Honeycomb bodies with multi-zoned honeycomb structures and co-extrusion manufacturing methods
AssigneeCorning Incorporated
InventorsDouglas Munroe Beall, David John Thompson
Life of this patent
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Abstract
A honeycomb body with a honeycomb structure having an inner zone of a first plurality of walls and an outer zone of a second plurality of walls at least partially surrounding the inner zone. The honeycomb structure has Pi that is greater than Po and MPSi that is greater than MPSo, wherein Pi is an average bulk porosity of the first plurality of walls, Po is an average bulk porosity of the second plurality of walls, MPSi is a median pore size of pores in the first plurality of walls, and MPSo is a median pore size of pores in the second plurality of walls. Various honeycomb structures, honeycomb extrusion apparatus, and co-extrusion methods are disclosed.
Claims16
A honeycomb body comprising a honeycomb structure comprising:
- an inner zone comprising a first plurality of walls;
- and
- an outer zone at least partially surrounding the inner zone, the outer zone comprising a second plurality of walls;
- and
- a transition zone between the inner zone and the outer zone, wherein an average bulk porosity of walls in the transition zone varies exponentially within the transition zone;
- Pi>Po;
- and
- MPSi>MPSo, and
- wherein Pi is an average bulk porosity of the first plurality of walls, Po is an average bulk porosity of the second plurality of walls, MPSi is a median pore size of pores in the first plurality of walls, and MPSo is a median pore size of pores in the second plurality of walls.
A honeycomb body comprising a honeycomb structure comprising:
- an inner zone comprised of a first plurality of walls;
- an outer zone at least partially surrounding the inner zone, the outer zone comprised of a second plurality of walls;
- and
- a transition zone between the inner zone and the outer zone, wherein an average bulk porosity of walls in the transition zone varies exponentially within the transition zone;
- and
- 40%≥Pi≥70%;
- 0.95 Pi≥Po;
- and
- 0.90 MPSi≥MPSo, and
- wherein Pi is an average bulk porosity of the first plurality of walls, Po is an average bulk porosity of the second plurality of walls, MPSi is a median pore size of pores in the first plurality of walls, and MPSo is a median pore size of pores in the second plurality of walls.
A method of manufacturing a honeycomb body, the method comprising:
- extruding a first batch mixture through a first die zone of a honeycomb extrusion die to form an inner zone of a honeycomb structure, the first batch mixture comprising a first pore-former;
- extruding a second batch mixture through a second die zone of the honeycomb extrusion die, the second die zone at least partially surrounding the first die zone, to form an outer zone of the honeycomb structure, the second batch mixture having a second pore-former different from the first pore-former;
- forming a green honeycomb structure;
- and
- firing the green honeycomb structure to form a fired honeycomb structure comprising the inner zone having a first plurality of walls, the outer zone at least partially surrounding the inner zone, and a transition zone between the inner zone and the outer zone, the outer zone having a second plurality of walls wherein
- Pi>Po;
- and
- MPSi>MPSo,
- wherein Pi is an average bulk porosity of the first plurality of walls, Po is an average bulk porosity of the second plurality of walls, MPSi is a median pore size of pores in the first plurality of walls, and MPSo is a median pore size of pores in the second plurality of walls;
- and
- wherein an average bulk porosity of walls in the transition zone varies exponentially within the transition zone.
Dependencies are inferred from the claim text.