Methods for forming ceramic honeycomb articles
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C04B-035/195
B01D-039/20
C04B-038/00
C04B-111/00
C04B-111/20
C04B-111/32
C04B-111/34
C04B-111/40
출원번호
US-0789945
(2010-05-28)
등록번호
US-9334191
(2016-05-10)
발명자
/ 주소
Miao, Weiguo
Wang, Jianguo
출원인 / 주소
Corning Incorporated
대리인 / 주소
Homa, Joseph M.
인용정보
피인용 횟수 :
0인용 특허 :
57
초록▼
Processes for manufacturing porous ceramic honeycomb articles are disclosed. The processes include mixing a batch of inorganic components with processing aids to form a plasticized batch. The batch of inorganic components include talc having dpt50≦10 μm, a silica-forming source having dps50≦20 μm, a
Processes for manufacturing porous ceramic honeycomb articles are disclosed. The processes include mixing a batch of inorganic components with processing aids to form a plasticized batch. The batch of inorganic components include talc having dpt50≦10 μm, a silica-forming source having dps50≦20 μm, an alumina-forming source having a median particle diameter dpa50 of less than or equal to 10.0 μm, and a pore former having dpp50≦20 μm. The plasticized batch is formed into a green honeycomb article and fired under conditions effective to form a porous ceramic honeycomb article comprising a cordierite crystal phase and having a microcrack parameter (Nb3) of from about 0.05 to about 0.25. After firing, the green honeycomb article the porous ceramic honeycomb article is exposed to a microcracking condition, which increases the microcrack parameter (Nb3) by at least 20%.
대표청구항▼
1. A process for manufacturing a porous ceramic honeycomb article, comprising: mixing a batch of inorganic components comprising talc having dpt50≦10 μm, a silica-forming source having dps50≦20 μm, an alumina-forming source having a median particle diameter dpa50 of less than or equal to 10.0 μm, an
1. A process for manufacturing a porous ceramic honeycomb article, comprising: mixing a batch of inorganic components comprising talc having dpt50≦10 μm, a silica-forming source having dps50≦20 μm, an alumina-forming source having a median particle diameter dpa50 of less than or equal to 10.0 μm, and a pore former having dpp50≦20 μm, wherein dpp50 is a median particle diameter of the pore former, dps50 is a median particle diameter of the silica-forming source, dpa50 is a median particle diameter of the alumina-forming source and dpt50 is a median particle diameter of the talc, with processing aids to produce a plasticized batch;forming the plasticized batch into a green honeycomb article;firing the green honeycomb article under conditions effective to form a porous ceramic honeycomb article comprising a cordierite crystal phase and having a microcrack parameter (Nb3) of from about 0.05 to about 0.25;subsequent to firing, exposing the porous ceramic honeycomb article to a microcracking condition, wherein after exposure to the microcracking condition, the porous ceramic honeycomb article comprises a microcrack parameter (Nb3) is at least 20% greater than the microcrack parameter prior to exposure to the microcracking condition. 2. The process of claim 1, wherein the batch of inorganic components further comprises clay having dpc50≦5 μm, wherein dpc50 is a median particle diameter of the clay. 3. The process of claim 1, wherein the microcracking condition comprises a thermal cycle. 4. The process of claim 3, wherein during the thermal cycle, the porous ceramic honeycomb article reaches a peak temperature of at least 400° C. 5. The process of claim 4, wherein after the porous ceramic honeycomb article reaches the peak temperature, the porous ceramic honeycomb article cools at a rate of at least 200° C./hr. 6. The process of claim 3, wherein the thermal cycle occurs after application of a washcoat to the porous ceramic honeycomb article. 7. The process of claim 1, wherein the porous ceramic honeycomb article further comprises a coefficient of thermal expansion (CTE) of about 7.0×10−7/° C. to about 15.0×10−7/° C. over from about 25° C. to about 800° C. prior to exposure to the microcracking condition, and a coefficient of thermal expansion of about 1.0×10−7/° C. to about 10.0×10−7/° C. over from about 25° C. to about 800° C. after exposure to the microcracking condition. 8. The process of claim 1, wherein the porous ceramic honeycomb article further comprises a df of less than or equal to about 0.4 both before and after exposure to the microcracking condition. 9. The process of claim 1, wherein the porous ceramic honeycomb article further comprises a surface porosity of about 38% to about 45% both before and after exposure to the microcracking condition. 10. The process of claim 1, wherein 3.0 μm≦dpt50≦10.0 μm. 11. A process for manufacturing a porous ceramic honeycomb article, comprising: mixing a batch of inorganic components with processing aids to produce a plasticized batch;forming the plasticized batch into a green honeycomb article;firing the green honeycomb article under conditions effective to form a porous ceramic honeycomb article comprising a cordierite crystal phase and having a microcrack parameter (Nb3) of from about 0.05 to about 0.25;subsequent to firing, exposing the porous ceramic honeycomb article to a microcracking condition that comprises heating the porous ceramic honeycomb article to a peak temperature of at least 400° C. and cooling the porous ceramic honeycomb article at a rate of at least 200° C./hr, wherein after exposure to the microcracking condition, the porous ceramic honeycomb article comprises a microcrack parameter (Nb3) is at least 20% greater than the microcrack parameter prior to exposure to the microcracking condition. 12. The process of claim 11, wherein the microcracking condition occurs after application of a washcoat to the porous ceramic honeycomb article. 13. The process of claim 11, wherein the porous ceramic honeycomb article further comprises a coefficient of thermal expansion (CTE) of about 7.0×10−7/° C. to about 15.0×10−7/° C. over from about 25° C. to about 800° C. prior to exposure to the microcracking condition, and a coefficient of thermal expansion of about 1.0×10−7/° C. to about 10.0×10−7/° C. over from about 25° C. to about 800° C. after exposure to the microcracking condition. 14. The process of claim 11, wherein the porous ceramic honeycomb article further comprises a df of less than or equal to about 0.4 both before and after exposure to the microcracking condition, wherein df=(d50−d10)/d50. 15. The process of claim 11, wherein the porous ceramic honeycomb article further comprises a df of less than or equal to about 0.3 both before and after exposure to the microcracking condition, wherein df=(d50−d10)/d50. 16. The process of claim 11, wherein the porous ceramic honeycomb article further comprises a df of less than or equal to about 0.2 both before and after exposure to the microcracking condition, wherein df=(d50−d10)/d50. 17. The process of claim 11, wherein the porous ceramic honeycomb article further comprises a surface porosity of about 38% to about 45% both before and after exposure to the microcracking condition. 18. A process for manufacturing a porous ceramic honeycomb article, comprising: mixing a batch of inorganic components with processing aids to produce a plasticized batch;forming the plasticized batch into a green honeycomb article;firing the green honeycomb article under conditions effective to form a porous ceramic honeycomb article comprising a cordierite crystal phase and having a microcrack parameter (Nb3) of from about 0.05 to about 0.25, a coefficient of thermal expansion (CTE) of about 7.0×10−7/° C. to about 15.0×10−7/° C. over from about 25° C. to about 800° C., and a df of less than or equal to about 0.4, wherein df=(d50−d10)/d50;subsequent to firing, exposing the porous ceramic honeycomb article to a microcracking condition that comprises heating the porous ceramic honeycomb article to a peak temperature of at least 600° C. and cooling the porous ceramic honeycomb article at a rate of at least 200° C./hr, wherein after exposure to the microcracking condition, the porous ceramic honeycomb article comprises a microcrack parameter (Nb3) at least 20% greater than the microcrack parameter prior to exposure to the microcracking condition, a coefficient of thermal expansion (CTE) of about 1.0×10−7/° C. to about 10.0×10−7/° C. over from about 25° C. to about 800° C., and a df of less than or equal to about 0.4. 19. The process of claim 18, wherein the microcracking condition occurs after application of a washcoat to the porous ceramic honeycomb article. 20. The process of claim 18, wherein the porous ceramic honeycomb article further comprises a df of less than or equal to about 0.3 both before and after exposure to the microcracking condition. 21. The process of claim 18, wherein the porous ceramic honeycomb article further comprises a df of less than or equal to about 0.2 both before and after exposure to the microcracking condition. 22. The process of claim 18, wherein the porous ceramic honeycomb article further comprises a surface porosity of about 38% to about 45% both before and after exposure to the microcracking condition. 23. The process of claim 18, wherein the porous ceramic honeycomb article further comprises a total porosity (% P) of from about 50% to about 70% both before and after exposure to the microcracking condition. 24. The process of claim 18, wherein the porous ceramic honeycomb article further comprises a surface porosity/total porosity ratio of greater than about 0.5 both before and after exposure to the microcracking condition. 25. The process of claim 18, wherein the porous ceramic honeycomb article further comprises a mean pore size (d50) of from about 7 μm to about 16 μm both before and after exposure to the microcracking condition. 26. The process of claim 18, wherein the porous ceramic honeycomb article further comprises a thermal shock limit of greater than 1000° C. after exposure to the microcracking condition. 27. The process of claim 18, wherein the porous ceramic honeycomb article has a 200/10 geometry and further comprises a modulus of rupture strength (MOR) of greater than about 300 psi prior to exposure to the microcracking condition, and a modulus of rupture strength of greater than about 200 psi after exposure to the microcracking condition. 28. The process of claim 18, wherein the porous ceramic honeycomb article has a 200/10 geometry and further comprises an elastic modulus (Emod) of greater than about 3.0×105 psi prior to exposure to the microcracking condition, and an elastic modulus of greater than about 2.0×105 psi after exposure to the microcracking condition. 29. The process of claim 18, wherein the cordierite crystal phase is present in an amount greater than 95% by mass of the porous ceramic honeycomb article, measured by x-ray diffraction. 30. The process of claim 18, wherein the firing conditions effective to form a porous ceramic honeycomb article comprising a cordierite crystal phase comprise heating to a hold temperature from about 1425° C. to about 1435° C. 31. The process of claim 18, wherein the batch of inorganic components comprises talc having dpt50≦10 μm, a silica-forming source having dps50≦20 μm, an alumina-forming source having a median particle diameter dpa50 of less than or equal to 10.0 μm, and a pore former having dpp50≦20 μm, wherein dpp50 is a median particle diameter of the pore former, dps50 is a median particle diameter of the silica-forming source, dpa50 is a median particle diameter of the alumina forming source, and dpt50 is a median particle diameter of the talc. 32. The process of claim 31, wherein the batch of inorganic components further comprises clay having dpc50≦10 μm, wherein dpc50 is a median particle diameter of the clay.
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