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    • 3. 发明申请
    • LOW EXPANSION, HIGH POROSITY, HIGH STRENGTH CORDIERITE BODY AND METHOD
    • 低膨胀度,高孔隙度,高强度正交体和方法
    • WO0076939A9
    • 2002-06-20
    • PCT/US0015792
    • 2000-06-08
    • CORNING INC
    • BEALL DOUGLAS MMALARKEY CHRISTOPHER JMERKEL GREGORY A
    • F01N3/28B01D53/86B01J35/04B01J35/10C04B35/195C04B38/00
    • C04B38/0006C04B35/195C04B2111/00129C04B2111/0037C04B2111/0081C04B2111/32Y10T428/24149Y10T428/24273C04B38/0051C04B38/0054C04B38/007
    • A sintered ceramic that exhibits an average linear coefficient of thermal expansion (25-800 DEG C) below about 5.0x10 DEG C , 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 /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.
    • 表现出低于约5.0×10 -7℃的平均线性热膨胀系数(25-800℃)的烧结陶瓷,总孔隙率在20%至30%之间。 此外,烧结陶瓷制品表现出孔径分布,使得孔的至少约86%的孔径小于约2μm。 最后,陶瓷制品表现出相互连通的孔结构,其中孔呈现出大致细长的形状,即孔主要以其长轴在纤维网的平面中取向。 本发明还涉及一种生产堇青石烧结陶瓷制品的方法,该方法首先将形成堇青石的无机粉末批料混合和塑化,其中包含平均粒径小于约2μm的平板状滑石,优选滑石形态指数大于 约0.75。 批料还包含至少4重量%的具有超过50m 2 / g的比表面积的可分散的形成A12O3的源的无机粉末批料混合物和一种或多种高岭土,煅烧高岭土, 二氧化硅和刚玉,各自具有小于5μm的中值粒度。 由此提供的增塑粉末批料通过蜂窝状挤压模挤出而形成绿色蜂窝状体,将生坯状的蜂窝体烧制至足以将生坯成型为具有上述特性的结晶堇青石陶瓷制品的温度和时间。