# US 2019/0169072 A1 · Ceramic batch mixtures having decreased wall drag

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- Number: US 2019/0169072 A1
- Document ID: US20190169072A1
- Status: Published application
- Kind: A1
- Application number: 16/269,121
- Filed: 2019-02-06
- Published: 2019-06-06
- Earliest claimed: 2015-03-30
- Assignees: Corning Incorporated
- Applicants: Corning Incorporated
- Inventors: Daniel Edward McCauley; Maxime Moreno; Conor James Walsh; Stephanie Stoughton Wu
- Web page: https://patentgrep.com/patent/US20190169072A1

## CPC

- C04B 35/14: based on silica
- C04B 35/10: based on aluminium oxide
- C04B 35/185: Mullite {3Al2O3-2SiO2}
- C04B 35/195: Alkaline earth aluminosilicates, e.g. cordierite {or anorthite}
- C04B 35/478: based on aluminium titanates
- C04B 35/565: based on silicon carbide
- C04B 35/632: Organic additives
- C04B 38/0006: {Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083)}
- C04B 2111/00129: {Extrudable mixtures}
- C04B 2111/00198: {Characterisation or quantities of the compositions or their ingredients expressed as mathematical formulae or equations}
- C04B 2235/3206: Magnesium oxides or oxide-forming salts thereof
- C04B 2235/3217: Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
- C04B 2235/3232: Titanium oxides or titanates, e.g. rutile or anatase
- C04B 2235/3236: Alkaline earth titanates
- C04B 2235/3418: Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
- C04B 2235/3826: Silicon carbides
- C04B 2235/6021: Extrusion moulding
- C04B 2235/61: Mechanical properties, e.g. fracture toughness, hardness, Young's modulus or strength
- C04B 2235/96: Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE

## Abstract

According to embodiments, a batch mixture includes inorganic components, a non-polar carbon chain lubricant, and an organic surfactant having a polar head. The non-polar carbon chain lubricant and the organic surfactant are present in concentrations satisfying the relationship: B(C1(d+d0)+C2(f+f0))=SC, where: d0+d is an amount of non-polar carbon chain lubricant in percent by weight of the inorganic components, by super addition; f0+f is an amount of organic surfactant in percent by weight of the inorganic components, by super addition; B is a scaling factor; C1 is a scaling factor of the concentration of the non-polar carbon chain lubricant; and C2 is a scaling factor of the concentration of the organic surfactant. Embodiments provide that 3.6≤SC≤14.

## Claims

### Claim 1

A method of manufacturing a honeycomb structure comprising extruding a batch mixture through an extrusion die at one or more batch velocities and at one or more batch temperatures, the batch mixture being comprised of one or more inorganic components comprising one or more ceramic or ceramic-forming ingredients, a non-polar carbon chain lubricant, and an organic surfactant, wherein the amount of the non-polar carbon chain lubricant and the organic surfactant in the batch mixture is synergistically adjusted.

### Claim 2 (depends on 1)

The method of claim 1 wherein either the amount of the non-polar carbon chain lubricant, or the amount of the organic surfactant, or both the amounts of the non-polar carbon chain lubricant and the amount of the organic surfactant are adjusted.

### Claim 3 (depends on 1)

The method of claim 1 wherein the non-polar carbon chain lubricant and the organic surfactant are present in concentrations satisfying the relationship:
B[C_1(d+3)+C_2(f+0.3)]=SC,
where:
d is an amount added of the non-polar carbon chain lubricant in percent by weight of the inorganic component, by super addition, and 3≤(d+3)≤10;
f is an amount added of the organic surfactant in percent by weight of the inorganic component, by super addition, and 1≤(f+0.3)≤10;
0.5≤C1≤1.5;
0.5C1≤C2≤4C1;
0.4≤B≤2; and
3.6≤SC≤14.

### Claim 4 (depends on 1)

The method of claim 1 wherein either the amount of the non-polar carbon chain lubricant or the organic surfactant, or both, in the batch mixture is adjusted by selecting the amounts in accordance with the results of a rate sweep test on the batch mixture corresponding to a low level of wall drag.

### Claim 5 (depends on 4)

The method of claim 4 wherein wall drag is determined by a rate sweep test comprising simultaneously extruding the batch mixture through first and second dies in a capillary rheometer at a plurality of velocities and a plurality of temperatures, both dies have a 1 mm circular opening, the first die having a 0.25 mm length and the second die having a 16 mm length, and measuring pressures, wherein differences in pressure between the two dies are measured wall shear stress and can be attributed to wall drag.

### Claim 6 (depends on 5)

The method of claim 5 wherein the wall drag is less than about 10 psi.

### Claim 7 (depends on 5)

The method of claim 5 wherein the wall drag is less than about 8 psi.

### Claim 8 (depends on 5)

The method of claim 5 wherein the wall drag is less than about 6 psi.

### Claim 9 (depends on 5)

The method of claim 5 wherein the wall drag is less than about 4 psi.

### Claim 10 (depends on 1)

The method of claim 1 wherein the amount of non-polar carbon chain lubricant and the amount of organic surfactant in a batch mixture are selected such that the batch mixture has a measured wall shear stress in a rate sweep test of less than about 10 psi over the range of velocities from about 0.1 in/s to about 2.5 in/s at temperatures between about 10° C. and about 45° C.

### Claim 11 (depends on 1)

The method of claim 1 wherein the amount of non-polar carbon chain lubricant and the amount of organic surfactant in the batch mixture are selected such that the batch mixture has a measured wall shear stress in a rate sweep test of less than about 8 psi over the range of velocities from about 0.1 in/s to about 2.5 in/s at temperatures between about 24° C. and about 45° C.

### Claim 12 (depends on 1)

The method of claim 1 wherein the amount of non-polar carbon chain lubricant and the amount of organic surfactant in the batch mixture is selected such that the batch mixture has a measured wall shear stress in a rate sweep test of less than about 6 psi over the range of velocities from about 0.1 in/s to about 2.5 in/s at temperatures between about 31° C. and about 45° C.

### Claim 13 (depends on 1)

The method of claim 1 wherein the amount of non-polar carbon chain lubricant and the amount of organic surfactant in the batch mixture is selected such that the batch mixture has a measured wall shear stress in a rate sweep test of less than about 6 psi over the range of velocities from about 0.1 in/s to about 2.5 in/s at temperatures between about 24° C. and about 45° C.

### Claim 14 (depends on 1)

The method of claim 1 wherein the amount of non-polar carbon chain lubricant and the amount of organic surfactant in the batch mixture is selected such that the batch mixture has a measured wall shear stress in a rate sweep test of less than about 4 psi over the range of velocities from about 0.1 in/s to about 2.5 in/s at temperatures between about 24° C. and about 45° C.

### Claim 15 (depends on 1)

The method of claim 1 wherein the organic surfactant comprises a fatty acid.

### Claim 16 (depends on 15)

The method of claim 15 wherein the fatty acid comprises stearic acid, oleic acid, tall oil, linoleic acid, or combinations thereof.

### Claim 17 (depends on 1)

The method of claim 1 wherein the inorganic component comprises at least one ceramic ingredient selected from the group consisting of: cordierite, aluminium titanate, silicon carbide, mullite, alumina, and combinations thereof.

### Claim 18 (depends on 1)

The method of claim 1 wherein the inorganic component comprises at least one ceramic-forming ingredient selected from the group consisting of: alumina, silica, magnesia, titania, aluminium-containing ingredient, silicon-containing ingredient, titanium-containing ingredient, and combinations thereof.

### Claim 19 (depends on 1)

The method of claim 1 wherein the organic surfactant has a polar head.

### Claim 20 (depends on 1)

The method of claim 1 wherein the non-polar carbon chain lubricant is a mineral oil.