery from comprising some inorganic powdered raw materials to prepare the method for composite cordierite aluminum magnesium titanate ceramic of the present invention.Usually, the method comprises first providing package and contains the inorganic batch composition of magnesium oxide source, silica source, alumina source and titania source.Then, this inorganic batch composition mixed with one or more processing aids, described processing aid is selected from lower group: softening agent, lubricant, tackiness agent, pore former and solvent, so that the ceramic precursor batch composition forming plasticising.The ceramic precursor batch composition of this plasticising is shaped or otherwise forms green compact, optionally dry, then fire under described green being effectively converted into the condition of ceramic.
Magnesium oxide source such as but not limited to can be selected from following material one or more: MgO, Mg (OH)
2, MgCO
3, MgAl
2o
4, Mg
2siO
4, MgSiO
3, MgTiO
3, Mg
2tiO
4, MgTi
2o
5, talcum and calcination of talc.Or, described magnesium oxide source can be selected from following material one or more, forsterite, peridotites, chlorite or serpentine.More preferably, the median particle diameter of magnesium oxide source is no more than 35 microns, is more preferably no more than 30 microns.For this reason, as alleged herein, all granularities are all measured by laser diffraction technology, such as Mai Qike (Microtrac) particle-size analyzer.
Alumina source forms the source of aluminum oxide such as but not limited to being selected from, such as corundum, Al (OH)
3, boehmite, diaspore, transitional alumina, such as gama-alumina or ρ-aluminum oxide.Or alumina source can be the mixture (compound) of aluminium and other metal oxide, described metal oxide such as MgAl
2o
4, Al
2tiO
5, mullite, kaolin, calcined kaolin, pyrophyllite (phyrophyllite), kyanite etc.In one embodiment, the weighted average median particle size of alumina source is more preferably 10 microns to 60 microns, is more preferably 20 microns to 45 microns.In another embodiment, alumina source can be that one or more form the combination of the source of aluminum oxide and the mixture of one or more aluminium and another kind of metal oxide.
Except above-mentioned with magnesium or except the mixture of aluminum oxide, the titania source provided can be TiO
2powder.
The silica source provided can be SiO
2powder, such as quartz, cryptocrystalline quartz, fused silica, diatomite, low alkali zeolite or colloided silica.In addition, the silica source provided also can be the mixture with magnesium and/or aluminium, comprises such as trichroite, chlorite etc.In another embodiment, the median particle diameter of silica source is more preferably at least 5 μm, more preferably at least 10 μm, or more preferably at least 20 μm.
As mentioned above, can optionally add one or more metal oxide sintering aid or additive in precursor batch, fire window to reduce firing temperature and to expand to be formed needed for ceramic composition.The amount of the sintering aid existed can be such as the 0-5 % by weight of total composition, and sintering aid can comprise such as one or more metal oxides, as Fe
2tiO
5, Y
2o
3and La
2o
3.In one embodiment, when adding yttrium oxide (Y with the amount of 0.5 % by weight to 4.0 % by weight, more preferably 1.0 % by weight to 2.0 % by weight
2o
3) and/or lanthanum trioxide (La
2o
3) time, find yttrium oxide (Y
2o
3) and/or lanthanum trioxide (La
2o
3) be sinter additives excellent especially.Similarly, when the amount with 0 % by weight to 3 % by weight adds Fe
2tiO
5time, it is conducive to the decomposition of slowing down in oxidizing atmosphere.
In addition, ceramic precursor batch composition can comprise other additives, such as tensio-active agent, lubricating oil and pore-forming material.The non-limitative example that can be used as the tensio-active agent of shaping additive comprises C
8-C
22lipid acid and/or their derivative.The other surface active agent composition that can use together with described lipid acid is C
8-C
22fatty ester, C
8-C
22fatty alcohol and combination thereof.Exemplary tensio-active agent is stearic acid, lauric acid, tetradecanoic acid, oleic acid, linolic acid, palmitinic acid and derivative thereof, Yatall MA (tall oil), the combination of stearic acid and Texapon Special and the combination of all these compounds.In an illustrative embodiments, tensio-active agent can be lauric acid, stearic acid, oleic acid, Yatall MA and these combination.In some embodiments, the amount of tensio-active agent is about 0.25 % by weight to about 2 % by weight.
The non-limitative example that can be used as the lubricating oil of shaping additive can be, blend in Semen Maydis oil of light mineral oil, Semen Maydis oil, high molecular weight polybutenes, polyol ester, light mineral oil and wax emulsion blend, paraffin and these combination.In some embodiments, the amount of lubricating oil is about 1 % by weight to about 10 % by weight.In an illustrative embodiments, the amount of lubricating oil is about 3-6 % by weight.
If needed, described precursor composition can containing pore former to regulate porosity and the pore size distribution of the article fired being used for application-specific.Pore former evaporation or vaporization can occur, to obtain required usual higher porosity and/or the easy changing matter matter of larger mean pore sizes by the burning between or heating period dry to green.A kind of suitable pore former can include but not limited to: carbon; Graphite; Starch; Timber, shell class or nut powder; Polymkeric substance, such as polyethylene beads; Wax etc.When using particle pore former, the median particle diameter of particle pore-forming material can be 10 microns to 70 microns, more preferably 20 microns to 50 microns.
The inorganic batch components forming pottery fully can mix with liquid excipients and shaping additive with optional any sintering aid and/or pore former, and these shaping additives give raw material with plastic formability and green strength when raw material is shaped as green.When forming is done by extrusion, the most normally, with cellulose ether binder, such as methylcellulose gum, Vltra tears, methyl cellulose derivatives and/or their arbitrary combination are as temporary organic binder, using sodium stearate as lubricant.The relative quantity of shaping additive can according to the factors vary of such as raw materials used characteristic and amount etc.Such as, the amount of shaping additive is generally about 2 % by weight to about 10 % by weight, more preferably about 3 % by weight to about 6 % by weight methylcellulose gum, and about 0.5 % by weight to about 1 % by weight, more preferably about 0.6 % by weight sodium stearate, stearic acid, oleic acid or Yatall MA.Raw material and shaping additive mix with dry form usually, then mix with the water as supporting agent.The consumption of water can change with batch of material, therefore can be determined by the extrudability testing concrete batch of material in advance.
Liquid vehicle component can according to the Change of types of material used, with to processibility and and ceramic batch mixture in the consistency of other components carry out optimizing.Usually, the content of liquid carrier is generally the 20-50 % by weight of the composition of plasticising.In one embodiment, liquid vehicle component can comprise water.In another embodiment, according to the component of ceramic batch composition, should be appreciated that, can with an organic solvent, such as methyl alcohol, ethanol or their mixture are as liquid carrier.
Can by such as typical ceramic manufacturing technology such as uniaxially compacting or isostatic pressed suppress, extrude, slip casting and injection moulding, from precursor composition formation or the shaping green compact of plasticising.When ceramic has cellular geometry, such as, when catalytic converter flow-through substrate or diesel particulation wall-flow filter, preferably adopt and extrude.Gained green can be optionally dry, fires subsequently under effectively described green being converted into ceramic condition in gas burning kiln or electric kiln.Such as, the firing condition that effectively green can be converted into ceramic can comprise, 1250 DEG C to 1450 DEG C, such as, 1300 DEG C to 1350 DEG C, or heat green at the highest heat refining (soak) temperature of 1330 DEG C to 1380 DEG C, maintain this highest cooking temperature sufficiently long time to make green be converted into ceramic, then with certain speed cooling, this underspeed is to cause thermal shocking to the goods of sintering.
In addition, described effective firing condition can be included in heat green body under first cooking temperature of 1240 DEG C to 1350 DEG C (more preferably 1270 DEG C to 1330 DEG C), keep this first cooking temperature 2 to 10 hours (more preferably 4 to 8 hours), then under second cooking temperature of 1270 DEG C to 1450 DEG C (more preferably 1300 DEG C-1350 DEG C), this green is heated, keep this second cooking temperature 2 to 10 hours (more preferably 4 to 8 hours), then same to be not enough to cause the speed of thermal shocking to cool to the goods of sintering.
In order to obtain wall-flow filter, as known in the art, a part of hole of honeycomb body structure is blocked at entrance end or inlet end face.Only block in the end in hole, plug depth is about 1-20 millimeter usually, but can change plug depth.The hole of a part blocks at exit end, but this some holes does not correspond to those holes in inlet end plugged.Therefore, each hole only at one end blocks.Preferred arrangement mode blocks every a hole with halma board pattern at designated surface.
With reference to MgO-Al
2o
3-TiO
2-SiO
2the phase equilibrium diagram (being drawn by the present inventor) of system, can understand the result of study forming basis of the present invention better.Certainly, can recognize, the many borders between the phase region comprised in this phasor represent the result of EQUILIBRIUM CALCULATION FOR PROCESS and extrapolation, instead of the result of actual facies analysis.Although these phase regions itself use experimental verification, the exact temperature and the composition that represent boundaries between phase fields are all approximations.In any case the phasor of Fig. 1 depicts stable combined along aluminium titanates (Al
2tiO
5) and trichroite (Mg
2al
4si
5o
18) pseudo-binary juncture is with the change of temperature and composition.In fact, this phasor shows, the mixture of trichroite and AT is at high temperature easy to form other phase, comprises mullite, titanium oxide, liquid and has the solid solution phase of pseudobrookite crystalline structure.
Study this figure and can draw two important features.The first, in order to make pseudobrookite phase and trichroite reach balance, usually there is the restriction to the composition of this sosoloid, specifically, pure AT often can not reach with trichroite and exist evenly.Quaternary MgO-Al when Fig. 2 illustrates 1325 DEG C
2o
3-TiO
2-SiO
2with the facies relationship in two magnesium titanates, aluminium titanates and the trichroite ternary section that is end points in system, show the pseudobrookite balanced with trichroite at this temperature and comprise two magnesium titanates at least about 25 % by weight mutually.The second, Fig. 1 display in the figure, relatively low temperature province (~ 1390 DEG C, but, the eutectic liquid that in this system, eutectic point is minimum remarkable lower than the temperature of this temperature under exist) have liquid to occur.
According to another kind of example embodiment, sintering aid can comprise cerium oxide (CeO
2) or cerium oxide and other metal oxide one or more of as Fe
2tiO
5, Y
2o
3, and La
2o
3combination.Such as, sintering aid can comprise the combination of cerium oxide and yttrium oxide, the combination of cerium oxide and lanthanum trioxide, or the combination of cerium oxide and yttrium oxide and lanthanum trioxide.Contriver finds that cerium oxide or cerium oxide and other metal oxide one or more of are as Fe
2tiO
5, yttrium oxide and lanthanum trioxide mixture, obtain similar CTE, porosity, aperture and pore size distribution, and rare earth cost is lower than being used alone yttrium oxide.
In a kind of example embodiment, the scope of the amount of cerium oxide can be 0.1-5.0 % by weight.Such as, the scope of the amount of cerium oxide can be 0.2-2.0 % by weight, 0.3-1.0 % by weight, and 1.5-2.5 % by weight.As mentioned above, in a kind of example embodiment, cerium oxide and other metal oxide one or more of are as Fe
2tiO
5, yttrium oxide and lanthanum trioxide mixture can be sintering aid.The scope of the amount of mixture can be 0.1-5.0 % by weight.Such as, the scope of the amount of mixture can be 0.3-4.0 % by weight, 0.4-2.5 % by weight, 0.5-1.5 % by weight, and 2.5-4.5 % by weight.
Embodiment
Hereinafter with reference to about more of the present invention exemplary further illustrate the present invention with specific embodiment, these embodiments are only illustrative, are not used for being construed as limiting.According to some embodiments, prepare a series of invention ceramic, the basic inorganic batch that described ceramic has as provided by the weight percentage of ultimate constituent phase in table 1 forms, in table 2 according to the composition that the weight percent of one-component oxide compound represents, they do not comprise any sinter additives.
Table 1
Table 2
Table 3 to table 11 and 13 provides the data of the embodiments of the invention manufactured according to the essentially consist of table 1 and table 2.Wherein list for the manufacture of the raw material of sample, pore former and sintering aid (being median particle diameter in bracket).These embodiments provided are by component powders being ground together with organic binder bond with water, then extrude, dry and fire and make.The sample extruded to be wrapped in paper tinsel and with hot-air dry or microwave drying.As described below, some sample is prepared without drying step by pressed powder.Then, in electric kiln, fire sample, firing condition is heating rate's to the first cooking temperature with 60 DEG C/h and keeps 6 hours, then keeps 6 hours again with 60 DEG C/h of heating rate's to the second cooking temperatures.Table 3 also provides cooking temperature to table 11 and 13.These embodiments will be discussed hereinafter further.Except where indicated, all measurements are all for having 200 hole/inches
2with the porous insert of 406 microns of (16 mils (mil)) wall thickness.Unless otherwise noted, all samples are all fire in electric kiln in atmosphere.CTE adopts dilatometry by the directional survey of passage being parallel to honeycomb.Porosity and pore size distribution are measured with mercury porosimeter and obtain.
Table 3 to table 11 and 13 also provides " maximum △ L when 1000 DEG C ", and the △ L/L value 1000 DEG C time of its thermal expansion gained be defined as because producing when thermal expansion sample is heated to 1000 DEG C from room temperature deducts this thermal expansion sample and is cooled to the minimum △ L/L produced the process of the lesser temps that there is minimum △ L/L from 1000 DEG C.Maximum △ L value when have recorded 1000 DEG C with percentages in table 3 to table 11 and 13, therefore, such as 1000 DEG C time 0.15% maximum △ L equal 0.15 × 10
-2△ L value, be also equivalent to 1500ppm or 1500 × 10
-6inch/inch.Maximum △ L value when 1000 DEG C is the tolerance of the hysteresis phenomenon degree of thermal dilatometry (△ L/L is to temperature) in heating and cooling process.
Except the character data in meter 3 to table 11 and 13, also carry out several specific measurement, to characterize the thermostability of material of the present invention, and pressure drop performance when determining that they are used as diesel particulate filter.
Thermostability (decomposition rate) is assessed by two kinds of methods.In first method, the sample of invention object and contrast aluminum titanate composition is remained on 1100 DEG C, and measure their length within the time of maximum 100 hours.The decomposition of pseudobrookite phase is along with the reduction (shrinking or negative length variations) of volume.Result shown in Fig. 3 shows that invention object has satisfactory stability, and therefore, the decomposition rate of pseudobrookite phase is than contrast at least slow 10 times of aluminum titanate composition.In the second method of assessment decomposition rate, before and after being kept 100 hours at the temperature of 950-1250 DEG C by sample isothermal, measure the CTE of invention composition and contrast aluminum titanate composition.Because the decomposition of pseudobrookite phase reduces the crack amount, the increase CTE that split, so the increase of CTE is an index of degree of decomposition after thermal treatment.Result is shown in Figure 4, and it shows that invention object has the thermostability of raising.
The strainer of unloaded strainer and supported catalyst is measured the pressure drop of the strainer of unloaded strainer and the load soot be made up of representational cordierite aluminum magnesium titanate pottery of the present invention and aluminum titanate control ceramic.Strainer of the present invention is 300/12 pore structure.After implementing conventional preliminary polymer solution passivation, use AL-20 colloidal alumina to carry out basal plane and repair coating painting base repair coating.The representative result of this pressure drop test is shown in Figure 5, therefrom can find, carries out basal plane and repairs the percentage ratio of the rear filter pressure drop increase of the present invention of coating lower than contrast aluminum titanate filter.The microstructure that these tested basal planes repair the strainer of coating is shown in Fig. 6.
Table 3 to the data in table 11 and 13 it also illustrate some exemplary range of the character reached by invention pottery physical efficiency of the present invention.Embodiment 1 to 7 in table 3 represents the basic quaternary three-phase composition (table 1 and table 2) without sinter additives.These embodiments show, and when porosity is 44-52%, mean pore sizes is 15-27 micron, can realize low-thermal-expansion (6 to 20 × 10
-7/ DEG C), be suitable as diesel particulate filter.D
fvalue is 0.24 to 0.45.The highest firing temperature of the best of these compositions is about 1355 DEG C to 1360 DEG C.Thick aluminum oxide for embodiment 4-7 produces larger aperture and lower fires contraction.
Embodiment 8 to 15 in table 4 illustrates, adds about 2 % by weight Y in the base composition of embodiment 1-3
2o
3lower firing temperature (1290-1320 DEG C) can be allowed and reach high porosity (41-50%) and low-thermal-expansion (10-14 × 10
-7/ DEG C) wide fire steady temperature range.Mean pore sizes is 16 to 22 microns, d
fvalue is decreased to 0.17 to 0.31.Shrink variation with temperature also less.This can realize required character with wider process window.Best firing temperature is about 1310 DEG C.
Embodiment 16 to 22 in table 5 shows, only adds additional about 1%Y in the base composition of embodiment 1-3
2o
3firing temperature can be made to be reduced to 1310-1350 DEG C, and the best is about 1320 DEG C.The firing temperature that a small amount of additive produces and to fire process window be between the basic four-tuple compound firing temperature corresponding with adding 2 % by weight additives and fire between process window.Physical properties is also extremely conducive to diesel particulate filter applications.
Embodiment 23 in table 6 shows, and compared with embodiment 8-15, uses less (10 microns) alumina powder to produce less aperture, slightly large contraction and slightly large thermal expansion.
Embodiment 24 to 30 in table 6 shows, and compared with embodiment 8-15, uses the alumina powder of more Large stone to produce larger hole, less thermal expansion and less contraction.Due to thick aluminum oxide and 2 % by weight yttrium oxide, this composition has highly stable fires process window.The squeeze-up of Here it is in dielectric oven dry 2 inch diameters.
Embodiment 31-37 in table 7 indicates composition, and wherein all magnesium is provided by talcum, and the wherein granularity of aluminum oxide less (~ 18 microns of MPS).All embodiments all have 1.9 % by weight yttrium oxide additives.Embodiment 31 uses the yam starch of 15%.Embodiment 32 uses 15% W-Gum, and this provides less hole but very narrow pore size distribution.Embodiment 33 is containing 30% graphite, but still the mean pore sizes provided (12 microns) and narrow pore size distribution (d
f=0.29).Embodiment 34 uses the mixture of W-Gum and graphite to reach excellent character.Embodiment 35 shows, and fires program for same, and thicker aluminum oxide and talcum cause less firing to shrink and make aperture compare embodiment 32 and increase.The embodiment 36 be made up of green soya bean starch obtains the hole of 15 microns and very narrow pore size distribution.Use the embodiment 37 of yam starch to show, thicker aluminum oxide and talcum make aperture increase relative to embodiment 31.
Embodiment 38-50 in table 8 and 9 shows the multiple combination thing of example embodiment.Embodiment 38-50 shows in these example ranges of embodiment, and changes pore former, raw material, firing temperature and additive metal oxide (as shown by the preceding examples), can optimize the final porosity for application-specific and aperture.
Embodiment 51-67 shows that sintering aid and cerium oxide, the mixture of cerium oxide and yttrium oxide mixture, cerium oxide and yttrium oxide and lanthanum trioxide, the mixture of cerium oxide and lanthanum trioxide or lanthanum trioxide obtain similar CTE, porosity, aperture and pore size distribution, and rare earth cost is lower than being used alone yttrium oxide.
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Embodiment 51-54 in table 10 and 11 is the comparative example comprising yttrium oxide.Embodiment 55-58 comprises cerium oxide.Embodiment 59 and 60 comprises yttrium oxide and cerium oxide simultaneously.The formula of these embodiments is in table 10 and 11.Embodiment 51-60 all uses the graphite of 4% and 22% starch (additional quantity as the inorganic materials shown in table 10 and 11 adds), and as other batch ingredients all additional quantity 4.5% methylcellulose gum and 1% Yatall MA.By these embodiments and deionized water mixing, be extruded into the vesicular structure with 300 holes/square inch and 330 microns of (13 mil) wall thickness, drying in the kiln that air is fired also is fired 1350 DEG C and keeps 16 hours.The character firing goods of embodiment 51-60, in table 10 and 11, also show based on ready market price relative to 1%Y
2o
3the normalized additive relative cost of cost estimate.
Table 12 lists some representative prices of rare earth material, and it is at least high than other batch material all 10 times.
Fig. 7 shows the thermal expansivity (CTE) of table 10 and the comparative example 51-54 in 11 and embodiment 55-60 with relative rare earth cost (1%Y
2o
3=1) change.As shown in Figure 7, when keep similar aperture, porosity and pore size distribution (table 10 and 11) time, and be used alone compared with yttrium oxide, use cerium oxide or yttrium oxide and cerium oxide mixture to obtain lower than set-point such as lower than 12*10
-7/ DEG C the cost needed for CTE lower.Use this index, the rare earth cost that may reduce is at least 50%.
These lower cost compositions are with the stable in properties of firing temperature and the similar of higher cost composition.Table 13 shows embodiment 52,53,56, and 60 fire character after 12 hours at 1320,1330,1340,1350 and 1360 DEG C in electric kiln.
Table 10
Table 11
Table 12
Table 13
Embodiment 61-68 is by the batch composition shown in the blended large scale 14 of dry type and the additive shown in interpolation table 15 and dry type is blended again prepares.Before firing, the powder of each batch of material is suppressed in die head and forms 8X8X65mm bar.Table 16 to table 18 provides the data of the invention embodiment manufactured according to the essentially consist of table 14 and table 15.The data parameters provided is as above for as described in table 3 to 11 and 13.As prepared embodiment 61-68 for as described in embodiment 1-60 above.
Embodiment 61 and 62 in table 16 uses cerium oxide as sintering aid.Embodiment 63-67 shown in table 16 uses lanthanum trioxide (La
2o
3) or La
2o
3with the mixture of cerium oxide.Comparative example 68 in table 16 uses the batch composition without sintering aid additive.Table 16 shows embodiment 61-67 in electric kiln, fires character after 12 hours at 1330 DEG C.These results are similar to and are used alone CeO
2or Y
2o
3, but thermal expansivity ratio is used alone CeO
2or Y
2o
3height is 3*10 about
-7/ DEG C.
Embodiment 69-84 in table 17 uses yttrium oxide, cerium oxide or lanthanum trioxide as sintering aid.Embodiment 69-77 in table 17 uses yttrium oxide as sintering aid.Embodiment 78-83 in table 17 uses cerium oxide as sintering aid.Embodiment 84 uses lanthanum trioxide as sintering aid.Be used alone compared with yttrium oxide, embodiment 78-84 presents acceptable porosity, pore size distribution, CTE value and fires window character, and relatively rare earth cost lower than being used alone yttrium oxide.
Table 18 show the hold-time be the character of embodiment 61 and 68 under the condition of 16 hours with the change of firing temperature, show CeO
2there is provided wide and fire window.
Table 19 comprise embodiment 53,54,57 and 58 with X-ray diffraction (XRD) measure with % by weight phase represented and pseudobrookite phase composite.These embodiments analyzed all are fired at 1365 DEG C.Pseudobrookite phase composite is measured by the lattice parameter of the pseudobrookite phase by XRD determining.Li Teweide (Rietveld) refine of XRD figure spectrum is used to measure Entropy density deviation.
It will be readily apparent to one skilled in the art that and can carry out various modifications and changes when not departing from the spirit or scope of the present invention to the present invention.Therefore, the present invention should be contained these amendments of the present invention and variation, as long as these amendments and variation are within the scope of claims and equivalent thereof.
Table 14
TABLE 15
Table 16
Table 17
Table 17 (Continued)
Table 18
Table 18 (Continued)
Table 19
Claims (25)
1. one kind comprises the ceramic of first crystal phase and the second crystal phase, described first crystal mainly comprises the sosoloid of aluminium titanates and two magnesium titanates mutually, described second crystal comprises trichroite mutually, represents the composed as follows of described ceramic: 4-10%MgO with the weight percentage of oxide compound benchmark; 40-55%Al
2o
3; 25-44%TiO
2; 5-25%SiO
2and sintering aid, described sintering aid comprises at least one in lanthanide oxide and yttrium oxide.
2. ceramic as claimed in claim 1, it is characterized in that, described lanthanide oxide comprises cerium oxide.
3. ceramic as claimed in claim 1, is characterized in that, described sintering aid comprises at least one in cerium oxide and yttrium oxide and lanthanum trioxide.
4. the ceramic according to any one of claim 1-3, its with oxide compound benchmark represent composed as follows: a (Al
2tiO
5)+b (MgTi
2o
5)+c (2MgO2Al
2o
35SiO
2)+d (3Al
2o
32SiO
2)+e (MgOAl
2o
3)+f (2MgOTiO
2)+g (X)+i (Fe
2o
3 .tiO
2)+j (TiO
2), wherein a, b, c, d, e, f, g, i and j are the weight fractions of each component, make (a+b+c+d+e+f+g+i+j)=1.00, and wherein, X is sintering aid.
5. ceramic as claimed in claim 4, is characterized in that, 0.3≤a≤0.75,0.075≤b≤0.3,0.02≤c≤0.5, and 0.001≤g≤0.05.
6. the ceramic as described in claim 4 or 5, is characterized in that, 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≤0.1,0.001≤g≤0.05,0.0≤i≤0.05,0.0≤j≤0.2 and 0.0≤k≤0.1.
7. the ceramic according to any one of claim 4-6, is characterized in that, 0.0025≤g≤0.02.
8. the ceramic according to any one of claim 4-7, is characterized in that, described sintering aid comprises cerium oxide.
9. the ceramic according to any one of claim 4-8, is characterized in that, described sintering aid also comprises at least one in yttrium oxide and lanthanum trioxide.
10. ceramic as claimed in any one of claims 1-9 wherein, it is characterized in that, the overall porosity %P of described ceramic is greater than 40 volume %.
11. ceramics according to any one of claim 1-10, it is characterized in that, the thermal expansivity that described ceramic records within the scope of 25-1000 DEG C is less than or equal to 14 × 10
-7/ DEG C.
12. ceramics according to any one of claim 1-11, it is characterized in that, relative to the gross weight of inorganic batch composition, described sintering aid is according to the weight percent basis meter of oxide compound, and its amount is for being greater than 0.1 to 5 % by weight.
13. ceramics according to any one of claim 1-12, its with % by weight of oxide compound for benchmark represent composed as follows: 5-10%MgO, 40-50%Al
2o
3, 30-35%TiO
2, and 10-20%SiO
2.
14. ceramics according to any one of claim 1-13, it mean pore sizes d comprised
50scope is 10 microns to 30 microns.
15. ceramics according to any one of claim 1-14, it mean pore sizes d comprised
50scope is 15 microns to 25 microns.
16. 1 kinds of diesel particulate filters, it comprises the ceramic according to any one of claim 1-15, it is characterized in that, described diesel particulate filter comprises polynuclear plane, and this polynuclear plane has inlet chamber and the downstream chamber of multiple axially extended end blocking.
17. 1 kinds of ceramics, it comprises:
Pseudobrookite phase, it mainly comprises aluminum oxide, magnesium oxide and titanium oxide;
Comprise the second-phase of trichroite; With
Sintering aid, it comprises at least one in lanthanide oxide and yttrium oxide.
18. ceramics as claimed in claim 17, it is characterized in that, described lanthanide oxide comprises cerium oxide.
19. ceramics as claimed in claim 17, is characterized in that, described sintering aid comprises at least one in cerium oxide and yttrium oxide and lanthanum trioxide.
20. 1 kinds of methods manufacturing ceramic, the method comprises:
Providing package is containing the inorganic batch composition of magnesium oxide source, silica source, alumina source, titania source and at least one sintering aid;
By described inorganic batch composition and one or more processing aids admixed together, described processing aid is selected from lower group: softening agent, lubricant, tackiness agent, pore former and solvent, to form the ceramic precursor batch composition of plasticising.
The ceramic precursor batch composition of described plasticising is configured as green; And
Under described green being changed into the condition of ceramic effectively, fire green, this ceramic comprises pseudobrookite phase and second-phase, and described pseudobrookite mainly comprises aluminum oxide, magnesium oxide and titanium oxide mutually; Described second-phase comprises trichroite,
Wherein said sintering aid comprises at least one in lanthanide oxide and yttrium oxide.
21. methods as claimed in claim 20, it is characterized in that, described lanthanide oxide comprises cerium oxide.
22. methods as claimed in claim 21, is characterized in that, described sintering aid comprises at least one in cerium oxide and yttrium oxide and lanthanum trioxide.
23. methods according to any one of claim 20-22, it is characterized in that, relative to the gross weight of inorganic batch composition, described at least one sintering aid is according to the weight percent basis meter of oxide compound, and its amount is for being greater than 0.1 to 5 % by weight.
24. methods according to any one of claim 20-23, is characterized in that, by extruding the ceramic precursor batch composition of the described plasticising that is shaped.
25. methods according to any one of claim 20-24, it is characterized in that, the firing condition that effectively green can be converted into ceramic comprises: heat green body under the highest cooking temperature of 1250 DEG C to 1450 DEG C, and being maintained by this highest cooking temperature is enough to make green be converted into the time of ceramic.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US13/584,993 | 2012-08-14 | ||
| US13/584,993 US8673045B2 (en) | 2006-06-30 | 2012-08-14 | Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same |
| US13/676,567 | 2012-11-14 | ||
| US13/676,567 US8956436B2 (en) | 2006-06-30 | 2012-11-14 | Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same |
| PCT/US2013/052620 WO2014028207A1 (en) | 2012-08-14 | 2013-07-30 | Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN104995154A true CN104995154A (en) | 2015-10-21 |
Family
ID=50101400
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201380051106.8A Pending CN104995154A (en) | 2012-08-14 | 2013-07-30 | Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same |
Country Status (5)
| Country | Link |
|---|---|
| EP (1) | EP2885258A1 (en) |
| JP (1) | JP6275140B2 (en) |
| CN (1) | CN104995154A (en) |
| IN (1) | IN2015DN01567A (en) |
| WO (1) | WO2014028207A1 (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108117385A (en) * | 2017-12-26 | 2018-06-05 | 中国科学院上海硅酸盐研究所 | Titania based medium ceramic material of a kind of high electric strength of large scale and its preparation method and application |
| CN108367225A (en) * | 2015-12-09 | 2018-08-03 | 康宁股份有限公司 | Porous ceramic compositions, filters, and articles |
| CN109415274A (en) * | 2016-07-05 | 2019-03-01 | 揖斐电株式会社 | The manufacturing method of honeycomb structure and honeycomb structure |
| CN112969673A (en) * | 2018-08-31 | 2021-06-15 | 康宁股份有限公司 | Cordierite-indialite-pseudobrookite structural ceramic bodies, batch composition mixtures, and methods of making ceramic bodies |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| MX384576B (en) * | 2013-09-23 | 2025-03-14 | Corning Inc | CORDIERITE-MULLITE-ALUMINUM MAGNESIUM TITANATE COMPOSITIONS WITH A HIGH CORDIERITE TO MULLITE RATIO AND CERAMIC ARTICLES COMPRISING THE SAME. |
| US9868670B2 (en) | 2014-09-05 | 2018-01-16 | Corning Incorporated | High cordierite-to-mullite ratio cordierite-mullite-aluminum magnesium titanate compositions and ceramic articles comprising same |
| JP6502495B2 (en) * | 2014-11-19 | 2019-04-17 | コーニング インコーポレイテッド | Ceramic powder with controlled size distribution |
| US20190177232A1 (en) * | 2016-06-13 | 2019-06-13 | Corning Incorporated | Aluminum titanate compositions, aluminum titanate articles, and methods of making same |
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| JPS5689844A (en) * | 1979-12-25 | 1981-07-21 | Asahi Glass Co Ltd | Ceramic honeycomb and its production |
| US4329162A (en) | 1980-07-03 | 1982-05-11 | Corning Glass Works | Diesel particulate trap |
| EP0463437B2 (en) | 1990-06-22 | 1998-12-02 | Bayer Ag | Sintered bodies based on aluminium titanate, process for their production and use thereof |
| US20060021308A1 (en) * | 2004-07-29 | 2006-02-02 | Merkel Gregory A | Mullite-aluminum titanate body and method for making same |
| US8974724B2 (en) * | 2006-11-29 | 2015-03-10 | Corning Incorporated | Aluminum titanate batch compositions and method |
-
2013
- 2013-07-30 JP JP2015527473A patent/JP6275140B2/en active Active
- 2013-07-30 IN IN1567DEN2015 patent/IN2015DN01567A/en unknown
- 2013-07-30 EP EP13745776.8A patent/EP2885258A1/en not_active Withdrawn
- 2013-07-30 WO PCT/US2013/052620 patent/WO2014028207A1/en active Application Filing
- 2013-07-30 CN CN201380051106.8A patent/CN104995154A/en active Pending
Patent Citations (2)
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| CN1044645A (en) * | 1989-01-30 | 1990-08-15 | 兰克西敦技术公司 | Produce from the product that supports the method for aluminium titanates complex body and produce thus |
| CN102690117A (en) * | 2006-06-30 | 2012-09-26 | 康宁股份有限公司 | Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same |
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108367225A (en) * | 2015-12-09 | 2018-08-03 | 康宁股份有限公司 | Porous ceramic compositions, filters, and articles |
| CN108367225B (en) * | 2015-12-09 | 2022-05-13 | 康宁股份有限公司 | Porous ceramic compositions, filters, and articles |
| US11668214B2 (en) | 2015-12-09 | 2023-06-06 | Corning Incorporated | Porous ceramic composition, filter, and articles |
| CN109415274A (en) * | 2016-07-05 | 2019-03-01 | 揖斐电株式会社 | The manufacturing method of honeycomb structure and honeycomb structure |
| CN108117385A (en) * | 2017-12-26 | 2018-06-05 | 中国科学院上海硅酸盐研究所 | Titania based medium ceramic material of a kind of high electric strength of large scale and its preparation method and application |
| CN108117385B (en) * | 2017-12-26 | 2020-11-10 | 中国科学院上海硅酸盐研究所 | Large-size high-electric-strength titanium oxide-based dielectric ceramic material and preparation method and application thereof |
| CN112969673A (en) * | 2018-08-31 | 2021-06-15 | 康宁股份有限公司 | Cordierite-indialite-pseudobrookite structural ceramic bodies, batch composition mixtures, and methods of making ceramic bodies |
| US11891339B2 (en) | 2018-08-31 | 2024-02-06 | Corning Incorporated | Cordierite-indialite-pseudobrookite structured ceramic bodies, batch composition mixtures, and methods of manufacturing ceramic bodies therefrom |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2015526379A (en) | 2015-09-10 |
| EP2885258A1 (en) | 2015-06-24 |
| IN2015DN01567A (en) | 2015-07-03 |
| JP6275140B2 (en) | 2018-02-07 |
| WO2014028207A1 (en) | 2014-02-20 |
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