Title:
LOW EXPANSION, HIGH POROSITY, HIGH STRENGTH CORDIERITE BODY AND METHOD
Document Type and Number:
WIPO Patent Application WO2000076939
Kind Code:
A9
Abstract:
A sintered ceramic that exhibits an average linear coefficient of thermal expansion (25-800 DEG C) below about 5.0x10<-7> DEG C<-1>, a total porosity between the range of 20% to about 30%. Furthermore, the sintered ceramic article exhibits a pore size distribution such that at least about 86% of pores are of a pore size of less than about 2 mu m. Lastly, the ceramic article exhibits an interconnected pore structure with the pores exhibiting a generally elongated shape, i.e., the pores are predominately oriented with their long axis in the plane of the webs. This invention also relates to a method for producing a sintered cordierite ceramic article involving first compounding and plasticizing a cordierite-forming inorganic powder batch comprising a platy talc having median particle of size less than about 2 mu m, and preferably a talc morphology index greater than about 0.75. The batch further comprises at least 4% by weight of the inorganic powder batch mixture of a dispersible A12O3-forming source having a specific surface area in excess of 50m<2>/g and one or more of the components of kaolin, calcined kaolin, silica, and corundum, each having a median particle sizes less than 5 mu m. The plasticized powder batch thus provided is next formed into a green honeycomb by extrusion through a honeycomb extrusion die and the green honeycomb is fired to a temperature and for a time sufficient to convert the green honeycomb into a crystallized cordierite ceramic article having the aforementioned properties.
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Inventors:
BEALL DOUGLAS M
MALARKEY CHRISTOPHER J
MERKEL GREGORY A
MALARKEY CHRISTOPHER J
MERKEL GREGORY A
Application Number:
PCT/US2000/015792
Publication Date:
June 20, 2002
Filing Date:
June 08, 2000
Export Citation:
Assignee:
CORNING INC (US)
International Classes:
F01N3/28; B01D53/86; B01J35/04; B01J35/10; C04B35/195; C04B38/00; (IPC1-7): C04B35/195
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