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Patent US3885977A successfully refreshed from Google Patents.
US3885977A
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Anisotropic cordierite monolith
Assignee: Corning Glass Works
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Filing: 1973-11-05
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Granted: 1975-05-27
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Expires: 1993-11-05
Abstract
Abstract An extruded, honeycombed, monolithic fired ceramic whose primary crystal phase is cordierite and whose microstructure is characterized by a greater than random orientation of the anisotropic cordierite crystallites with their low expansion direction aligned substantially parallel to the plane of the webs of the monolith. The axial expansion coefficient of the honeycomb, with composition near that of stoichiometric cordierite, may be as low as 5.5 X 10 7 in./in./*C. or lower in the range of 25*-1000*C. The product is particularly adapted to use as a catalytic support matrix for emissions control.
Inventors
- 👤 Irwin M Lachman
- 👤 Ronald M Lewis
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 09:41
CPC Classifications
C; C04; C04B; C04B38/00; C04B38/0006; B; B01; B01D; B01D53/00; B01D53/34; B01D53/74; B01D53/86; C03; C03C; C03C10/00; C03C10/0036; C03C10/0045; C04B35/00; C04B35/01; C04B35/16; C04B35/18; C04B35/195; C04B2111/00; C04B2111/00241; C04B2111/00387; C04B2111/00474; C04B2111/00793; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24149
Claims Analysis
Total Claims: 34
Claim 1
Independent Claim
147 words
IN ANISOTROPIC, POLYCRYSTALLINE SINTERED CERAMIC PRODUCT HAVING CORDIERITE AS ITS PRIMARY PHASE AND CONSISTING ESSENTIALLY ON AN ANALYTICAL OXIDE BASIS OF 11.5-16.5% RO, 33-41% AL2O3 AND 46.6-53% SIO2 AND HAVING A COEFFICIENT OF THERMAL EXPANSION IN AT LEAST ONE DIRECTION OF LESS THAN 11.0 X 10**-7 IN./IN./*C. OVER THE RANGE OF 25*-1000*C., AND WHEREIN RO CONSISTS ESSENTIALLY OF ONE MEMBER SELECTED FROM THE GROUP CONSISTING OF NIO, COO, FEO, MNO AND TIO2, THE NIO WHEN SELECTED BEING LESS THAN 25% BY WEIGHT OF THE RO, THE COO WHEN SELECTED BEING LESS THAN 15% BY WEIGHT OF THE RO, THE FEO WHEN SELECTED BEING LESS THAN 40% BY WEIGHT OF THE RO, THE MNO WHEN SELECTED BEING LESS THAN 98% BY WEIGHT OF THE RO, THE TIO2 WHEN SELECTED BEING LESS THAN 15% BY WEIGHT OF THE RO, AND THE BALANCE OF THE RO BEING SUBSTANTIALLY ALL MGO.
Claim 2
Dependent Claim
147 words
IN ANISOTROPIC, POLYCRYSTALLINE SINTERED CERAMIC PRODUCT HAVING CORDIERITE AS ITS PRIMARY PHASE AND CONSISTING ESSENTIALLY ON AN ANALYTICAL OXIDE BASIS OF 11.5-16.5% RO, 33-41% AL2O3 AND 46.6-53% SIO2 AND HAVING A COEFFICIENT OF THERMAL EXPANSION IN AT LEAST ONE DIRECTION OF LESS THAN 11.0 X 10**-7 IN./IN./*C. OVER THE RANGE OF 25*-1000*C., AND WHEREIN RO CONSISTS ESSENTIALLY OF ONE MEMBER SELECTED FROM THE GROUP CONSISTING OF NIO, COO, FEO, MNO AND TIO2, THE NIO WHEN SELECTED BEING LESS THAN 25% BY WEIGHT OF THE RO, THE COO WHEN SELECTED BEING LESS THAN 15% BY WEIGHT OF THE RO, THE FEO WHEN SELECTED BEING LESS THAN 40% BY WEIGHT OF THE RO, THE MNO WHEN SELECTED BEING LESS THAN 98% BY WEIGHT OF THE RO, THE TIO2 WHEN SELECTED BEING LESS THAN 15% BY WEIGHT OF THE RO, AND THE BALANCE OF THE RO BEING SUBSTANTIALLY ALL MGO.
Claim 3
Dependent Claim
55 words
An anisotropic, polycrystalline sintered ceramic product having cordierite as its primary crystal phase and consisting essentially of, by weight on an analytical oxide basis, 11.5-16.5% MgO, 33-41% Al2O3, 46.6-53.0% SiO2 and having a coefficient of thermal expansion, in at least one direction, of less than 11.0 X 10 7 in./in./*C. over the range of 25*-1000*C.
Claim 4
Dependent Claim
55 words
An anisotropic, polycrystalline sintered ceramic product having cordierite as its primary crystal phase and consisting essentially of, by weight on an analytical oxide basis, 11.5-16.5% MgO, 33-41% Al2O3, 46.6-53.0% SiO2 and having a coefficient of thermal expansion, in at least one direction, of less than 11.0 X 10 7 in./in./*C. over the range of 25*-1000*C.
Claim 5
Dependent Claim
21 words
A ceramic product as recited in claim 2 which contains less than, by weight, 0.1% CaO and 0.4% Na2O plus K2O.
Claim 6
Dependent Claim
68 words
A ceramic product as recited in claim 2 wherein the product comprises an extruded honeycomb, having a matrix of thin walls forming a multiplicity of open ended cells extending from one end to another end of the honeycomb and the thin walls having a substantially smaller coefficient of thermal expansion in the direction parallel to the axes of the open ended cells than transverse to the thin walls.
Claim 7
Dependent Claim
24 words
A ceramic product as recited in claim 4 which consists essentially, on the analytical oxide basis, of 12.5-15.5% MgO, 34.2-39.5% Al2O3 and 48.0-51.6% SiO2.
Claim 8
Dependent Claim
29 words
A ceramic product as recited in claim 5 wherein the total weight of MgO, Al2O3, and SiO2 is at least 97% of the entire weight of the ceramic product.
Claim 9
Dependent Claim
31 words
A ceramic product as recited in claim 2 wherein the coefficient of thermal expansion is between 4.0 X 10 7 in./in./*C. and 9.0 X 10 7 in./in./*C. over the range 25*-1000*C.
Claim 10
Dependent Claim
68 words
A ceramic product as recited in claim 7 wherein the product comprises an extruded honeycomb, having a matrix of thin walls forming a multiplicity of open ended cells extending from one end to another end of the honeycomb and the thin walls having a substantially smaller coefficient of thermal expansion in the direction parallel to the axes of the open ended cells than transverse to the thin walls.
Claim 11
Dependent Claim
24 words
A ceramic product as recited in claim 8 which consists essentially, on the analytical oxide basis, of 12.5-15.5% MgO, 34.2-39.5% Al2O3 and 48.0-51.6% SiO2.
Claim 12
Dependent Claim
30 words
A ceramic product as recited in claim 9 wherein the total weight percent of MgO, Al2O3, and SiO2 is at least 97% of the entire weight of the ceramic product.
Claim 13
Dependent Claim
33 words
An anisotropic sintered ceramic product consisting of substantially all crystalline cordierite phase and having a chemical oxide analysis by weight, 9-20% MgO, 30-50% Al2O3, and 41-56.5% SiO2, and having an I-ratio, defined as:
Claim 14
Dependent Claim
33 words
An anisotropic sintered ceramic product consisting of substantially all crystalline cordierite phase and having a chemical oxide analysis by weight, 9-20% MgO, 30-50% Al2O3, and 41-56.5% SiO2, and having an I-ratio, defined as:
Claim 15
Dependent Claim
32 words
The product as recited in claim 11 wherein the chemical oxide analysis by weight is 11.5-16.5% MgO, 33-41% Al2O3, and 46.6-53% SiO2 and the I-ratio in at least one direction is 0.43-0.55.
Claim 16
Independent Claim
153 words
A method of orienting cordierite crystallites in a fired ceramic which comprises: a. selecting raw materials comprising clay and such other ceramic materials as will yield an analytical batch composition by weight on the oxide basis of 9-20% MgO, 30-50% Al2O3, and 41-56.5% SiO2, wherein the clay is selected from the group consisting of platelet clay, stacked clay which can be delaminated into platelets during processing, and mixtures thereof. b. intimately blending the raw materials with an effective amount of vehicle and extrusion aids to impart plastic formability and green strength to the raw materials and to delaminate a substantial amount of the stacked clay into platelets, c. anisostatically forming the raw materials into a green body to impart a consistent planar orientation to the platelet clay, d. drying the green body, and e. firing the green body at a temperature and for a time sufficient to essentially complete the cordierite phase formation.
Claim 17
Independent Claim
153 words
A method of orienting cordierite crystallites in a fired ceramic which comprises: a. selecting raw materials comprising clay and such other ceramic materials as will yield an analytical batch composition by weight on the oxide basis of 9-20% MgO, 30-50% Al2O3, and 41-56.5% SiO2, wherein the clay is selected from the group consisting of platelet clay, stacked clay which can be delaminated into platelets during processing, and mixtures thereof. b. intimately blending the raw materials with an effective amount of vehicle and extrusion aids to impart plastic formability and green strength to the raw materials and to delaminate a substantial amount of the stacked clay into platelets, c. anisostatically forming the raw materials into a green body to impart a consistent planar orientation to the platelet clay, d. drying the green body, and e. firing the green body at a temperature and for a time sufficient to essentially complete the cordierite phase formation.
Claim 18
Dependent Claim
33 words
The method as recited in claim 13 wherein the clay is platelet clay and the other ceramic materials are selected from the group consisting of talc, alumina, aluminum hydroxide, silica, and mixtures thereof.
Claim 19
Dependent Claim
64 words
The method as recited in claim 13 wherein the raw materials are selected to yield a fired ceramic consisting essentially by weight on the oxide basis, 11.5-16.5% MgO, 33-41% Al2O3 and 46.6-53% SiO2, and the fired ceramic is a monolithic honeycomb having a matrix of thin walls forming a multiplicity of open ended cells extending from one end to another end of the honeycomb.
Claim 20
Dependent Claim
18 words
The method as recited in claim 15 wherein the raw materials comprise delaminated kaolin clay, talc and alumina.
Claim 21
Dependent Claim
27 words
The method as recited in claim 15 wherein the other ceramic materials are selected from the group consisting of talc, alumina, aluminum hydroxide, silica and mixtures thereof.
Claim 22
Dependent Claim
13 words
The method as recited in claim 17 wherein the clay is delaminated kaolin.
Claim 23
Dependent Claim
14 words
The method as recited in claim 18 wherein the anisostatic forming method is extrusion.
Claim 24
Dependent Claim
14 words
The method as recited in claim 15 wherein the temperature for firing is 1340*C-1450*C.
Claim 25
Dependent Claim
23 words
The method as recited in claim 15 wherein the raw materials contain less than, by weight, 0.1% CaO and 0.4% Na2O plus K2O.
Claim 26
Dependent Claim
117 words
The method as recited in claim 13 wherein the raw materials are selected to yield a fired ceramic consisting essentially by weight on the oxide basis, 12.5-15.5% MgO, 34.2-39.5% Al2O3, and 48-51.6% SiO2 and wherein the fired ceramic is a monolithic honeycomb having a matrix of thin walls forming a multiplicity of open ended cells extending from one end to another end of the honeycomb, and the coefficient of thermal expansion for the fired ceramic in the direction parallel to the axes of the open ended cells is less than 9.0 X 10 7 in./in./*C. over the temperature range of 25*-1000*C and less than the coefficient of thermal expansion of the thin walls in a transverse direction.
Claim 27
Dependent Claim
18 words
The method as recited in claim 22 wherein the raw materials comprise delaminated kaolin clay, talc, and alumina.
Claim 28
Dependent Claim
27 words
The method as recited in claim 22 wherein the other ceramic materials are selected from the group consisting of talc, alumina, aluminum hydroxide, silica, and mixtures thereof.
Claim 29
Dependent Claim
13 words
The method as recited in claim 24 wherein the clay is delaminated kaolin.
Claim 30
Dependent Claim
14 words
The method as recited in claim 25 wherein the anisostatic forming method is extrusion.
Claim 31
Dependent Claim
91 words
A polycrystalline cordierite sintered ceramic product having a chemical oxide analysis by weight, 9-20% MgO, 30-50% Al2O3 and 41-56.5% SiO2 and comprising a monolithic honeycomb having a matrix of thin walls forming a multiplicity of open ended cells extendiNg from one end of the product to the other end of the product and being characterized by a microstructure having a greater than random orientation of cordierite crystallites imparting a substantially lower coefficient of thermal expansion to any direction in the plane of the thin walls than transverse to the thin walls.
Claim 32
Dependent Claim
91 words
A polycrystalline cordierite sintered ceramic product having a chemical oxide analysis by weight, 9-20% MgO, 30-50% Al2O3 and 41-56.5% SiO2 and comprising a monolithic honeycomb having a matrix of thin walls forming a multiplicity of open ended cells extendiNg from one end of the product to the other end of the product and being characterized by a microstructure having a greater than random orientation of cordierite crystallites imparting a substantially lower coefficient of thermal expansion to any direction in the plane of the thin walls than transverse to the thin walls.
Claim 33
Dependent Claim
47 words
The cordierite product as recited in claim 27 having a chemical oxide analysis by weight 11.5-16.5% MgO, 33-41% Al2O3 and 46.6-53% SiO2 and a coefficient of thermal expansion in at least the axial direction of less than 11 X 10 7 in./in./*C. over the temperature range 25*-1000*C.
Claim 34
Dependent Claim
52 words
The cordierite product as recited in claim 27 having a chemical oxide analysis by weight 12.5-15.5% MgO, 34.2-39.5% Al2O3 and 48-51.6% SiO2 and a coefficient of thermal expansion in at least the axial direction of between 4.0 X 10 7 in./in./*C. and 9.0 X 10 7 in./in./*C. over the temperature range 25*-1000*C.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-05-26 | 1978-11-25 | 1979-05-27 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-05-26 | 1982-11-25 | 1983-05-27 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-05-26 | 1986-11-25 | 1987-05-27 | $7700.00 | Window Closed / Lapsed |