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Geopolymer composites and structures formed therefrom

A technology of mineral polymers and composite materials, applied in the direction of loose filter material filters, other household appliances, hydraulically coagulable material layered products, etc., which can solve environmental and health hazards and other problems

Inactive Publication Date: 2009-02-18
CORNING INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0002] Diesel engines emit fewer emissions and are more fuel efficient than gasoline engines; however, diesel exhaust emissions pose environmental and health hazards

Method used

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  • Geopolymer composites and structures formed therefrom
  • Geopolymer composites and structures formed therefrom
  • Geopolymer composites and structures formed therefrom

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0030] Composition 4 is 90% by weight cordierite bound with 10% by weight potassium aluminosilicate mineral polymer and added 5% by weight B 2 o 3 (Percentage of total formulation) Modified ceramics prepared as follows: 2.07g Glomax LL, 186.4g cordierite and 1g CMC (AqualonR Cellulose Gum) binder were mixed for 3 minutes; 8.27g Ludox and 10.36g were added to 100g water g boron oxide (B 2 o 3 ), heated until the boron oxide was dissolved, then added to the dry mixture and mixed; 10.34 g of Kasil-1 was added to the mixed ingredients and mixed thoroughly to form a solution. This solution is then added to the dry ingredients and mixed thoroughly to form a geopolymer bound wet mix. The furnish was dried and heated to 800° C. to produce a dry composition of approximately 94.7 wt. % cordierite and 5.3 wt. % potassium boroaluminosilicate glass (assuming no cordierite decomposition). The CTE of Example 1 is about 17.5×10 -7 / °C (25 to 800°C).

Embodiment 2

[0032] Composition 10, containing 90% by weight of transparent silica bound with 10% by weight of potassium aluminosilicate mineral polymer, and with an excess of 3% by weight of B 2 o 3 Additive-modified ceramics were prepared as follows: 559.2 g of crushed vitreous silica, 31 g of Kasil-1, 6.28 g of Glomax LL, 24.8 g of Ludox and 18.66 g boron oxide. Upon drying and heating to 800°C, the batch yielded a dry composition containing approximately 92.8% by weight silica and 7.2% by weight potassium boroaluminosilicate glass (assuming no decomposition of the silica particles upon heating). The CTE of Example 2 is about 11×10 -7 / °C (25 to 800°C).

Embodiment 3

[0034] Composition 9, containing 80% by weight transparent silica, 10% by weight cordierite bound with 10% by weight potassium aluminosilicate mineral polymer, and with an excess of 3% by weight B 2 o 3 Additive-modified ceramics, prepared as follows: 31 g Kasil-1, 6.28 g Glomax LL, 24.8 g Ludox, 18.66 g boron oxide, 503.24 g of Fused silica and 55.92 g of ground cordierite. Upon drying and heating to 800° C., the batch produced a glass containing approximately 83.6 wt. % silica, 9.2 wt. % cordierite (assuming no cordierite decomposition), and 7.2 wt. % potassium boroaluminosilicate geopolymer glass (assuming no dry composition of silica or cordierite particle decomposition). The CTE of Example 3 is about 10.0×10 -7 / °C (25 to 800°C).

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Abstract

Geopolymer composite materials having low coefficient of thermal expansion are disclosed. The materials are useful in high temperature applications due to their low coefficient of thermal expansion and high strength. Also disclosed is a boron modified water glass geopolymer composition that is compatible with ceramic particulate material such as cordierite and fused silica. The geopolymer composite may be extruded to form structures such as honeycomb monoliths, flow filters or used as a plugging or skinning cement and may be fired at temperatures at or below 1100 DEG C. Both the structures and the cement have high green and fired strength, a low coefficient of thermal expansion, and good acid durability. The cost of manufacturing objects using the material of the present invention is substantially reduced, in comparison with typically production methods of cordierite based bodies, due to the substantially shortened firing times.

Description

field of invention [0001] This invention relates to low thermal expansion coefficient geopolymer composites and articles formed therefrom. The materials of the present invention are useful in applications such as diesel particulate filters, catalytic converters, NO x Fabrication of high temperature objects such as adsorbents, catalyst supports, honeycomb monoliths and flow filter bodies for high temperature fluids and other high temperature applications. Specifically, finely divided particles of a low coefficient of thermal expansion (CTE) material such as cordierite, silica, other low CTE materials, or composites thereof in combination with a mineral polymer are disclosed. This mineral polymer is usually formed by reacting an activated clay such as metakaolin with an alkaline aqueous silicate solution and can be modified by adding boron oxide to provide a Low CET material that reduces cracking. The materials of the present invention can be extruded and used without pre-cal...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): C04B33/00B01D24/00
CPCB32B13/04C04B41/5077C04B35/18B32B3/26C04B41/009B32B2307/554C04B28/008C04B2235/3472C03C14/004B32B2605/08C04B35/447C04B41/85B32B2307/584C04B35/19B32B2307/702C04B2235/365B32B2307/306C04B38/0006B32B1/08C04B35/195B32B2307/726C04B2111/00793B32B3/12B32B13/02C03C2214/04B32B2307/724B32B2307/714C04B2235/421C03C2214/32Y02P40/10C04B14/047C04B14/06C04B14/30C04B14/366C04B22/0013C04B40/0268C04B41/5024
Inventor G·H·比尔L·R·平克尼P·D·特珀谢S·A·蒂切
Owner CORNING INC
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