US 12,391,620 B2
Batch mixtures containing pre-reacted inorganic particles and methods of manufacture of ceramic bodies therefrom
Huthavahana Sarma Kuchibhotla, Milpitas, CA (US); Christophe Michel Remy, Canandaigua, NY (US); Patrick David Tepesch, Corning, NY (US); and Elizabeth Marie Vileno, Corning, NY (US)
Assigned to CORNING INCORPORATED, Corning, NY (US)
Appl. No. 17/297,296
Filed by CORNING INCORPORATED, Corning, NY (US)
PCT Filed Nov. 21, 2019, PCT No. PCT/US2019/062523
§ 371(c)(1), (2) Date May 26, 2021,
PCT Pub. No. WO2020/112469, PCT Pub. Date Jun. 4, 2020.
Claims priority of provisional application 62/773,233, filed on Nov. 30, 2018.
Prior Publication US 2022/0024822 A1, Jan. 27, 2022
Int. Cl. C04B 35/478 (2006.01); C04B 35/64 (2006.01)
CPC C04B 35/478 (2013.01) [C04B 35/64 (2013.01); C04B 2235/3217 (2013.01); C04B 2235/3236 (2013.01); C04B 2235/3418 (2013.01); C04B 2235/76 (2013.01); C04B 2235/786 (2013.01)] 26 Claims
OG exemplary drawing
 
1. A method of making a ceramic body, the method comprising:
mixing together a batch mixture comprising a total amount of inorganic particles comprised of a first quantity of particles and a second quantity of particles, wherein the first quantity of particles comprises constituents capable of producing aluminum titanate via reactive sintering at one or more reactive sintering temperatures, wherein the first quantity of particles comprises a reactive alumina source, a reactive titania source, and a reactive silica source, and wherein the second quantity of particles comprises pre-reacted crystalline particles comprising aluminum titanate in an amount from 70 wt % to 99 wt % and magnesium dititanate in an amount from 1 wt % to 30 wt % relative to the total amount of inorganic particles, wherein the pre-reacted crystalline particles have a pseudobrookite type crystal structure and are stable with respect to the first quantity of particles at the one or more reactive sintering temperatures;
shaping the batch mixture into a green ceramic body comprising the total amount of inorganic particles; and
heating the green ceramic body at the one or more reactive sintering temperatures and for one or more times sufficient to cause the reactive alumina source, the reactive titania source, and the reactive silica source to reactively sinter and form the ceramic body with a predominant solid state phase comprising crystalline aluminum titanate having the pseudobrookite type crystal structure,
wherein the pre-reacted crystalline particles present in the green ceramic body constitute less than or equal to 33 wt. % of the total amount of inorganic particles.