公开(公告)号：DE69818845T2

公开(公告)日：2004-08-19

申请号：DE69818845

申请日：1998-07-23

Applicant: CORNING INC

Inventor： CHALASANI DEVI ,  FISCHER MICHAEL ,  MALARKEY J ,  MCCARTHY R ,  STUTTS E ,  ZAK E

IPC: B28B3/20 ,  C04B35/195 ,  C04B35/622 ,  C04B35/632 ,  C04B35/636 ,  C04B38/00

Abstract: Powder mixtures and a method of forming and shaping the mixtures. The method involves compounding the components of powder materials, binder, solvent for the binder, surfactant, and non-solvent with respect to at least the binder, the solvent, and the powder materials. The non-solvent is lower in viscosity than the binder combined with the solvent. The solvent is present in an amount that is less than the amount that would be present otherwise. The components are mixed and plasticized, and shaped to form a green body. The choice of components results in improved wet green strength in the green body. The method is especially useful for extrusion processing of aqueous binder systems such as water and cellulose ethers and hydrophobic non-solvents, to form structures such as honeycombs. In the body, the ratio, upon subsequent firing, of the isostatic strength to the A-axis strength is at least about 20 % higher than in bodies made without the mixture composition of the invention. A honeycomb body having a ratio of the isostatic strength to the A-axis strength of at least about 0.33 upon firing.

公开(公告)号：DE60030127T2

公开(公告)日：2007-03-15

申请号：DE60030127

申请日：2000-06-08

Applicant: CORNING INC

Inventor： BEALL M ,  MALARKEY J ,  MERKEL A

IPC: C04B35/195 ,  F01N3/28 ,  B01D53/86 ,  B01J35/04 ,  B01J35/10 ,  C04B38/00

Abstract: A sintered ceramic that exhibits an average linear coefficient of thermal expansion (25-800° C.) below about 5.0x10 ° C. , a total porosity between the range of 20% to about 30%. Furthermore, the sintered ceramic article exhibits a pore size distribution such that at least about 86% of pores are of a pore size of less than about 2 mum. Lastly, the ceramic article exhibits an interconnected pore structure with the pores exhibiting a generally elongated shape, i.e., the pores are predominately oriented with their long axis in the plane of the webs. This invention also relates to a method for producing a sintered cordierite ceramic article involving first compounding and plasticizing a cordierite-forming inorganic powder batch comprising a platy talc having median particle of size less than about 2 mum, and preferably a talc morphology index greater than about 0.75. The batch further comprises at least 4% by weight of the inorganic powder batch mixture of a dispersible Al2O3-forming source having a specific surface area in excess of 50 m /g and one or more of the components of kaolin, calcined kaolin, silica, and corundum, each having a median particle sizes less than 5 mum. The plasticized powder batch thus provided is next formed into a green honeycomb by extrusion through a honeycomb extrusion die and the green honeycomb is fired to a temperature and for a time sufficient to convert the green honeycomb into a crystallized cordierite ceramic article having the aforementioned properties.

公开(公告)号：DE69818845D1

公开(公告)日：2003-11-13

申请号：DE69818845

申请日：1998-07-23

Applicant: CORNING INC

Inventor： CHALASANI DEVI ,  FISCHER MICHAEL ,  MALARKEY J ,  MCCARTHY R ,  STUTTS E ,  ZAK E

IPC: B28B3/20 ,  C04B35/195 ,  C04B35/622 ,  C04B35/632 ,  C04B35/636 ,  C04B38/00

Abstract: Powder mixtures and a method of forming and shaping the mixtures. The method involves compounding the components of powder materials, binder, solvent for the binder, surfactant, and non-solvent with respect to at least the binder, the solvent, and the powder materials. The non-solvent is lower in viscosity than the binder combined with the solvent. The solvent is present in an amount that is less than the amount that would be present otherwise. The components are mixed and plasticized, and shaped to form a green body. The choice of components results in improved wet green strength in the green body. The method is especially useful for extrusion processing of aqueous binder systems such as water and cellulose ethers and hydrophobic non-solvents, to form structures such as honeycombs. In the body, the ratio, upon subsequent firing, of the isostatic strength to the A-axis strength is at least about 20 % higher than in bodies made without the mixture composition of the invention. A honeycomb body having a ratio of the isostatic strength to the A-axis strength of at least about 0.33 upon firing.

公开(公告)号：DE60030127D1

公开(公告)日：2006-09-28

申请号：DE60030127

申请日：2000-06-08

Applicant: CORNING INC

Inventor： BEALL M ,  MALARKEY J ,  MERKEL A

IPC: C04B35/195 ,  F01N3/28 ,  B01D53/86 ,  B01J35/04 ,  B01J35/10 ,  C04B38/00

Abstract: A sintered ceramic that exhibits an average linear coefficient of thermal expansion (25-800° C.) below about 5.0x10 ° C. , a total porosity between the range of 20% to about 30%. Furthermore, the sintered ceramic article exhibits a pore size distribution such that at least about 86% of pores are of a pore size of less than about 2 mum. Lastly, the ceramic article exhibits an interconnected pore structure with the pores exhibiting a generally elongated shape, i.e., the pores are predominately oriented with their long axis in the plane of the webs. This invention also relates to a method for producing a sintered cordierite ceramic article involving first compounding and plasticizing a cordierite-forming inorganic powder batch comprising a platy talc having median particle of size less than about 2 mum, and preferably a talc morphology index greater than about 0.75. The batch further comprises at least 4% by weight of the inorganic powder batch mixture of a dispersible Al2O3-forming source having a specific surface area in excess of 50 m /g and one or more of the components of kaolin, calcined kaolin, silica, and corundum, each having a median particle sizes less than 5 mum. The plasticized powder batch thus provided is next formed into a green honeycomb by extrusion through a honeycomb extrusion die and the green honeycomb is fired to a temperature and for a time sufficient to convert the green honeycomb into a crystallized cordierite ceramic article having the aforementioned properties.

公开(公告)号：DE69910392D1

公开(公告)日：2003-09-18

申请号：DE69910392

申请日：1999-06-02

Applicant: CORNING INC

Inventor： BEALL M ,  CHALASANI DEVI ,  MALARKEY J

IPC: B28B3/20 ,  C04B35/195 ,  C04B35/622 ,  C04B35/632 ,  C04B38/00

Abstract: 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.