Beta-spodumene-cordierite composition, article, and method

A technology of spodumene and cordierite, applied in the field of β-spodumene-cordierite composition, product and method

Pending Publication Date: 2016-08-10
CORNING INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0006] An important challenge in the manufacture of porous ceramic honeycombs is to provide the strength required for handling, potting and use while providing high porosity and / or thin cell walls

Method used

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  • Beta-spodumene-cordierite composition, article, and method
  • Beta-spodumene-cordierite composition, article, and method
  • Beta-spodumene-cordierite composition, article, and method

Examples

Experimental program
Comparison scheme
Effect test

Embodiment A

[0033] Example A - Ceramic Composition

[0034] Tables 1 and 2 below give the batch composition and physical properties of some spodumene-cordierite composites. For comparison, examples of cordierite materials are also reported, including commercially available cordierite (composition C1 ), non-microcracked cordierite containing lanthanum glass (composition 2 ) and non-microcracked cordierite (composition C3) made primarily from mineral batches seeded with cordierite crystals to limit the domain size. Composite compositions prepared according to the invention in Tables 1 and 2 were compounded using the α-spodumene mineral as the lithium source, which mineral contained 6% by weight of Li 2 O, 25.3 wt% Al 2 o 3 and 64.6 wt% SiO 2 , the balance including traces (each less than 1% by weight) of Fe 2 o 3 、Na 2 O, K 2 O.P 2 o 5 and MnO 2 .

[0035] The batch compositions in Table 1 are expressed in parts by weight. For each batch composition reported, Table 1 contains t...

Embodiment B

[0043] Example B - Catalyst Compatibility

[0044] Poisoning of the catalyst surface by the alkali component of the sintered ceramic is found to be a problem for the β-spodumene catalyst substrate. For three-way washcoat catalysts, two mechanisms have been found. The first mechanism arises from the fact that the pH of the washcoat slurry is usually below 4. Therefore, the protons from the acidic washcoat slurry can ion-exchange with the lithium from the spodumene, so some lithium ions can deposit on the catalyst sites, poisoning the catalyst activity. The origin of the second mechanism is that lithium can diffuse from spodumene to the catalyst at high temperature. The presence of steam in the combustion exhaust stream accelerates this process.

[0045] By comparing the catalytic conversion efficiencies of propylene, carbon monoxide, and nitrous oxide on the respective catalysts deposited on spodumene-cordierite composite honeycomb substrates and conventional cordierite hone...

Embodiment

[0061] Example C - Catalyst Substrate Stability

[0062] The effect of washcoating on the properties of the catalyst substrate can be significant, including changes from firing the initially applied washcoat as well as changes after extended operating thermal cycling times.

[0063] The data presented in Table 4 below compares the effects of washcoating and heat aging on the physical properties of cordierite and spodumene-cordierite composite honeycomb articles. Four honeycombs with different compositions were compared, including the EX-2 spodumene-cordierite composite composition in Tables 1 and 2, the cordierite compositions C2 and C3 reported in Tables 1 and 2, and a wide range of automotive exhaust systems Another commercially available cordierite honeycomb composition C4 was used.

[0064] Table 4 contains the following physical property values ​​for each honeycomb sample tested: modulus of rupture (MOR) strength, modulus of elasticity (EMOD), strain tolerance (ST), aver...

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Abstract

Porous spodumene-cordierite honeycomb bodies of high strength but low volumetric density, useful for the manufacture of close-coupled engine exhaust converters, gasoline engine particulate exhaust filters, and NOx integrated engine exhaust filters, are provided through the reactive sintering of batches comprising sources of magnesia, alumina and silica together with a lithia source, such as a spodumene or petalite ore.

Description

[0001] Instructions for Divisional Application [0002] The application date of this application is November 17, 2010, the international application number is PCT / US2010 / 056965, and the national application number after entering the Chinese national phase is 201080053960.4, entitled "β-spodumene-cordierite composition, product and method” is a divisional application of the invention patent application. [0003] Cross References to Related Applications [0004] This application claims the benefit of and priority to U.S. Provisional Patent Application Serial No. 61 / 265,106, filed November 30, 2009, entitled "Beta-Spodumene-cordierite Compositions, Articles, and Methods," which application is incorporated herein by The content is relied upon and is hereby incorporated by reference in its entirety. technical field [0005] The articles and methods disclosed herein generally relate to porous ceramic materials and related porous ceramic structures, such as honeycomb structures use...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): C04B38/06C04B35/19
CPCC04B35/19C04B38/0006C04B38/068C04B2111/00793C04B2235/36C04B2235/3481C04B38/0074C04B38/007C04B38/0054C04B38/0067C04B38/0645B01J23/40B01J23/464C04B35/6263C04B2235/3203C04B2235/3206C04B2235/3217C04B2235/3218C04B2235/3222C04B2235/3225C04B2235/3227C04B2235/3418C04B2235/3445C04B2235/3463C04B2235/3472C04B2235/349C04B2235/656C04B2235/6567C04B2235/77C04B2235/80C04B2235/96C04B2235/9607Y10T428/24149Y10T428/26C04B38/0009F01N3/0222F01N3/2828
Inventor G·A·默克尔C·W·坦纳
Owner CORNING INC
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