Batch compositions comprising spheroidal pre-reacted inorganic particles and spheroidal pore-formers and methods of manufacture of honeycomb bodies therefrom

A method of manufacturing a honeycomb body, comprising:

• mixing a batch mixture comprising pre-reacted inorganic spheroidal particles, fine inorganic particles, organic binder, pore-former spheroidal particles, and a liquid vehicle to form a paste,
• wherein the pre-reacted inorganic spheroidal particles have a pre-reacted particle size distribution of:
• 10 μm≤DI50≤50 μm, and
• DIb≤2.0;
• and
• wherein the pore-former spheroidal particles having a pore-former particle size distribution of:
• 0.40 DI50≤DP50≤0.90 DI50, and
• DPb≤1.32, and
• wherein each of DI90, DI50, and DI10 is a coarse particle diameter, a median particle diameter, or a fine particle diameter, respectively, of the pre-reacted particle size distribution of the pre-reacted inorganic spheroidal particles in which 90%, 50%, or 10%, respectively, of the pre-reacted inorganic spheroidal particles have a diameter that is equal to or less than the coarse particle diameter, the median particle diameter, or the fine particle diameter, each of DP90, DP50, DP10 is a coarse particle diameter, a median particle diameter, or a fine particle diameter, respectively, of the pore-former particle size distribution of the pore-former spheroidal particles in which 90%, 50%, or 10%, respectively, of the pore-former spheroidal particles have a diameter that is equal to or less than the coarse particle diameter, the median particle diameter, or the fine particle diameter, respectively, DIb is a breadth factor of the pre-reacted particle size distribution of the pre-reacted inorganic spheroidal particles and DIb={DI90-DI10}/DI50, and DPb is a breadth factor of the pore-former particle size distribution of the pore-former spheroidal particles and DPb={DP90-DP10}/DP50;
• and
• wherein the fine inorganic particles comprise less than 20 wt % having a median particle diameter of less than 5 μm based on a total weight of the pre-reacted inorganic spheroidal particles;
• and
• forming the paste into a wet green honeycomb body.