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    Fabrication of cordierite bodies
    1.
    发明授权
    Fabrication of cordierite bodies 失效

    公开(公告)号：US5114644A

    公开(公告)日：1992-05-19

    申请号：US654528

    申请日：1991-02-13

    申请人： Douglas M. Beall ,  Evelyn M. DeLiso ,  Donald L. Guile ,  Martin J. Murtagh

    发明人： Douglas M. Beall ,  Evelyn M. DeLiso ,  Donald L. Guile ,  Martin J. Murtagh

    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.

    Fabrication of cordierite bodies
    2.
    发明授权
    Fabrication of cordierite bodies 失效
    堇青石体的制作

    公开(公告)号：US5114643A

    公开(公告)日：1992-05-19

    申请号：US654527

    申请日：1991-02-13

    申请人： Douglas M. Beall ,  Evelyn M. DeLiso ,  Martin J. Murtagh

    发明人： Douglas M. Beall ,  Evelyn M. DeLiso ,  Martin J. Murtagh

    IPC分类号： B01J21/14 ,  C04B35/195

    CPC分类号： C04B35/195 ,  B01J21/14

    摘要： A body is disclosed which is at least about 90% by weight cordierite, and has a coefficient of thermal expansion of less than about 16.times.10.sup.-7 /.degree.C. from about 25.degree. C. to about 1000.degree. C. Also disclosed is a method of fabricating the body. Raw materials are selected to form a nominal composition consisting essentially of in percent by weight about 11.5 to about 16.5 MgO, about 33.0 to about 41.0 Al.sub.2 O.sub.3, and about 46.5 to about 53 SiO.sub.2. The raw materials can be a combination of silica and magnesium aluminate spinel, a combination of silica, magnesium aluminate spinel, and a MgO yielding component, or a combination of silica, magnesium aluminate spinel, and a Al.sub.2 O.sub.3 yielding components. The raw materials are provided absent of clay and talc. The raw materials are blended with an effective amount of vehicle and forming aids to impart plastic formability and green strength thereto form a plastic mixture. The raw materials are formed into a green body which is dried and fired at a sufficient temperature for a sufficient time to form the cordierite body.

    Modified cordierite precursors
    7.
    发明授权
    Modified cordierite precursors 失效
    改性堇青石前体

    公开(公告)号：US5409870A

    公开(公告)日：1995-04-25

    申请号：US979807

    申请日：1992-11-20

    申请人： Robert J. Locker ,  Martin J. Murtagh

    发明人： Robert J. Locker ,  Martin J. Murtagh

    IPC分类号： B01J21/14 ,  B01J37/00 ,  C04B35/195 ,  C04B38/00 ,  F01N3/28 ,  F02B3/06 ,  C04B35/18

    CPC分类号： C04B38/0006 ,  B01J21/14 ,  B01J37/0009 ,  C04B35/195 ,  F01N3/2828 ,  F02B3/06

    摘要： Cordierite-containing articles are produced by a method comprising the steps of providing raw materials including including alumina-yielding ingredients, magnesia-yielding ingredients, and silica-yielding ingredients, suitable to form an analytical batch composition by weight on an oxide basis of 9-20 weight percent MgO, 30-50 weight percent Al.sub.2 O.sub.3, and 41-56.5 weight percent SiO.sub.2. The raw materials include talc having a BET surface area of no greater than about 4.0 m.sup.2 /g, and uncalcined clay having an average particle size of no greater than about 2.0 .mu.m. The raw materials are blended with an effective amount of vehicle and forming aids to form a plastic mixture. The plastic mixture is anisostatically formed into a green body and dried. The dried green body is fired at a temperature and for a time effective to form a cordierite/containing ceramic article. The cordierite-containing articles exhibit a coefficient of thermal expansion of not greater than about 4.0.times.10.sup.-7 /.degree.C. and transverse I ratios of not less than about 0.85. The method of the present invention is particularly useful in forming cordierite honeycomb structures used as catalyst supports for automobiles or as particulate filters for the exhaust fluids of diesel engines.

    摘要翻译： 含堇青石的制品通过包括以下步骤的方法制备，所述方法包括提供原料，包括包括产生氧化铝的成分，产生氧化镁的成分和产生二氧化硅的成分的原料，适合于以基于氧化物的9- 20重量％的MgO，30-50重量％的Al 2 O 3和41-56.5重量％的SiO 2。 原料包括BET表面积不大于约4.0m 2 / g的滑石和平均粒度不大于约2.0μm的未煅烧粘土。 将原料与有效量的载体和成型助剂混合以形成塑料混合物。 将塑料混合物不均匀地形成生坯并干燥。 干燥的生坯在温度和时间下有效地形成堇青石/含陶瓷制品。 含堇青石制品的热膨胀系数不大于约4.0×10-7 /℃，横向I比不小于约0.85。 本发明的方法特别可用于形成用作汽车用催化剂载体的堇青石蜂窝结构体或用于柴油发动机废气的颗粒过滤器。

    Methods for applying a washcoat and heat treating a ceramic honeycomb, and treated articles
    8.
    发明申请
    Methods for applying a washcoat and heat treating a ceramic honeycomb, and treated articles 有权
    用于涂覆修补基面涂层和热处理陶瓷蜂窝体的方法以及处理过的制品

    公开(公告)号：US20090142541A1

    公开(公告)日：2009-06-04

    申请号：US11998288

    申请日：2007-11-29

    申请人： Thomas J. Glasson ,  Martin J. Murtagh ,  Donna R. Seyler

    发明人： Thomas J. Glasson ,  Martin J. Murtagh ,  Donna R. Seyler

    IPC分类号： B32B3/12 ,  B05D3/02

    CPC分类号： C04B41/5031 ,  B01J23/40 ,  B01J35/04 ,  B01J37/0215 ,  B01J37/08 ,  C04B41/009 ,  C04B41/87 ,  C04B2111/00793 ,  C04B2111/0081 ,  F01N3/0222 ,  F01N3/035 ,  Y10T428/24149 ,  C04B41/4539 ,  C04B41/4547 ,  C04B35/00 ,  C04B35/195 ,  C04B35/478

    摘要： A method for treating a microcracked, ceramic substrate is provided that obviates the need for filling the microcracks of the substrate via a passivation step prior to sintering a layer of washcoat to the surfaces of the substrate that may either contain a catalyst, or provide a support layer for a catalyst subsequently applied. In the first step of the method, a slurry of particles of a washcoating composition is applied over the surface of the substrate such that particles of the composition are lodged into microcracks of the substrate. Next, the substrate is heat treated to between about 700° C. and 1300° C. The applicants have discovered that such heat treating not only sets the washcoating particles into the substrate, but also causes the microcracks in the substrate to permanently enlarge as a result of the resistance of the lodged particles of washcoating composition against the walls of the microcracks as they attempt to close as a result of thermal expansion of the substrate. The consequent enlargement of the microcracks advantageously reduces both the coefficient of thermal expansion (CTE) and the modulus of elasticity (Emod) of the resulting substrate without substantially reducing the modulus of rupture strength (MOR) of the resulting substrate such that the thermal shock parameter TSP=MOR/[CTE·Emod] remains substantially the same or is higher. The method is particularly applicable to ceramic honeycomb structures used as catalytic converters in automotive exhaust systems.

    摘要翻译： 提供了一种用于处理微裂纹陶瓷基底的方法，其消除了在将一层修补基面涂层烧结到可含有催化剂的基底表面之前经由钝化步骤填充基底的微裂纹的需要，或提供载体 随后应用催化剂层。 在该方法的第一步中，将一种洗涤涂层组合物的颗粒的浆料施加在基材的表面上，使得该组合物的颗粒浸入基材的微裂纹中。 接下来，将基板热处理至约700℃至1300℃。申请人已经发现，这种热处理不仅将洗涂层颗粒设置到基板中，而且还使得基板中的微裂纹作为 由于衬底的热膨胀，试图关闭时，洗涂组合物的填充颗粒抵抗微裂纹的壁的电阻的结果。 微裂纹的随之而来的扩大有利地降低了所得衬底的热膨胀系数（CTE）和弹性模量（Emod），而基本上不降低所得衬底的断裂强度模量（MOR），使得热冲击参数 TSP = MOR / [CTE.Emod]保持基本相同或更高。 该方法特别适用于汽车排气系统中用作催化转化器的陶瓷蜂窝结构。

    Fabrication of low thermal expansion, high porosity cordierite body
    9.
    发明授权
    Fabrication of low thermal expansion, high porosity cordierite body 失效
    制造低热膨胀，高孔隙堇青石体

    公开(公告)号：US5258150A

    公开(公告)日：1993-11-02

    申请号：US802877

    申请日：1991-12-06

    申请人： Gregory A. Merkel ,  Martin J. Murtagh

    发明人： Gregory A. Merkel ,  Martin J. Murtagh

    IPC分类号： C04B35/195 ,  C04B35/64 ,  C04B38/00 ,  C04B38/06 ,  B29C65/00

    CPC分类号： C04B38/00 ,  C04B35/195 ,  C04B35/64

    摘要： A body is made up of at least about 93% by weight cordierite, having a coefficient of thermal expansion of no greater than about 4.times.10.sup.-7 .degree.C.sup.-1, from about 25.degree. C. to about 800.degree.0 C., and a total porosity of greater than about 42%. A method for producing the body which includes selecting raw materials to form a composition which forms cordierite on firing, the raw materials being composed of: talc having a BET surface area of no greater than about 5 m.sup.2 /g, 0 to about 48% by weight of clay, which can be platelet clay, stacked clay which can be delaminated into platelets during processing, and mixtures thereof, an aluminum oxide yielding component having an average particle size of either about 3 to about 8 micrometers in diameter, or no greater than about 3 micrometers in diameter, and free silica, intimately blending the raw materials with an effective amount of vehicle and forming aids to impart plastic formability and green strength to the raw materials and to form a plastic mixture therefrom. If the particle size of the aluminum oxide yielding component is no greater than about 3 micrometers in diameter, the raw materials are blended additionally with a burnout agent. The raw materials are formed into a green body which is dried and fired at a sufficient temperature for a sufficient time to form the cordierite body.

    Method for producing cordierite articles
    10.
    发明授权
    Method for producing cordierite articles 失效
    堇青石制品生产方法

    公开(公告)号：US5141686A

    公开(公告)日：1992-08-25

    申请号：US274398

    申请日：1988-11-21

    申请人： Martin J. Murtagh

    发明人： Martin J. Murtagh

    IPC分类号： C04B35/195 ,  C04B38/00

    CPC分类号： C04B35/195 ,  C04B38/0051 ,  C04B2111/00189

    摘要： A method of preparing a precursor or cordierite-forming particulate raw material mixture is improved upon by characterizing the talc particles utilized in the raw material mixture in accordance with a Morphology X-ray Diffraction Index or the surface area of the talc particles. Talc particles having a predetermined or desired Morphology X-ray Diffraction Index or surface area are utilized in preparing the raw material mixture. A cordierite article is produced having pores therethrough, which pores have shapes that are "blocky" or "platy" as a result of the talc morphology. "Platy" pores in the fired cordierite article result in higher Water Absorption values and an increase in coatability by high surface area washcoat and catalyst; conversely, "blocky" pores result in lower Water Absorption values and a decrease in coatability by high surface area washcoat and catalyst.

    摘要翻译： 通过根据形态X射线衍射指数或滑石颗粒的表面积表征原料混合物中使用的滑石颗粒，改善了制备前体或堇青石形成颗粒原料混合物的方法。 具有预定或期望的形态X射线衍射指数或表面积的滑石颗粒用于制备原料混合物。 产生具有孔的堇青石制品，由于滑石形态，这些孔具有“块状”或“板状”的形状。 在煅烧的堇青石制品中的“扁平”孔隙导致更高的吸水值和高表面积修补基面涂层和催化剂的涂布性的增加; 相反，“块状”孔隙导致较低的吸水值和高表面积修补基面涂层和催化剂的涂布性降低。