Method of preparing a monolithic structure having flow channels

Abstract

A method of preparing ceramic monolithic structures having flow channels and their use as heat exchangers, filters, and catalyst supports are disclosed. In the method, a substantially uniform mixture of a composition comprising a ceramic powder, a polyolefin binder, and a plasticizer is shaped to form flat sheets and a series of ribs is formed on a first side of at least a portion of the sheets. After extraction of the plasticizer, a ceramic cement composition is applied to the ribs or to the second side of the sheets and the sheets are positioned in a layered structure such that the ceramic cement composition is in adhesive contact with a surface of the adjacent sheet. Firing the layered structure to sinter the ceramic powder and the cement composition and to decompose the polyolefin provides a monolithic structure of desirable strength and controlled porosity.

Dependencies are inferred from the claim text.