Ceramic composite beads and methods for making the same

Abstract

The disclosure relates to methods for making a ceramic or glass-ceramic, the methods comprising spray-drying a mixture comprising batch materials to form agglomerated particles; bringing the agglomerated particles into contact with a plasma for a residence time sufficient to form fused particles; and annealing the fused particles at a temperature and for a time sufficient to form ceramic or glass-ceramic particles. Fused glass particles, ceramic or glass-ceramic particles, and ceramic or glass-ceramic articles, such as ceramic honeycombs, made by these methods are also disclosed herein.

1 . A method for making a ceramic or glass-ceramic, comprising:
 spray-drying a mixture comprising batch materials to form agglomerated particles;   bringing the agglomerated particles into contact with a plasma for a residence time sufficient to react and melt the agglomerated particles to form fused particles; and   annealing the fused particles at a temperature and for a time sufficient to form ceramic or glass-ceramic particles.   
     
     
         2 . The method of  claim 1 , wherein the mixture is a slurry comprising inorganic batch materials, at least one solvent, and optionally at least one additive chosen from binders, surfactants, dispersants, and anti-foaming agents. 
     
     
         3 . The method of  claim 1 , the batch materials comprise metal oxides, carbides, nitrides, or borides, and combinations thereof. 
     
     
         4 . The method of  claim 1 , wherein the plasma has a temperature ranging from about 9,000K to about 11,000K. 
     
     
         5 . The method of  claim 1 , wherein the agglomerated particles are heated to a temperature of at least about 2000° C., and wherein the residence time is less than about 10 seconds. 
     
     
         6 . The method of  claim 1 , wherein the fused particles are annealed at a temperature ranging from about 700° C. to about 1650° C., for a time ranging from about 1 hour to about 100 hours. 
     
     
         7 . The method of  claim 1 , wherein the batch composition has a T g  greater than about 1600° C. 
     
     
         8 . The method of  claim 1 , further comprising forming a glass-ceramic article from the glass-ceramic particles. 
     
     
         9 . The method of  claim 1 , further comprising forming a green article from the fused particles, wherein the annealing step comprises annealing the green article comprising the fused particles. 
     
     
         10 . A ceramic or glass-ceramic article made according to the method of  claim 1 . 
     
     
         11 . A ceramic or glass-ceramic particle having an average particle size ranging from about 10 microns to about 50 microns and comprising less than about 5% residual glass phase, wherein the ceramic or glass-ceramic particle has a substantially homogeneous fine microstructure. 
     
     
         12 . The ceramic or glass-ceramic particle of  claim 11 , wherein the ceramic or glass-ceramic particle comprises cordierite, aluminum titanate, spinel, mullite, and composites thereof. 
     
     
         13 . The ceramic or glass-ceramic particle of  claim 11 , wherein the ceramic or glass-ceramic particle is substantially spherical in shape. 
     
     
         14 - 20 . (canceled)