# US 2022/0033318 A1 · Methods of making plugged honeycomb bodies with cement patties

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- Number: US 2022/0033318 A1
- Document ID: US20220033318A1
- Status: Published application
- Kind: A1
- Application number: 17/296,399
- Filed: 2019-11-15
- Published: 2022-02-03
- Earliest claimed: 2018-11-30
- Assignees: Corning Incorporated
- Applicants: Corning Incorporated
- Inventors: Keith Norman Bubb
- Web page: https://patentgrep.com/patent/US20220033318A1

## CPC

- C04B 38/0006: {Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083)}
- B01D 46/0001: {Making filtering elements}
- B01D 46/2418: {Honeycomb filters (used for filtering exhaust gases of an internal combustion engine F01N3/022; ceramic honeycomb structures per se C04B38/0006)}
- B28B 11/006: {Making hollow articles or partly closed articles}
- C04B 14/303: {Alumina}
- C04B 26/285: {Cellulose or derivatives thereof (C04B26/24 takes precedence)}
- C04B 28/24: containing alkyl, ammonium or metal silicates; containing silica sols {(reaction mixtures resulting in mineral polymers C04B28/006; polymeric reaction products of alkali metal silicates with isocyanates C08G18/3895)}
- 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 35/584: based on silicon nitride
- C04B 35/6365: {Cellulose or derivatives thereof}
- C04B 38/0012: {characterised by the material used for sealing or plugging (some of) the channels of the honeycombs}
- C04B 2111/00793: {as filters or diaphragms}
- C04B 2201/10: for the viscosity
- 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
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)

## Abstract

A method of plugging a honeycomb body includes mixing a plugging mixture at a mixing temperature, wherein the plugging mixture comprises a plurality of inorganic particles, inorganic binder, organic binder, and water; dispensing the plugging mixture into a patty mold at a dispensing temperature; cooling the plugging mixture within the patty mold to a cooled temperature, such that a cement patty is formed; and pressing the cement patty into a plurality of channels in a honeycomb body, wherein the mixing temperature and the dispensing temperature are above a hydration point temperature of the organic binder in the plugging mixture, and the cooled temperature is below the hydration point temperature of the organic binder in the plugging mixture.

## Claims

### Claim 1

A method of forming a plugging cement patty, comprising:
mixing a plugging mixture at a mixing temperature, the plugging mixture comprising a plurality of inorganic particles, an inorganic binder, an organic binder, and a liquid;
dispensing the plugging mixture at a dispensing temperature; and
cooling the plugging mixture to a cooled temperature to form the plugging cement patty, wherein the dispensing temperature is above a hydration point temperature of the organic binder in the plugging mixture and the cooled temperature is below the hydration point temperature of the organic binder in the plugging mixture.

### Claim 2 (depends on 1)

The method of claim 1, wherein a viscosity of the plugging mixture at the mixing temperature is from about 1 cP to about 100 cP.

### Claim 3

(canceled)

### Claim 4 (depends on 1)

The method of claim 1, wherein a viscosity of the plugging mixture at the dispensing temperature is from about 1 cP to about 100 cP.

### Claim 5

(canceled)

### Claim 6 (depends on 1)

The method of claim 1, wherein a viscosity of the plugging mixture at the cooled temperature is from about 1,500,000 cP to about 10,000,000 cP.

### Claim 7 (depends on 1)

The method of claim 1, wherein a viscosity of the plugging mixture at the cooled temperature is from about 3,000,000 cP to about 5,000,000 cP.

### Claim 8 (depends on 1)

The method of claim 1, wherein the organic binder comprises methylcellulose.

### Claim 9 (depends on 8)

The method of claim 8, wherein the plurality of inorganic particles comprises cordierite.

### Claim 10 (depends on 9)

The method of claim 9, wherein the inorganic binder comprises colloidal silica.

### Claim 11

A method of forming a plugging cement patty for plugging a honeycomb body, comprising the steps of:
mixing a plugging mixture at a mixing temperature, wherein the plugging mixture comprises cordierite, colloidal silica, organic binder, and water;
dispensing the plugging mixture into a patty mold at a dispensing temperature; and
cooling the plugging mixture to a cooled temperature within the patty mold to form the plugging cement patty, wherein the cooled temperature is below a hydration point temperature of the organic binder in the plugging mixture, further wherein the mixing temperature and the dispensing temperature are above the hydration point temperature of the organic binder in the plugging mixture.

### Claim 12 (depends on 11)

The method of claim 11, wherein a weight percentage of the organic binder as a super addition relative to a combined total weight of the cordierite in the plugging mixture is from about 0.5 wt. % to about 6 wt. %.

### Claim 13 (depends on 11)

The method of claim 11, wherein the weight percentage of the organic binder as a super addition relative to the combined total weight of the cordierite in the plugging mixture is from about 0.75 wt. % to about 3.0 wt. %.

### Claim 14 (depends on 11)

The method of claim 11, wherein the weight percentage of the organic binder as a super addition relative to the combined total weight of the cordierite in the plugging mixture is about 1.5 wt. %.

### Claim 15 (depends on 11)

The method of claim 11, wherein the organic binder comprises methylcellulose.

### Claim 16 (depends on 11)

The method of claim 11, wherein the step of cooling the plugging mixture to the cooled temperature further comprises the step of subjecting the plugging mixture to a cooling bath having a temperature below the cooled temperature.

### Claim 17 (depends on 11)

The method of claim 11, wherein a viscosity of the plugging mixture at the cooled temperature is from about 3,000,000 cP to about 5,000,000 cP.

### Claim 18

A method of plugging a honeycomb body comprising the steps of:
mixing a plugging mixture at a mixing temperature, wherein the plugging mixture comprises a plurality of inorganic particles, an inorganic binder, an organic binder, and water;
dispensing the plugging mixture into a patty mold at a dispensing temperature;
cooling the plugging mixture within the patty mold to a cooled temperature such that a plugging cement patty is formed; and
pressing the plugging cement patty into a plurality of channels in the honeycomb body, wherein the mixing temperature and the dispensing temperature are above a hydration point temperature of the organic binder in the plugging mixture, further wherein the cooled temperature is below the hydration point temperature of the organic binder in the plugging mixture.

### Claim 19 (depends on 18)

The method of claim 18, wherein the hydration point temperature of the organic binder in the plugging mixture is from about 20° C. to about 100° C.

### Claim 20 (depends on 18)

The method of claim 18, wherein the hydration point temperature of the organic binder in the plugging mixture is from about 25° C. to about 60° C.

### Claim 21

(canceled)

### Claim 22 (depends on 18)

The method of claim 18, wherein the inorganic binder comprises methylcellulose.

### Claim 23 (depends on 18)

The method of claim 18, wherein the step of pressing the plugging cement patty into the plurality of channels in the honeycomb body is performed at a temperature below the hydration point temperature of the organic binder.