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公开(公告)号：US06566290B2
公开(公告)日：2003-05-20
申请号：US09969569
申请日：2001-10-01
申请人： Douglas M. Beall , George H. Beall
发明人： Douglas M. Beall , George H. Beall
IPC分类号： C04B3519
CPC分类号： C04B35/19 , C04B35/10 , C04B35/44 , C04B38/0006 , C04B2111/00793 , Y10S55/30 , C04B38/0054 , C04B38/0074
摘要： A ceramic article which consists essentially, by weight on the oxide basis, of 10-25% SiO2, 65-85% Al2O3, and 2-12% Li2O and comprises beta-eucryptite as a first phase having a negative component in thermal expansion and a melting point Tm1, and a second phase having a positive component in thermal expansion which is higher than the component in thermal expansion of the first phase and a melting point Tm2, wherein Tm2>Tm1, wherein the first phase is at most 50% by weight of the ceramic, and wherein the ceramic is characterized by microcracking. Tm2 is at least 1800° C. The ceramic article exhibits a near zero coefficient of thermal expansion from room temperature to 800° C., a high refractoriness, and a high resistance to thermal shock properties which make the inventive ceramic extremely desirable in high temperature applications, such as filters for diesel exhaust engines.
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公开(公告)号：US06562284B2
公开(公告)日：2003-05-13
申请号：US10027993
申请日：2001-12-19
IPC分类号： C04B35195
CPC分类号： C04B38/0006 , C04B35/195 , C04B35/63 , C04B35/632 , C04B35/636 , C04B2235/3217 , C04B2235/3218 , C04B2235/3418 , C04B2235/3445 , C04B2235/349 , C04B2235/449 , C04B2235/5409 , C04B2235/5436 , C04B2235/5445 , C04B2235/9615
摘要： This invention relates to a method of producing a honeycomb ceramic body exhibiting a predetermined radial dimension comprising producing a green ceramic honeycomb body that exhibits a radial dimension at least 9% greater than the predetermined radial dimension and a cell density of at least 500 cpsi. The method further involves shrinking the green body during firing to form a sintered honeycomb ceramic body exhibiting the final predetermined radial dimension. This invention also relates to a method of producing a ceramic body comprising the following steps: (a) compounding and plasticizing a ceramic raw material mixture and forming the plasticizable raw material mixture into a green ceramic body by extrusion through an extrusion die; (b) drying the green body and thereafter firing the green body at a time and at a temperature sufficient to sinter the ceramic body resulting in a radial shrinkage of the green ceramic body in the radial dimension due to the firing of at least 9%.
摘要翻译： 本发明涉及一种生产具有预定径向尺寸的蜂窝状陶瓷体的方法，其包括生产呈现比预定径向尺寸大至少9％的径向尺寸和至少500cpsi的泡孔密度的生陶瓷蜂窝体。 该方法还包括在焙烧期间收缩生坯以形成呈现最终预定径向尺寸的烧结蜂窝陶瓷体。 本发明还涉及一种陶瓷体的制造方法，其特征在于包括以下步骤：（a）将陶瓷原料混合物进行配混和塑化，并通过挤出模挤出将可塑性原料混合物形成生坯陶瓷体;（b） 干燥生坯，然后在足以烧结陶瓷体的时间和温度下焙烧生坯，导致由于烧制至少9％，生坯陶瓷体在径向尺寸上的径向收缩。
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23.发明授权公开(公告)号：US06432856B1
公开(公告)日：2002-08-13
申请号：US09590106
申请日：2000-06-08
IPC分类号： C04B3503
CPC分类号： C04B38/0006 , C04B35/195 , C04B2111/00129 , C04B2111/0037 , C04B2111/0081 , C04B2111/32 , Y10T428/24149 , Y10T428/24273 , C04B38/0051 , C04B38/0054 , C04B38/007
摘要： A sintered ceramic honeycomb article that exhibits an average linear coefficient of thermal expansion (25-800° C.) below about 5.0×10−7° C.−1, a total porosity between the range of 20% to about 30%, and a pore size distribution such that at least about 86% of pores are of a pore size of less than about 2 &mgr;m with the pores exhibiting a generally elongated shape oriented with their long axis in the plane of the webs, the article being made from a cordierite-forming inorganic powder batch comprising a platy talc having median particle of size less than about 2 &mgr;m, at least 4% by weight of a dispersible Al2O3-forming source having a specific surface area in excess of 50 m2/g, and one or more of the components of kaolin, calcined kaolin, silica, and corundum, each having a median particle sizes less than 5 &mgr;m.
摘要翻译： 一种烧结陶瓷蜂窝体制品，其平均线性热膨胀系数（25-800℃）低于约5.0×10-7℃-1，总孔隙率在20％至30％之间，和 孔尺寸分布使得至少约86％的孔具有小于约2μm的孔径，其中孔具有以其长轴在幅平面中定向的大致细长形状，该制品由堇青石制成 包含具有中值粒径小于约2μm的片状滑石的至少4重量％的比表面积超过50m 2 / g的可分散Al 2 O 3形成源的至少4重量％的无机粉末批料，以及一种或多种 的高岭土，煅烧高岭土，二氧化硅和刚玉的组分，各自具有小于5μm的中值粒度。
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公开(公告)号：US5114644A
公开(公告)日：1992-05-19
申请号：US654528
申请日：1991-02-13
IPC分类号： B01J21/16 , B01J21/14 , C04B35/195 , C04B38/00
CPC分类号： C04B35/195 , B01J21/14
摘要： A body is disclosed which is at least about 90% by weight cordierite, has a mean pore size of less than about 10.0 microns, and a coefficient of thermal expansion of no greater than about 9.0.times.10.sup.-7 /.degree.C. from about 25.degree. C. to 1000.degree. C. Also disclosed is a method of fabricating the body. Raw materials are selected to form a composition consisting essentially of in percent by weight about 12 to 16 magnesium oxide, about 35 to 41 aluminum oxide, and about 43 to 53 silica. The raw materials are absent of clay and talc. The magnesium oxide is supplied by a magnesium oxide component having an average particle size of no greater than about 15.0 micrometers in diameter. The aluminum oxide is supplied by an aluminum oxide component having an average particle size of no greater than about 8.0 micrometers in diameter. The composition is capable of forming cordierite in the subsequent firing step. The raw materials are blended with an affective amount of vehicle and forming aids to impart plastic formability and green strength thereto and form a plastic mixture. The raw materials are formed into a green body which is dried and fired. The firing is done by heating to a first temperature of about 1000.degree. C. to 1200.degree. C. and thereafter raising the temperature at a rate of less than about 100.degree. C. per hour to a second temperature sufficient to form cordierite, and maintaining the second temperature for a sufficient time to form the cordierite body.
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公开(公告)号：US06843822B2
公开(公告)日：2005-01-18
申请号：US10736929
申请日：2003-12-15
申请人： Douglas M. Beall , Johnny Marcher
发明人： Douglas M. Beall , Johnny Marcher
CPC分类号： B01D46/0001 , B01D39/2068 , B01D46/2425 , B01D46/2429 , B01D46/2451 , B01D46/2466 , B01D46/247 , B01D2046/2481 , B01D2046/2496 , B23H9/00 , B23H2200/30 , F01N3/022 , F01N2330/06 , F01N2330/30 , Y02T10/20 , Y10S55/30 , Y10T428/131 , Y10T428/24149 , Y10T428/24157 , Y10T428/24744
摘要： A honeycomb structure which includes an inlet end and an outlet end opposing each other and a plurality of cell channels extending along an axis from the inlet end to the outlet end, the cell channels having non-equal, square cross-sections, and an extrusion die for making the same.
摘要翻译： 蜂窝结构，其包括彼此相对的入口端和出口端以及沿着从入口端到出口端的轴线延伸的多个单元通道，单元通道具有不相等的正方形横截面，并且挤出 死于做同样的事情
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公开(公告)号：US06541407B2
公开(公告)日：2003-04-01
申请号：US09867321
申请日：2001-05-29
IPC分类号： C04B35195
CPC分类号： C04B38/0051 , B01D39/2068 , C04B35/195 , C04B38/00 , C04B2111/00793 , F01N3/022 , F01N2330/06 , Y10S55/30 , C04B38/0006 , C04B38/0054 , C04B38/0074 , C04B38/0067
摘要： A ceramic comprising predominately a cordierite-type phase approximating the stoichiometry Mg2Al4Si5O18 and having a coefficient of thermal expansion (25-800° C.) of greater than 4×10−7/° C. and less than 13×10−7/° C. and a permeability and a pore size distribution which satisfy the relation 2.108 (permeability)+18.511 (total pore volume)+0.1863 (percentage of total pore volume comprised of pores between 4 and 40 micrometers)>24.6. The ceramic is suitable in the fabrication of cellular, wall-flow, diesel particulate filters having a pressure drop in kPa that at an artificial carbon soot loading of 5 grams/liter and a flow rate of 26 scfm is less than 8.9−0.035 (number of cells per square inch)+300 (cell wall thickness in inches), a bulk filter density of at least 0.60 g/cm3 and a volumetric heat capacity of at least 0.67 J cm−3 K−1 as measured at 500° C.
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公开(公告)号：US06455124B1
公开(公告)日：2002-09-24
申请号：US09727741
申请日：2000-12-01
申请人： Douglas M. Beall , Thomas W. Brew , Christopher J. Malarkey , Mark A. Spetseris , David R. Treacy, Jr.
发明人： Douglas M. Beall , Thomas W. Brew , Christopher J. Malarkey , Mark A. Spetseris , David R. Treacy, Jr.
IPC分类号： B32B312
CPC分类号： B28B3/269 , B01J35/04 , C04B35/195 , C04B38/0006 , Y10T428/24149
摘要： Fine circumferential skin cracking in extruded thin-walled cordierite honeycombs having channel wall thicknesses not exceeding about 0.004 inches (100 &mgr;m) but skin layers of substantially higher thickness is prevented by extruding the honeycombs under conditions that enhance cordierite crystal alignment in the skin; thin-walled honeycomb products having skins free of fine cracks that are well-matched in thermal expansion to the honeycomb cores are provided.
摘要翻译： 挤出的薄壁堇青石蜂窝中的细圆周皮肤开裂，其通道壁厚度不超过约0.004英寸（100μm），但是通过在增强皮肤中堇青石晶体取向的条件下挤出蜂窝来防止厚度显着更高的皮肤层; 提供了具有与蜂窝芯的热膨胀良好匹配的细小裂纹的薄壁蜂窝制品。
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28.发明授权公开(公告)号：US06368992B1
公开(公告)日：2002-04-09
申请号：US09605171
申请日：2000-06-28
IPC分类号： C04B35632
CPC分类号： B28B3/269 , C04B35/195 , C04B35/622 , C04B35/632 , C04B38/0006 , C04B2111/00129
摘要： A binder system for use in the formation of ceramic or other powder-formed greenware comprising a binder, a solvent for the binder, a surfactant, and a component that is non-solvent with respect to the binder and solvent. The non-solvent component exhibits a lower viscosity than the solvent when containing the binder and comprises a low molecular weight oil having a 90% recovered distillation temperature range of between about 220 to 400° C. Also disclosed is a process of forming and shaping plasticized powder mixtures and a process for forming ceramic articles utilizing the binder system.
摘要翻译： 用于形成陶瓷或其它粉末形式的绿色软化剂的粘合剂体系，其包含粘合剂，粘合剂的溶剂，表面活性剂和相对于粘合剂和溶剂为非溶剂的组分。 非溶剂组分在含有粘合剂时表现出比溶剂低的粘度，并且包含90％回收蒸馏温度范围在约220-400℃之间的低分子量油。还公开了一种将塑化的 粉末混合物和利用粘合剂体系形成陶瓷制品的方法。
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公开(公告)号：US06241940B1
公开(公告)日：2001-06-05
申请号：US09320938
申请日：1999-05-27
IPC分类号： B28B322
CPC分类号： B28B3/269 , C04B35/195 , C04B35/622 , C04B35/632 , C04B38/0006 , C04B2111/00129
摘要： A binder system for use in the formation of ceramic or other powder-formed greenware including a binder, a solvent for the binder, a surfactant, and a component that is non-solvent with respect to the binder and solvent. The non-solvent component exhibits a lower viscosity than the solvent when containing the binder and includes a low molecular weight oil having a 90% recovered distillation temperature range of between about 220 to 400° C. Also disclosed is a process of forming and shaping plasticized powder mixtures and a process for forming ceramic articles utilizing the binder system.
摘要翻译： 用于形成陶瓷或其它粉末形式的绿色软化剂的粘合剂体系，其包括粘合剂，粘合剂的溶剂，表面活性剂和相对于粘合剂和溶剂是非溶剂的组分。 当含有粘合剂时，非溶剂组分显示比溶剂低的粘度，并且包括具有在约220至400℃之间的90％回收蒸馏温度范围的低分子量油。还公开了一种将塑化的 粉末混合物和利用粘合剂体系形成陶瓷制品的方法。
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公开(公告)号：US06214437B1
公开(公告)日：2001-04-10
申请号：US09199024
申请日：1998-11-24
IPC分类号： B32B312
CPC分类号： C04B38/0006 , C04B35/195 , C04B2111/00129 , Y10T428/24149
摘要： Cordierite honeycomb bodies having low coefficients of thermal expansion (CTE) and correspondingly high resistance to thermal shock, and a method for making them, wherein an alumina-yielding raw material having high specific surface area and which disperses into very fine particles in the batch, preferably together with fine talc as the sole batch source of magnesium, are disclosed; the use of fine talc enables the production of thin-walled extruded honeycomb structures exhibiting both low average CTE and high porosity, a combination particularly desirable for applications such as catalytic substrates for the control of combustion engine exhaust emissions.
摘要翻译： 具有低热膨胀系数（CTE）和相应的耐热冲击性的堇青石蜂窝体及其制造方法，其中具有高比表面积并分散成批次中的非常细小颗粒的产生氧化铝的原料， 优选与细滑石一起作为唯一的批次镁源; 精细滑石的使用使得能够生产具有低平均CTE和高孔隙率的薄壁挤压蜂窝结构体，特别适用于用于控制内燃机废气排放物的催化底物的应用。
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