Method for producing ceramic cellular structure having high cell density

A process for producing a ceramic cellular structure comprising:

• a. corrugating a green ceramic tape having a cell density of from 500 to 1600 cells per square inch of cross-sectional area and wall thicknesses from 2 to 30 mils to produce a corrugated first tape member, said tape consisting essentially of finely divided sinterable solid particles of ceramic raw materials substantially uniformly distributed throughout a fugitive plastic support matrix, the weight ratio of said supporting matrix to said raw materials being from about 1 to 3 to about 1 to 6, said supporting matrix consisting essentially of from about 28.5 to 74.5 weight percent of a two part resin, the resin consisting essentially of polyvinyl butyral in the amount of from 50 to 95 weight percent, remainder an amine thermosetting resin, selected from the group consisting of melamine formaldehyde and urea formaldehyde, and from about 25 to 70 weight percent of a plasticizer selected from the group consisting of alkyl phthalate and dialkyl phthalate plasticizers and from about 0.5 to about 1.5 percent by weight of a deflocculating agent,
• b. adhering a substantially flat second tape mbember containing substantially the same ceramic raw material and supporting matrix to the nodes of the first corrugated tape member to form a bilayered tape member, and
• c. adhering said bilayered tape member and a predetermined number of subsequent bilayered tape members to each other to form a cellular structure having alternate corrugated and flat members.