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Method for making porous ceramic articles with fugitive pore former

A pore-forming agent, ceramic technology, applied in the field of batch material composition for forming ceramics, which can solve the problems of reduced complexity, high porosity, cracks, etc.

Inactive Publication Date: 2013-03-27
CORNING INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

The use of porogens such as starch, graphite, or a mixture of the two can cause serious problems with cracking when drying and firing ceramic green bodies
For example, the penetration depth of microwaves during drying of the green body may be limited by the presence of porogens such as graphite, or there are significant temperature gradients in the green body during drying or firing; For porosity, the firing cycle may need to be adjusted and extended, resulting in higher cost, complexity and reduced productivity, especially in the case of particulate filters such as DPF, which require high porosity (such as greater than 50%), so Adding a large amount of this type of pore forming agent, such as adding more than 40% by weight of inorganic raw materials

Method used

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  • Method for making porous ceramic articles with fugitive pore former
  • Method for making porous ceramic articles with fugitive pore former
  • Method for making porous ceramic articles with fugitive pore former

Examples

Experimental program
Comparison scheme
Effect test

Embodiment

[0087] To further illustrate the disclosed content, the following examples provide those skilled in the art with a complete description of the realization and evaluation of ceramic precursor batch compositions, ceramic products and methods. These examples are exemplary and non-limiting. Efforts have been made to ensure the accuracy of values ​​(such as quantity, temperature, etc.); however, there may be some variations and deviations. Unless otherwise indicated, parts are parts by weight, temperature is expressed in °C or ambient temperature, and pressure is at or near atmospheric.

[0088] In the following examples, a series of seven cordierite-forming batch compositions were prepared. All seven batch formulations were prepared from a raw material mixture containing the following components, the mixture containing: 38.5% by weight of 22 micron (sieve size -325 mesh) talc, 12.5% ​​by weight of 10 micron kaolin, 12.4% by weight % 9 microns (sieve size -325 mesh) emery, 21.0 wt% ...

Embodiment 9

[0102] Example 9 (without pore former) represents the porosity baseline obtained from the raw material package used.

[0103] Examples 10-15 illustrate the increase in porosity caused by the addition of a short-acting pore former to the reference batch. The results of some examples are shown in Picture 10 in.

[0104] The thermal analysis (TGA) results of the paste containing the short-acting pore former are shown in curve 2. These curves clearly show that the significant weight loss at lower temperatures (below 150°C) corresponds to the sublimation of the short-acting porogen.

[0105] table 3

[0106]

[0107] Table 3 shows that short-acting pore formers can be used in combination with other known pore formers. All the samples in Table 3 were extruded from the prepared paste using a known extrusion method.

[0108] The porosity of all formulations shown in this table are obtained using a mixture of pore formers. Examples 16 and 18 show the ability of short-acting pore formers u...

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Abstract

Ceramic batch compositions for forming porous ceramic articles are disclosed. The ceramic-forming precursor batch composition comprises inorganic ceramic-forming batch components and a recyclable porogen such as cyclododecane. Methods for making porous ceramic articles are also disclosed.

Description

[0001] The full content of all publications, patents or patent documents mentioned herein are incorporated herein by reference. Technical field [0002] The present disclosure relates to the manufacture of porous ceramic products, such as wall-flow filters and flow-through substrates, including filters and substrates containing honeycomb structures, and more specifically, to the inclusion of short-acting pore formers The ceramic-forming batch composition. Background technique [0003] The porous ceramic honeycomb structure can be used in pollution control devices, such as diesel particulate filters (DPF). The pores of the ceramic material can be formed by adding a pore-forming agent to the batch, and then burning off the pore-forming agent during the firing cycle to create voids or pores. The use of pore-forming agents such as starch, graphite or a mixture of the two can cause serious problems with cracks when drying and firing ceramic green bodies. For example, the penetration ...

Claims

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Application Information

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Patent Type & Authority Patents(China)
IPC IPC(8): C04B35/185C04B35/195C04B35/478C04B35/565C04B38/00C04B38/06
CPCC04B2111/00793C04B38/0605C04B35/478C04B35/185C04B35/195C04B2111/0081C04B35/565Y10T428/2982Y10T428/24149C04B2235/6562C04B2235/6567C04B38/0006C04B38/0054C04B38/0074
Inventor Y·布罗谢顿D·亨利M·弗雷德霍姆C·吉勒M·莫雷诺
Owner CORNING INC