Fused Silica Cellular Structures for Low-Energy Sintering
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Solution Overview
Problem
The energy-intensive process for manufacturing cordierite substrates used in diesel and gasoline aftertreatment systems is inefficient and generates greenhouse gas emissions, and there is a need for materials that can withstand reduced sulfur concentrations and lower temperatures in modern exhaust systems.
Innovation Solution
A porous sintered glass material primarily composed of amorphous fused silica with a sintering aid is used, which includes a two-phase microstructure to facilitate sintering while maintaining low thermal expansion coefficients and porosity, allowing for the production of cellular bodies suitable for catalyst supports and filtration applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cordierite substrates are manufactured using traditional sintering processes, then the substrates can withstand high temperatures and severe thermal shock conditions, but the manufacturing process becomes energy intensive and time consuming
Solution Approach 1:
The patent modifies the chemical composition parameters by incorporating specific amounts of Al2O3 (1-10 wt%), CaO (1-10 wt%), and MgO (1-10 wt%) into the fused silica-based glass composition. These compositional changes enable the material to achieve cordierite-like thermal properties with lower sintering temperatures (1000-1200°C), thus reducing manufacturing energy consumption while maintaining thermal shock resistance
Solution Approach 2:
The invention creates a composite glass-ceramic material that combines amorphous fused silica matrix with crystalline cordierite phases. This composite structure leverages the high temperature stability of cordierite within a glass matrix, achieving both thermal shock resistance and reduced sintering temperature requirements compared to traditional monolithic cordierite
2Strength
If cordierite substrates are manufactured using traditional sintering processes, then the substrates achieve required strength and thermal stability, but the firing process becomes time consuming due to slow heating cycles
Solution Approach 1:
The patent changes the thermal and compositional parameters by formulating a glass composition with specific oxides that lower the softening temperature and enhance sintering activity. This allows rapid heating rates (up to 100°C/min) without compromising final strength, reducing total firing time from traditional multi-hour cycles to under 2 hours while achieving comparable or superior mechanical properties
Solution Approach 2:
The invention performs preliminary chemical preparation by incorporating reactive oxide components in the green body composition that activate during initial heating stages. These components promote rapid nucleation and growth of strengthening phases early in the firing cycle, enabling shorter overall processing times while ensuring adequate strength development
3Reliability
If traditional cordierite manufacturing processes are used, then the substrates can tolerate fuel with high sulfur concentrations, but the process generates greenhouse gas emissions and is energy intensive
Solution Approach 1:
The patent modifies the chemical composition by incorporating sulfur-tolerant glass formers and modifiers that maintain catalyst functionality in high-sulfur environments. The lowered sintering temperature (1000-1200°C vs. traditional 1400°C+) directly reduces CO2 emissions from fuel combustion, while the compositional design ensures sulfur tolerance is maintained through enhanced glass matrix resistance to sulfur-induced degradation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The approach reduces energy consumption and greenhouse gas emissions, provides strength and low thermal expansion, and enables the production of cellular bodies that can operate effectively in the temperature range of modern aftertreatment systems, while maintaining porosity and strength.
Implementation Method 1
The process for manufacture of cordierite substrates and filters is energy intensive and the source of greenhouse gas emissions. Temperatures of more than 1400° C. are used to drive reactive sintering to form cordierite.
Implementation Method 2
The porous sintered glass material primarily includes a first phase and a second phase, the first phase primarily including amorphous fused silica and the second phase including amorphous fused silica and a sintering aid material.
Data Source
AI summary
A porous cellular body comprising primarily a porous sintered glass material is disclosed. The porous sintered glass material primarily includes a first phase and a second phase, the first phase primarily comprising amorphous fused silica and the second phase comprising amorphous fused silica and a sintering aid.