Low bulk density, high geometric surface area honeycomb bodies
AssigneeCorning Incorporated
InventorsDavid Jack Bronfenbrenner, Michael James Lehman
Life of this patent
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Abstract
Ceramic honeycomb bodies and methods for then manufacture are provided. The ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in−1 (3.66 mm−1), a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.4 mm2.
Claims18
A ceramic honeycomb body comprising:
- an inlet face, an outlet face, and a plurality of parallel, elongate, open-ended cells formed by a web of intersecting cell walls having a web thickness (tw) traversing the ceramic honeycomb body from the inlet face to the outlet face thereof, each cell defining a cell perimeter P and cell area (Acell), the open-ended cells configured with a cell density in cells per square inch (CPSI) and defining a percentage open frontal area (% OFA) of the ceramic honeycomb body, wherein % OFA=CPSI*Acell, the intersecting cell walls being comprised of a ceramic material having a density ρc and a volume percentage porosity (% porosity), wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in−1, a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.4 mm2.
A method of manufacturing a ceramic honeycomb body comprising an inlet face, an outlet face, and a plurality of parallel, elongate, open-ended cells formed by intersecting cell walls having a web thickness (tw) traversing the ceramic honeycomb body from the inlet face to the outlet face thereof, each cell defining a perimeter P and cell area (Acell), the open-ended cells comprising a cell density in cells per square inch (CPSI) and defining a percentage open frontal area (% OFA) of the ceramic honeycomb body, wherein % OFA=CPSI*Acell, the intersecting cell walls comprising a ceramic material having a density ρc and a volume percentage porosity (% porosity),
- wherein the method comprises forming a mixture of starting materials including a pore forming agent, then extruding the mixture into a green honeycomb body, then firing the green honeycomb body to provide a formed ceramic honeycomb body comprising a predetermined CPSI and a predetermined web thickness so that the formed ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in−1, a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.4 mm2.
Dependencies are inferred from the claim text.