US4434117A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method for producing a cordierite body
Assignee: Soken Inc
•
Filing: 1981-04-02
•
Granted: 1984-02-28
•
Expires: 2001-04-02
Abstract
Abstract A method for producing a cordierite body having a lower coefficient of thermal expansion and excellent thermal shock resistance which comprises the steps of mixing and kneading a batch raw material containing plate-shaped talc particles and non-plate shaped particles of other ceramic material, anisostatically forming the mixed batch raw material so as to impart a planar orientation to the plate-shaped talc particles and drying and firing the obtained formed body. By firing the plate-shaped talc particles, the shrinkage of the cordierite body can be decreased.
Inventors
- 👤 Kazuhiro Inoguchi
- 👤 Tomohiko Nakanishi
- 👤 Mitsuru Asano
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 12:22
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/01; C04B35/16; C04B35/18; C04B35/195
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
153 words
A method for producing a body consisting substantially completely of polycrystalline sintered cordierite said method comprising the successive steps of: (a) delaminating a talc stack along the (OOl) plane thereof into plate-shaped talc particles, each particle having an average particle diameter of about 2.8 to about 30 microns; (b) firing the so obtained plate-shaped talc particles; (c) mixing and kneading a batch raw material containing the fired plate-shaped talc particles produced in step (b) together with non-plate-shaped particles of another ceramic material selected from the group consisting of aluminum hydroxide, alumina, silica and kaolin and preparing a slurry, provided that the particles of said other ceramic material have an average diameter smaller than that of the fired plate-shaped talc particles; (d) anisostatically forming the slurry into a formed body having a predetermined shape while imparting a planar orientation to the plate-shaped talc particles; and thereafter (e) drying and firing the thus formed body.
Claim 2
Independent Claim
153 words
A method for producing a body consisting substantially completely of polycrystalline sintered cordierite said method comprising the successive steps of: (a) delaminating a talc stack along the (OOl) plane thereof into plate-shaped talc particles, each particle having an average particle diameter of about 2.8 to about 30 microns; (b) firing the so obtained plate-shaped talc particles; (c) mixing and kneading a batch raw material containing the fired plate-shaped talc particles produced in step (b) together with non-plate-shaped particles of another ceramic material selected from the group consisting of aluminum hydroxide, alumina, silica and kaolin and preparing a slurry, provided that the particles of said other ceramic material have an average diameter smaller than that of the fired plate-shaped talc particles; (d) anisostatically forming the slurry into a formed body having a predetermined shape while imparting a planar orientation to the plate-shaped talc particles; and thereafter (e) drying and firing the thus formed body.
Claim 3
Dependent Claim
27 words
The method according to claim 1 wherein the slurry is formed in step (d) by extrusion through an extrusion die provided with at least one narrow slit.
Claim 4
Dependent Claim
30 words
The method according to claim 2 wherein the slurry is formed into a honeycomb structure by an extrusion die having a large number of narrow slits surrounded by thin walls.
Claim 5
Dependent Claim
25 words
The method according to claim 1 wherein the firing of step (e) is conducted at a temperature of about 1340° C. to about 1460° C.
Claim 6
Dependent Claim
27 words
The method according to claim 1 wherein the plate-shaped talc particles are fired in step (b) at a temperature of about 900° C. to about 1400° C.
Claim 7
Dependent Claim
33 words
The method according to claim 1 or 5 wherein the resulting cordierite body exhibits a substantially uniform coefficient of thermal expansion which is independent of the average particle size of the prefired talc.
Claim 8
Independent Claim
172 words
A method for producing bodies consisting substantially completely of polycrystalline sintered cordierite each body so produced consistently exhibiting a substantially uniform coefficient of thermal expansion, said process consisting essentially of the sequential steps of: (1) delaminating a talc stack along the (OOl) plane thereof into plate-shaped talc particles, each particle having an average particle diameter of about 2.8 to about 30 microns; and thereafter; (2) firing the delaminated talc particles; (3) preparing a batch of raw material comprising mixing and kneading together (a) the fired plate-shaped particles produced in step (1), (b) non-plate shaped particles of another ceramic material selected from aluminum hydroxide, alumina, silica and kaolin, and (c)/water thereby producing a slurry provided that the particles of said other ceramic material (b) have an average diameter smaller than that of the fired plate-shaped talc particles (a); (4) anisostatically forming the slurry into a formed body having a predetermined shape while imparting a planar orientation to the plate-shaped talc particles; and finally (5) drving, and then firing the thus formed cordierite body.
Claim 9
Independent Claim
172 words
A method for producing bodies consisting substantially completely of polycrystalline sintered cordierite each body so produced consistently exhibiting a substantially uniform coefficient of thermal expansion, said process consisting essentially of the sequential steps of: (1) delaminating a talc stack along the (OOl) plane thereof into plate-shaped talc particles, each particle having an average particle diameter of about 2.8 to about 30 microns; and thereafter; (2) firing the delaminated talc particles; (3) preparing a batch of raw material comprising mixing and kneading together (a) the fired plate-shaped particles produced in step (1), (b) non-plate shaped particles of another ceramic material selected from aluminum hydroxide, alumina, silica and kaolin, and (c)/water thereby producing a slurry provided that the particles of said other ceramic material (b) have an average diameter smaller than that of the fired plate-shaped talc particles (a); (4) anisostatically forming the slurry into a formed body having a predetermined shape while imparting a planar orientation to the plate-shaped talc particles; and finally (5) drving, and then firing the thus formed cordierite body.
Claim 10
Dependent Claim
38 words
The method according to claim 7 in which the resulting cordierite body exhibits a coefficient of thermal expansion from about 9.2 to about 10.8×10 -7 /°C. and is independent of the average particle size of the prefired talc.
Claim 11
Dependent Claim
22 words
The method according to claim 7 in which the coefficient of thermal expansion ranges from about 9.3 to about 10.8×10 -7 /°C.
Claim 12
Dependent Claim
22 words
The method according to claim 7 in which the coefficient of thermal expansion ranges from about 9.2 to about 10.8×10 -7 /°C.
Claim 13
Dependent Claim
47 words
The method according to claim 8, 9, or 10 wherein the delaminated plate-shaped talc particles are fired in step (2) at a temperature of about 900° C. to about 1400° C. and the final product is fired in step (5) at about 1340° to about 1460° 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) | 1987-02-27 | 1987-08-29 | 1988-02-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-02-27 | 1991-08-29 | 1992-02-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-02-27 | 1995-08-29 | 1996-02-28 | $7700.00 | Window Closed / Lapsed |