High porosity ceramic honeycomb structure and method of manufacturing
AssigneeCorning Incorporated
InventorsDouglas Munroe Beall, Achim Karl-Erich Heibel, David John Thompson
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Abstract
A method of manufacturing a ceramic honeycomb structure by mixing a ceramic precursor batch composition having a median particle diameter less than or equal to about 10 μm and at least one starch-based pore former having a median particle diameter greater than or equal to about 10 μm. The method also includes forming a mixture of ceramic precursor batch composition and a starch-based pore former into a green ceramic structure having a web structure, and firing the green ceramic structure to yield a ceramic honeycomb structure.
Claims17
A method of manufacturing a ceramic honeycomb structure, comprising:
- forming a cordierite precursor batch composition mixture comprising a combination of constituent materials comprising:
- inorganic particles comprised of magnesia source particles, silica source particles, and alumina source particles, the inorganic particles having a median particle diameter less than or equal to about 10 μm, wherein the magnesia source particles or the alumina source particles comprise spinel particles and the amount of silica source is about 13% to about 24% by weight of the inorganic particles, and
- at least one starch-based pore former having a median particle diameter greater than or equal to about 10 μm;
- forming the mixture of ceramic precursor batch composition and at least one starch-based pore former into a green body having a honeycomb web structure of intersecting walls;
- and
- firing the green ceramic body to yield the ceramic honeycomb structure comprising a predominant cordierite crystalline phase.
A method of manufacturing a ceramic honeycomb structure, comprising:
- forming a cordierite precursor batch composition mixture comprising a combination of constituent materials comprising:
- inorganic particles comprised of magnesia source particles, silica source particles, and alumina source particles, the inorganic particles having a median particle diameter less than or equal to about 10 μm, wherein the magnesia source particles or the alumina source particles comprise spinel particles, and
- at least one starch-based pore former having a median particle diameter greater than or equal to about 10 μm;
- forming the mixture of ceramic precursor batch composition and at least one starch-based pore former into a green body having a honeycomb web structure of intersecting walls;
- and
- firing the green ceramic body to yield the ceramic honeycomb structure comprising a predominant cordierite crystalline phase, wherein the ceramic honeycomb structure comprises:
- a total porosity greater than or equal to about 55%;
- an average wall thickness less than or equal to about 150 μm;
- a median pore diameter greater than or equal to about 10 μm;
- a df less than or equal to about 0.45, where df=(d50-d10)/d50;
- and
- a strength (MOR/CFA) greater than or equal to about 900 psi.
Dependencies are inferred from the claim text.