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    Refractory NZP-type structures and method of making and using same
    22.
    发明授权
    Refractory NZP-type structures and method of making and using same 失效
    耐火NZP型结构及其制作与使用方法

    公开(公告)号：US06413895B1

    公开(公告)日：2002-07-02

    申请号：US09671722

    申请日：2000-09-27

    申请人： Gregory A. Merkel

    发明人： Gregory A. Merkel

    IPC分类号： C04B3503

    CPC分类号： C04B38/00 ,  B01D39/2068 ,  B01D39/2075 ,  C04B35/16 ,  C04B35/447 ,  C04B38/0006 ,  C04B2111/00198 ,  C04B2111/00793 ,  F01N3/022 ,  F01N2330/14 ,  F01N2370/22 ,  Y10S55/30 ,  Y10T428/24149 ,  C04B35/48 ,  C04B38/0051 ,  C04B38/0058 ,  C04B38/0074 ,  C04B38/068

    摘要： A structure made predominately of an NZP-type phase having the general formula RxZ4P6−ySiyO24, where 0≦x≦8, 0≦y≦6, R is Li, Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Y, and/or lanthanides, and Z is Zr, Ti, Nb, Ta, Y, and/or lanthanidess, and optionally a sintering additive. The structure has an open porosity of at least 20% by volume, median pore diameter in micrometers of at least a value defined by the quantity [10−0.10(% open porosity)], both as measured by mercury porosimetry, and four-point modulus of rupture as measured on a solid rod of circular cross section, of at least 300 psi. Method of making the structure involves forming a mixture of NZP-forming raw material powders that are metal oxide sources capable of reacting to form an NZP-type reaction product, and/or pre-reacted powder having the above general formula. The volumetric average of the median particle diameters of the raw material powders in the raw materials combination is at least 15 micrometers, and the particle diameters of at least 65% by volume of the totality of the raw material particles are greater than 11 micrometers. The mixture is shaped into a green structure, and fired to produce the finished structure. The structure is preferably multicellular, e.g. a honeycomb, where a fluid stream enters the structure, passes through the cells and is acted upon, and exits the structure. The structure is preferably an alternately plugged honeycomb suitable as a diesel particulate filter.

    摘要翻译： 主要由具有通式RxZ4P6-ySiyO24的NZP型相的结构，其中0 <= x <= 8,0 <= y <= 6，R是Li，Na，K，Rb，Cs，Mg，Ca ，Sr，Ba，Y和/或镧系元素，Z是Zr，Ti，Nb，Ta，Y和/或无镧，以及任选的烧结添加剂。 该结构具有至少20体积％的开放孔隙率，中值孔径（以微米为单位），至少由[10-0.10（开孔率））定义的值，通过水银孔率法测定，以及四点 至少300psi的圆截面的实心棒上测得的断裂模量。 制造结构的方法包括形成NZP形成原料粉末的混合物，其是能够反应形成NZP型反应产物的金属氧化物源，和/或具有上述通式的预反应的粉末。 原料组合中的原料粉末的中值粒径的体积平均值为至少15微米，原料颗粒的总体积的至少65体积％的粒径大于11微米。 将混合物成形为绿色结构，并烧制以生产成品结构。 该结构优选是多细胞的，例如 蜂窝体，其中流体流进入结构，通过细胞并被作用在并离开结构。 该结构优选为适合作为柴油微粒过滤器的交替堵塞的蜂窝体。

    Fabrication of ultra low thermal expansion cordierite structures
    23.
    发明授权
    Fabrication of ultra low thermal expansion cordierite structures 有权
    超低热膨胀堇青石结构的制造

    公开(公告)号：US06284693B1

    公开(公告)日：2001-09-04

    申请号：US09451309

    申请日：1999-11-30

    申请人： Douglas M. Beall ,  Gregory A. Merkel

    发明人： Douglas M. Beall ,  Gregory A. Merkel

    IPC分类号： C04B35195

    CPC分类号： C04B35/195 ,  C04B35/6263 ,  C04B35/63 ,  C04B35/632 ,  C04B35/634 ,  C04B35/6365 ,  C04B38/0006 ,  C04B2111/00129 ,  C04B2111/0025 ,  C04B2111/0037 ,  C04B2111/0081 ,  C04B2111/32 ,  C04B2235/3206 ,  C04B2235/3217 ,  C04B2235/3218 ,  C04B2235/3418 ,  C04B2235/3445 ,  C04B2235/349 ,  C04B2235/449 ,  C04B2235/5292 ,  C04B2235/5296 ,  C04B2235/5409 ,  C04B2235/5445 ,  C04B2235/77 ,  C04B2235/96 ,  C04B2235/9607 ,  F01N3/2828 ,  F01N2330/06 ,  Y10T428/24149

    摘要： Disclosed is sintered ceramic article that exhibits a primary crystalline phase of cordierite and analytical oxide composition, in weight percent, of 49-53% SiO2, 33-38% Al2O3, 12-16% MgO and exhibits a coefficient of thermal expansion no greater than about 4.0×10−7/° C. over the temperature range of about 25° C. to about 800° C. and a transverse-I ratio of not less than about 0.92. Also disclosed is a method for producing a sintered cordierite ceramic article involving preparing a plasticizable raw material, comprising a magnesium source, a SiO2-forming source and an additional component of either: (a) a clay-free, Al2O3-forming source having a surface area of greater than about 5 m2/g; or, (b) a clay and Al2O3-forming source combination wherein the clay comprises no greater than about 30%, by weight, of the total inorganic mixture, and the Al2O3-forming source exhibits a surface area of greater than about 40 m2/g. The mixture is formed into a green body substrate of the desired configuration and subsequently dried and fired for a time and at temperature sufficient to form a structure having the aforementioned CTE and I-ratio properties.

    摘要翻译： 公开了烧结陶瓷制品，其显示堇青石的主结晶相和分析氧化物组合物，其重量百分比为49-53％SiO 2，33-38％Al 2 O 3，12-16％MgO，并且显示出不大于 在约25℃至约800℃的温度范围内为约4.0×10 -7 /℃，横I比不小于约0.92。 还公开了一种生产堇青石烧结体烧结体的方法，包括制备可塑性原料，包括镁源，形成SiO 2的源和另外的组分：（a）不含粘土的Al 2 O 3形成源，其具有 表面积大于约5m2 / g; 或（b）粘土和Al 2 O 3形成源组合，其中粘土占总无机混合物的不大于约30重量％，并且Al 2 O 3形成源的表面积大于约40m 2 / G。 将混合物形成为所需构型的生坯基材，随后干燥并焙烧一段时间并在足以形成具有上述CTE和I比率性质的结构的温度下进行烧制。

    Low CTE cordierite bodies with narrow pore size distribution and method of making same
    24.
    发明授权
    Low CTE cordierite bodies with narrow pore size distribution and method of making same 有权
    具有窄孔径分布的低CTE堇青石体及其制备方法

    公开(公告)号：US6087281A

    公开(公告)日：2000-07-11

    申请号：US348307

    申请日：1999-07-07

    申请人： Gregory A. Merkel

    发明人： Gregory A. Merkel

    IPC分类号： B01J20/16 ,  B01J35/04 ,  C04B35/195 ,  C04B38/00

    CPC分类号： C04B38/00 ,  C04B35/195 ,  C04B2111/00793 ,  C04B2111/0081

    摘要： Cordierite body of CTE at 25-800.degree. C. of .ltoreq.4.times.10.sup.-7 C, at least 85% of porosity having pore diameter of 0.5-5.0.mu.; or >4-6.times.10.sup.-7 C.sup.-1, porosity at least 30 vol %, at least 85% of porosity has pore diameter 0.5-5.0.mu.. Raw materials talc, Al.sub.2 O.sub.3 source, and kaolin, calcined kaolin, and/or silica, and optionally spinel, particle diameter of talc .ltoreq.3.0.mu., of Al.sub.2 O.sub.3 source 200.degree. C./hr. When particle diameter of talc is .gtoreq.2.0.mu., and Al.sub.2 O.sub.3 source is 50.degree. C./hr and 50.degree. C./hr. When particle diameter of kaolin is >2.0.mu., heating rate from 1150.degree. C.-1275.degree. C. is 30.degree. C./hr.

    摘要翻译： CTE的堇青石体在25-800℃下，孔径为0.5-5.0μm的至少85％的孔隙率; 或> 4-6×10 -7 C -1，孔隙率至少为30体积％，孔隙率至少为85％具有孔径0.5-5.0微米。 原料滑石，Al2O3源和高岭土，煅烧高岭土和/或二氧化硅，并且任选的尖晶石，滑石的粒径为3.0μm的Al 2 O 3源<2.0μm，高岭土为原料的35重量％ 直径<2.0亩，与车辆混合，辅助成塑料混合物。 生坯体干燥，在1370℃-1435℃下烧成。当滑石的粒径<2.0μm，Al2O3原料为原料的20重量％时，分散的高表面积的Al 2 O 3源具有粒径 <0.3μm，为原料的5.0重量％，高岭土的粒径<2.0μm，加热速度为1150℃〜1275℃，为> 200℃/小时。 当滑石的粒径>2.0μm，Al 2 O 3源为原料的20重量％时，粒径<0.3μm的分散性高表面积Al 2 O 3源为原料的5.0重量％，粒子 高岭土的直径<2.0μm，加热速率为1150℃-1275℃，为> 50℃/小时和<600℃/小时。 当Al2O3源少于原料的20重量％时，粒径≤0.3μm的分散Al2O3源为原料的5.0重量％，高岭土的粒径<2.0μm，加热速度为1150℃ -1275℃> 50℃/小时。 当高岭土的粒径>2.0μm时，1150℃-1275℃的加热速率为<600℃/小时至> 30℃/小时。

    Method of producing fast-fired cordierite bodies
    25.
    发明授权
    Method of producing fast-fired cordierite bodies 失效
    生产快堇青石体的方法

    公开(公告)号：US6004501A

    公开(公告)日：1999-12-21

    申请号：US114994

    申请日：1998-07-14

    申请人： Edward E. Cornelius ,  Gregory A. Merkel

    发明人： Edward E. Cornelius ,  Gregory A. Merkel

    IPC分类号： B01J21/14 ,  C04B35/195 ,  C04B33/32

    CPC分类号： B01J21/14 ,  C04B35/195

    摘要： A cordierite body is produced by providing cordierite-forming raw materials as talc, calcined talc, MgO-forming component, magnesium aluminate spinel, SiO.sub.2 -forming component, Al.sub.2 O.sub.3 -forming component, kaolin, calcined kaolin, and/or mullite, such that the quantity R is less than about 1.207. R is0.253 (wt. % mullite powder)+0.278(wt. % SiO.sub.2 powder)+0.00590(wt. % SiO.sub.2 powder)(wt. % spinel powder)-0.0193(wt. % SiO.sub.2 powder)(heating time at maximum temperature)-0.348(heating time at maximum temperature)-0.00237(mean heating rate from 25.degree. C. to 1275.degree. C.)+0.0736(wt. % alpha Al.sub.2 O.sub.3 powder)(mean particle size of alpha Al.sub.2 O.sub.3 powder)+0.0892(wt. % Al(OH).sub.3 powder)(mean particle size of Al(OH).sub.3 powder)-0.215(wt. % dispersible high surface area Al.sub.2 O.sub.3 -forming component)+2.392(log.sub.10 (1+(wt. % MgO-forming component)(wt. % calcined kaolin))).The raw materials are intimately blended with effective amount of vehicle and forming aids to form a plastic mixture. A green body is formed, which is dried and heated from room temperature up to a maximum temperature of about 1360.degree. C. to 1435.degree. C. at an average heating rate of at least about 70.degree. C. per hour and held at maximum temperature for about 0.05 to 18 hours. The total heating time from room temperature to the end of the hold at the maximum temperature is about 4.5 to 20 hours. The resulting body is predominately cordierite, having a mean coefficient of thermal expansion from about 25.degree. C. to 800.degree. C. of less than about 9.times.10.sup.-7 .degree. C..sup.-1 in at least one direction.

    摘要翻译： 通过提供堇青石形成原料作为滑石，煅烧滑石，形成镁的组分，铝酸镁尖晶石，形成SiO 2的组分，Al 2 O 3形成组分，高岭土，煅烧高岭土和/或莫来石，生产堇青石体，使得 数量R小于1.207。 R为0.253（重量％莫来石粉末）+0.278（重量％SiO2粉末）+0.00590（重量％SiO2粉末）（重量％尖​​晶石粉末）-0.0193（重量％SiO 2粉末）（最高温度下的加热时间 ）-0.348（最高温度下的加热时间）-0.00237（平均加热速度为25℃至1275℃）+0.0366（重量％Al 2 O 3粉末）（αAl 2 O 3粉末的平均粒径）+0.0892（wt 。％Al（OH）3粉末）（Al（OH）3粉末的平均粒度）-0.215（重均分散性高表面积Al2O3形成组分）+2.392（log10（1+（重量％ 组分）（重量％煅烧高岭土）））。 原料与有效量的载体和成型助剂紧密混合以形成塑料混合物。 形成生坯体，将其从室温干燥并加热至约1360℃至1435℃的最高温度，平均加热速率为至少约70℃/小时，并保持在最高温度 约0.05至18小时。 在最高温度下从室温到保持结束的总加热时间为约4.5至20小时。 所得的主体主要是堇青石，在至少一个方向上具有从约25℃至800℃的小于约9×10 -7℃-1的平均热膨胀系数。

    Aluminum nitride bodies and method
    27.
    发明授权
    Aluminum nitride bodies and method 失效
    氮化铝体和方法

    公开(公告)号：US4952535A

    公开(公告)日：1990-08-28

    申请号：US381848

    申请日：1989-07-19

    申请人： Gregory A. Merkel

    发明人： Gregory A. Merkel

    IPC分类号： C04B35/581

    CPC分类号： C04B35/581

    摘要： There is disclosed a highly densified, sintered aluminum nitride body having a thermal conductivity in excess of 200 W/m.degree.K. and a strong resistance to attack by hot HC1. There is also disclosed a method of sintering aluminum nitride bodies which employs a variable thermal cycle whereby the body is either heated slowly through a pre-sintering temperature range of 1300.degree. to 1750.degree. C., or held at a temperature within that range for at least a half hour. Optionally, a green aluminum nitride body may be provided with up to 10% by weight of at least one metal fluoride dopant, and may be provided with a sufficient weight to maintain flatness during firing.

    摘要翻译： 公开了一种高致密度的烧结氮化铝体，其导热率超过200W / m°K.并且具有很强的抗热HC1的抵抗性。 还公开了一种烧结氮化铝体的方法，其采用可变的热循环，由此身体在1300℃至1750℃的预烧结温度范围内缓慢加热，或者保持在该范围内的温度 至少一个半小时。 任选地，绿色氮化铝体可以设置有至多10重量％的至少一种金属氟化物掺杂剂，并且可以具有足够的重量以保持烧制期间的平坦度。

    Phosphate-based ceramic
    30.
    发明授权
    Phosphate-based ceramic 失效

    公开(公告)号：US06576579B2

    公开(公告)日：2003-06-10

    申请号：US09969562

    申请日：2001-10-01

    申请人： Gregory A. Merkel

    发明人： Gregory A. Merkel

    IPC分类号： C04B3548

    CPC分类号： C04B35/447 ,  Y10S55/30

    摘要： A ceramic including a first phase having a general formula R1+(x/2)Zr4P6-xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦x≦2, wherein the first phase has a volumetric heat capacity (Cp1), and at least 10 weight percent of a second phase having a volumetric heat capacity (Cp2), wherein Cp2>Cp1. The ceramic has a coefficient of thermal expansion from 22° to 1000° C. of −15×10−7/° C. to +15×10−7/° C., a permeability of at least 0.25×10−12 m2, a total porosity of at least 35% by volume, and a median pore diameter of at least 6 micrometers, and a volumetric heat capacity of the solid Cp(solid) of at least 3.15 J/cm3 K.