High density cordierite ceramics from zeolite

Details High density cordierite ceramics from zeolite High density cordierite ceramics from zeolite

1989-12-19

1990-12-25

Dixon, Jr., William R.

Compositions: ceramic

Ceramic compositions

Refractory

501122, 501128, 423328, C04B 3518, C04B 3520, C04B 3522

Patent

active

049803239

ABSTRACT:
This invention relates to processes for preparing ceramic articles which are especially suited for electronic applications. The process involves taking a shaped article which has been formed from a magnesium exchanged zeolite powder, the zeolite selected from the group consistig of phillipsite, harmotome, gismondine, zeolite B, zeolite ZK-19 and zeolite W, and sintering it at a temperature of about 1,000.degree. to 1,350.degree. C. for about 1 to about 6 hours. The magnesium exchanged zeolite has a SiO.sub.2 /Al.sub.2 O.sub.3 ratio of about 2.3 to about 2.8 and a sodium content less than 0.5 weight percent. The ceramic article that is formed has a substantially crystalline cordierite phase and has a density of at least 90% of its theoretical density. A preferred process involves calcining the magnesium exchanged zeolite powder at a temperature of about 600.degree.-800.degree. C. to collapse the zeolite framework and give upon sintering a cordierite ceramic article which is substantially crack free. A preferred magnesium exchanged zeolite is magnesium exchanged zeolite B.

REFERENCES:
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patent: 4344851 (1982-08-01), Sherman et al.
patent: 4607015 (1986-08-01), Clough et al.
patent: 4680277 (1987-07-01), Horiuchi
patent: 4814303 (1989-03-01), Chowdhry et al.
J. R. Moyer et al., "Synthesis of Oxide Ceramic Powders by Aqueous Coprecipitation", Materials Research Soc. Symposium, 73, p. 117, (1986).
D. W. Breck, Zeolite Molecular Sieves, J. Wiley & Sons, N.Y., pp. 483-496 (1974).

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