Low Thermal Expansion High Strength Honeycomb Cement And Method Therefor

A cement mixture for a honeycomb body, the cement mixture comprising:

• a plurality of inorganic components comprising talc, kaolin, alumina, silica, and aluminum hydroxide, wherein the mixture contains less than or equal to 18.0% silica, greater than or equal to 17.0% aluminum hydroxide, between 10.0 and 15.0 wt % kaolin, between 20.0 and 45.0 wt % talc, and between 10.0 and 25.0 wt % alumina, in percent by weight of the inorganic components.

A method of manufacturing a honeycomb structure, the method comprising:

• applying a cement mixture to an outer surface of a honeycomb body to form an outer layer of the cement mixture on the honeycomb body, the cement mixture comprising a plurality of inorganic components comprising talc, kaolin, alumina, silica, and aluminum hydroxide, wherein the mixture contains less than or equal to 18.0% silica and greater than or equal to 17.0% aluminum hydroxide, in percent by weight of the inorganic components;
• then
• exposing the honeycomb body with the outer layer to a first firing environment for a time and at one or more temperatures sufficient to cause a first ceramic material to form in the outer layer.

A honeycomb structure comprising a ceramic honeycomb matrix having an outer layer, wherein the outer layer has a modulus of rupture of greater than 700 psi, as measured on a solid rod of circular cross section of the ceramic material, and a coefficient of thermal expansion at 800° C. on cooling of less than 15×10−7/° C.

A honeycomb structure comprising a ceramic honeycomb matrix having a plurality of walls defining a plurality of cells, and plugs disposed in at least some of the cells, wherein the plugs have a modulus of rupture of greater than 700 psi, as measured on a solid rod of circular cross section of the ceramic material, and a coefficient of thermal expansion at 800° C. on cooling of less than 15×10−7/° C.