IP Library › Granted Patent US 12,384,729
Granted Patent B2
US 12,384,729 · App. 17/129,040 · Granted Aug 12, 2025

Inorganic membrane filtration articles and methods thereof

Inventors: Curtis Robert Fekety (Corning, NY); Yunfeng Gu (Painted Post, NY); Yanxia Ann Lu (Painted Post, NY); Zhen Song (Painted Post, NY)
Assignee: CORNING INCORPORATED
C04B38/0009B01D46/2429B01D46/24491B01D46/24492B01D46/247B01D46/2474B01D46/2484B01D63/066B01D69/02B01D71/024C04B35/195C04B38/0006B01D46/2482C04B2111/00215C04B2111/00793C04B2111/00801C04B2235/32C04B2235/3201C04B2235/3206C04B2235/3208C04B2235/3217C04B2235/349C04B2235/5445C04B2235/606C04B2235/72C04B2235/79C04B2235/80C04B2235/96C04B2235/9692
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Quick Facts
Patent No.
US 12,384,729
App. No.
17/129,040
Granted
Aug 12, 2025
Kind
B2
Abstract

An inorganic membrane filtration article and methods for making the same. The membrane filtration article includes a sintered flow-through ceramic honeycomb with a plurality of partition walls defining a plurality of open channels from an inlet end of the honeycomb to an outlet end of the honeycomb. The honeycomb is formed from a cordierite composition with low-sodium and/or low-potassium content for enhanced filtration performance.

Claims (27)

1. A method of making a ceramic article, the method comprising:

forming a green membrane layer by applying a first composition onto at least a portion of partition walls of a honeycomb body, wherein the partition walls of the honeycomb body are formed from a second composition, the first composition comprises: Al 2 O 3 , SiO 2 , MgO, and a sodium content in the form of Na 2 O from 0.01 wt. % to 0.07 wt % Na 2 O, and the sodium content in the first composition is lower than a sodium content in the second composition of the honeycomb body; and

firing the green membrane layer on the honeycomb body walls to form a porous membrane layer comprising cordierite.

2. The method of claim 1 , wherein the partition walls comprise CaO 0.01-0.15 wt. %; Fe 2 O 3 0.4-1.0 wt. %; NiO 0.001-0.01 wt. %; and TiO 2 0.1-0.5 wt. %.

3. The method of claim 1 , wherein at least 50 wt. % of the first composition is comprised of: Al 2 O 3 31-37 wt. %; SiO 2 45-51 wt. %; MgO 10-16 wt. %; and (Na 2 O+K 2 O) 0.01-0.10 wt. %.

4. The method of claim 1 , wherein the first composition comprises: CaO 0.05-0.15 wt. %; Fe 2 O 3 0.3-1.0 wt. %; NiO 0.001-0.1 wt. %; and TiO 2 0.2-0.8 wt. %.

5. The method of claim 1 , wherein the first composition comprises K 2 O 0.01-0.03 wt. %.

6. The method of claim 1 , wherein the porous membrane layer has a median thickness from 5 microns to 25 microns.

7. The method of claim 1 , wherein the porous membrane layer comprises pore diameters from 0.1 micron to 5 microns.

8. The method of claim 1 , wherein the porous membrane layer comprises a median pore diameter D50 from 0.2 microns to 3 microns.

9. The method of claim 1 , wherein the porous membrane layer has a porosity from 40% to 60%.

10. The method of claim 1 , wherein the porous membrane layer further comprises alumina.

11. The method of claim 1 , wherein at least 95 wt. % of the porous membrane layer comprises a cordierite crystalline phase.

12. The method of claim 1 , wherein the porous membrane layer comprises a cordierite-alumina composite.

13. The method of claim 1 , wherein the porous membrane layer further comprises 1 wt. % to 50 wt. % alumina.

14. The method of claim 1 , wherein the green membrane layer is fired at from 1100° C. to 1300° C.

15. The method of claim 1 , wherein the honeycomb body is fired prior to applying the first composition to form the green membrane layer.

16. The method of claim 1 , wherein the honeycomb body is a green body upon which the first composition is applied to form the green membrane layer, and the firing step further comprises firing the green body into a ceramic honeycomb body.

17. The method of claim 16 , wherein the partition walls of the fired ceramic honeycomb body are porous partition walls.

18. The method of claim 17 , wherein the porous partition walls of the fired ceramic honeycomb comprise 0.001≤Na 2 O≤0.10 wt. %, or 0.001≤K 2 O≤0.03 wt. %, or 0.001≤Na 2 O+K 2 O≤0.13 wt. %.

19. The method of claim 17 , wherein the porous partition walls of the fired ceramic honeycomb comprise 0.001≤K 2 O≤0.03 wt. %.

20. The method of claim 1 , wherein at least 50 wt. % of the porous membrane layer is comprised of: Al 2 O 3 31-37 wt. %, SiO 2 45-51 wt. %, and MgO 10-16 wt. %.

21. The method of claim 17 , wherein the porous membrane layer comprises: Al 2 O 3 31-37 wt. %, SiO 2 45-51 wt. %, MgO 10-16 wt. %, and 0.001≤Na 2 O≤0.07 wt. %, and the porous partition walls comprise: Al 2 O 3 32-38 wt. %, SiO 2 47-53 wt. %, MgO 10-16 wt. %, Na 2 O 0.01-0.10 wt. %, CaO 0.01-0.15 wt. %, Fe 2 O 3 0.4-1.0 wt. %, NiO 0.001-0.01 wt. %, and TiO 2 0.1-0.5 wt. %.

22. The method of claim 17 , wherein the porous partition walls of the fired ceramic honeycomb comprise 0.001≤Na 2 O≤0.10 wt. %.

23. The method of claim 17 , wherein the porous partition walls of the fired ceramic honeycomb comprise 0.001≤K 2 O≤0.03 wt. %.

24. The method of claim 17 , wherein the porous partition walls of the fired ceramic honeycomb comprise 0.001≤Na 2 O+K 2 O≤0.13 wt. %.

25. The method of claim 1 , wherein the porous membrane layer comprises 0.01≤Na 2 O≤0.07 wt. %.

Continuity (3)
Continuation 15771458
Provisional Application 62248645 · Oct 30, 2015
Related Publication 20210107838A1 · Apr 15, 2021
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