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Beta-spodumene-cordierite composition, article, and method

A technology of spodumene and cordierite, applied in the field of β-spodumene-cordierite composition, product and method

Inactive Publication Date: 2012-08-08
CORNING INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0004] An important challenge in the manufacture of porous ceramic honeycombs is to provide the strength required for handling, potting and use while providing high porosity and / or thin cell walls

Method used

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  • Beta-spodumene-cordierite composition, article, and method
  • Beta-spodumene-cordierite composition, article, and method
  • Beta-spodumene-cordierite composition, article, and method

Examples

Experimental program
Comparison scheme
Effect test

Embodiment A

[0031] Example A-Ceramic composition

[0032] Tables 1 and 2 below show the batch composition and physical properties of some spodumene-cordierite composite materials. For comparison, examples of cordierite materials are also reported, including commercially available cordierite (composition C1) used to make catalyst substrates used to control engine emissions, and non-microcracked cordierite containing lanthanum glass (composition 2 ) And non-microcracked cordierite (composition C3) which is mainly made of mineral batch materials and added cordierite crystals as seed crystals in order to limit the crystal domain size. The composite compositions prepared according to the present invention in Tables 1 and 2 were compounded, using α-spodumene mineral as a lithium source, and the mineral contained 6% by weight of Li 2 O, 25.3 wt% Al 2 O 3 And 64.6 wt% SiO 2 , The balance includes trace amounts (less than 1% by weight each) of Fe 2 O 3 , Na 2 O, K 2 O, P 2 O 5 And MnO 2 .

[0033] The...

Embodiment B

[0042] Example B-catalyst compatibility

[0043] Studies have found that for β-spodumene catalyst substrates, it is a problem that the alkali component of the sintered ceramic poisons the catalyst surface. For three-effect washcoat catalysts, two mechanisms have been found. The origin of the first mechanism is that the pH of the washcoat slurry is usually lower than 4. Therefore, the protons from the acid washcoat slurry can be ion-exchanged with the lithium from the spodumene, so some lithium ions will be deposited on the catalyst sites and poison the catalyst activity. The origin of the second mechanism is that lithium can diffuse from the spodumene to the catalyst at high temperatures. The steam present in the combustion exhaust stream accelerates the process.

[0044] By comparing the catalytic conversion efficiency of propylene, carbon monoxide, and nitrous oxide on the catalysts deposited on the spodumene-cordierite composite honeycomb substrate and the conventional cordie...

Embodiment

[0060] Example C-Catalyst substrate stability

[0061] The effect of wash coating on the properties of the catalyst substrate may be significant, including changes caused by firing the initially applied wash coat and changes after prolonging the working thermal cycle time.

[0062] The data given in Table 4 below compares the effects of washing and heat aging on the physical properties of cordierite and spodumene-cordierite composite honeycomb products. Four honeycombs with different compositions were compared, including the EX-2 spodumene-cordierite composite composition in Tables 1 and 2, the cordierite composition C2 and C3 reported in Tables 1 and 2, and a wide range of automotive exhaust systems Another commercially available cordierite honeycomb composition C4 was used.

[0063] Table 4 contains the following physical property values ​​for each honeycomb sample tested: modulus of rupture (MOR) strength, modulus of elasticity (EMOD), strain tolerance (ST), average coefficient o...

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Abstract

Porous spodumene-cordierite honeycomb bodies of high strength but low volumetric density, useful for the manufacture of close-coupled engine exhaust converters, gasoline engine particulate exhaust filters, and NOx integrated engine exhaust filters, are provided through the reactive sintering of batches comprising sources of magnesia, alumina and silica together with a lithia source, such as a spodumene or petalite ore.

Description

[0001] Cross reference of related applications [0002] This application claims the rights and priority of U.S. Provisional Patent Application No. 61 / 265106 entitled "β-spodumene-cordierite composition, product and method" filed on November 30, 2009. The content is the basis and the full text is incorporated here by reference. Technical field [0003] The articles and methods disclosed herein generally involve porous ceramic materials and related porous ceramic structures, such as honeycomb structures that can be used as ceramic catalyst carrier substrates and particulate filters. Background technique [0004] An important challenge facing the manufacture of porous ceramic honeycombs is to provide the strength required for handling, potting and use, as well as high porosity and / or thin cell walls. Summary of the invention [0005] The present invention relates to a spodumene-cordierite composite product. This product includes an embodiment in which the product has a basic compositio...

Claims

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Application Information

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IPC IPC(8): C04B35/19C04B38/00C04B35/64C04B38/06
CPCC04B2235/3206C04B35/6263C04B2235/3218C04B38/0009C04B2235/3217C04B2235/6567C04B2235/3472C04B2235/80C04B2235/3222C04B2235/77C04B2235/9607C04B2235/96C04B2235/3203C04B2235/349B01J23/40F01N3/2828C04B2235/3418C04B35/19C04B38/0006C04B2235/3463C04B2111/00793F01N3/0222C04B2235/3227B01J23/464C04B2235/3445C04B2235/656C04B2235/3481C04B2235/3225C04B38/068C04B2235/36C04B38/0074C04B38/007C04B38/0054C04B38/0067C04B38/0645Y10T428/24149Y10T428/26
Inventor G·A·默克尔C·W·坦纳
Owner CORNING INC
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