Porous SS-Sic-Containing Ceramic Molded Article Comprising an Aluminum Oxide Coating, and Method for the Production Thereof

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This invention describes a method for producing a porous ceramic article composed mainly of β-silicon carbide (β-SiC) with a uniform aluminum oxide coating on the surfaces of its pores and channels. The process involves extruding a mixture containing silicon, carbon, and aluminum particles with an organic binder, pyrolyzing the mold, converting the structure into SiC, forming an aluminum layer, and oxidizing it to aluminum oxide. The resulting material has a three-dimensional, continuous β-SiC network with excellent thermal and mechanical stability and a controlled porosity, making it highly effective as a catalyst carrier or filter.

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• Diesel particulate filters for automotive or industrial engines, especially for high-temperature exhaust gas filtration.
• Catalyst carrier substrates for chemical reaction processes or for automotive catalytic converters.
• Filters for industrial hot gas purification, chemical processing, or energy production systems.
• Support structures for solar energy receivers or burners requiring high temperature stability and porosity.
• High-temperature, corrosion-resistant components for advanced manufacturing or chemical sectors.

BenefitsContent extracted from patent full text and abstract with AI.

• Improved ease of extrusion and reduced wear on production tools, enabling finer and thinner-walled structures than previously possible.
• High porosity with tunable pore size (0.1–50 μm), making the material ideal for filtration or as a catalyst carrier.
• Excellent thermal and chemical stability due to the continuous β-SiC skeleton and absence of grain boundaries.
• Enhanced adhesion for catalyst layers because of the aluminum oxide coating on pore and channel surfaces.
• Lower energy requirements for manufacturing (below 1500°C), reducing production costs compared to conventional SiC ceramics.
• Mechanical robustness and resistance to aggressive environments, making it well-suited for harsh operating conditions.

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Patent Abstract

The invention relates to a method for producing a porous ß-SiC-containing ceramic molded article comprising an aluminum oxide layer on the surface of the pores and channels of the porous ß-SiC-containing ceramic molded article. Said method encompasses the following steps: a) a molded article is extruded from a material composed of silicon-containing particles, aluminum-containing particles, carbon-containing particles, and a coking, organic binder; b) the porous molded article obtained in step (a) is pyrolyzed at a temperature ranging between 600 and 1000 °C; and c) the porous molded article is silicated by heating the same to a temperature ranging between 1100 and 1500 °C so as to obtain the porous ß-SiC-containing molded article that is provided with an aluminum layer on the surface, the surface of said aluminum layer being oxidized in step (d). The invention further relates to a porous SiC-containing ceramic molded article which comprises pores having an average pore size ranging from 0.1 to 50 ?m, an aluminum oxide layer on the surface of the open pores, and channels.