Porous cordierite ceramic honeycomb article with improved strength and method of manufacturing same

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, or
• MT>2660
• wherein
• MA=3645(IA)−106(CTE)+19(d90)+17(% porosity),
• MT=4711(IT)+116(CTE)−26(d90 )−28(% porosity),
• CTE from 25 to 800° C. of not more than 9×10−7/° C.;
• and
• a median pore diameter, d50, wherein d50≧13 μm.

A porous cordierite ceramic honeycomb article, comprising:

• MA<1800, or
• MT>3000
• wherein
• MA=3645(IA)−106(CTE)+19(d90)+17(% porosity),
• MT=4711 (IT)+116 (CTE)−26 (d90 )−28 (% porosity), and
• CTE from 25 to 800° C. of not more than 9×10−7/° C.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, or
• MT>2660
• wherein
• MA=3645(IA)−106(CTE)+19(d90)+17(% porosity),
• MT=4711(IT)+116(CTE)−26(d90 )−28(% porosity),
• % porosity≦52% ,
• d90≦29 um,
• IA≦0.33,
• CTE≦8×10−7/° C. (25-800° C.) in at least one direction, and
• d50≧10 um.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, and
• MT>2660
• wherein
• MA=3645(IA)−106(CTE)+19(d90)+17(% porosity),
• MT=4711(IT)+116(CTE)−26(d90 )−28(% porosity), and
• CTE from 25 to 800° C. of not more than 9×10−7/° C.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, and
• MT>2660
• wherein
• MA=3645(IA)−106(CTE)+19(d90)+17(% porosity),
• MT=4711(IT)+116(CTE)−26(d90 )−28(% porosity),
• CTE from 25 to 800° C. of not more than 9×10−7/° C., and
• an elastic modulus, E, at 25° C. of less than 1.3×106 PSI in a 200/20 cell geometry.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, and
• MT>2660
• wherein
• MA=3645(IA)−106(CTE)+19(d90)+17(% porosity),
• MT=4711(IT)+116(CTE)−26(d90 )−28(% porosity),
• CTE from 25 to 800° C. of not more than 9×10−7/° C., and
• ER<1.20 wherein ER is a ratio of the elastic modulus at 1000° C., E′, to an elastic modulus at 25° C., E.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, or
• MT>2660
• wherein
• MA=3645(IA)−106(CTE)+19(d90)+17(% porosity),
• MT=4711(IT)+116(CTE)−26(d90 )−28(% porosity),
• % porosity of at least 44% and not more than 53%,
• 10 μm≦d50≦20 μm,
• d90≦33 μm,
• (d50−d10)/d50≦0.55, and
• CTE≦8×10−7/° C. (25-800° C.) in at least one direction.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, or
• MT>2660
• wherein
• MA=3645(IA)−106(CTE)+19(d90)+17(% porosity),
• MT=4711(IT)+116(CTE)−26(d90 )−28(% porosity),
• % porosity of at least 46% and not more than 53%,
• 12 μm≦d50≦19μm,
• d90≦30 μm,
• (d50−d10)/d50≦0.50, and
• CTE≦8×10−7/° C. (25° C.-800° C.) in at least one direction.

A porous cordierite ceramic honeycomb article, comprising

• MA<2220, or
• MT>2660
• wherein
• MA=3645 (IA)−106 (CTE)+19 (d90)+17 (% porosity),
• MT=4711 (IT)+116 (CTE)−26 (d90 )−28 (% porosity),
• CTE from 25 to 800° C. of not more than 9×10−7/° C., and
• IT>0.86.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, or
• MT>2660
• wherein
• MA=3645 (IA)−106 (CTE)+19 (d90)+17 (% porosity),
• MT=4711 (IT)+116 (CTE)−26 (d90)−28 (% porosity),
• CTE from 25 to 800° C. of not more than 9×10−7/° C., and
• IA<0.40.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, or
• MT>2660
• wherein
• MA=3645 (IA)−106 (CTE)+19 (d90)+17 (% porosity),
• MT=4711 (IT)+116 (CTE)−26 (d90)−28 (% porosity),
• CTE from 25 to 800° C. of not more than 9×10−7/° C., and
• a thermal shock parameter, TSP≧550° C.
• wherein
• TSP=MOR(25° C.)/ {[E(25° C.)][CTE′(500-900° C.)]}.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, or
• MT>2660
• wherein
• MA=3645 (IA)−106 (CTE)+19 (d90)+17 (% porosity),
• MT=4711 (IT)+116 (CTE)−26 (d90 l )−28 (% porosity),
• CTE from 25 to 800° C. of not more than 9×10−7/° C., and
• a ratio of MOR/E at about 25° C. which is greater than or equal to 0.073%.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, or
• MT>2660
• wherein
• MA=3645 (IA)−106 (CTE)+19 (d90)+17 (% porosity),
• MT=4711 (IT)+116 (CTE)−26 (d90)−28 (% porosity),
• CTE from 25 to 800° C. of not more than 9×10−7/° C., and
• df≦0.40 wherein df=(d50−d10)/d50.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2000, and
• MT>2800
• wherein
• MA=3645 (IA)−106 (CTE)+19 (d90)+17 (% porosity),
• MT=4711 (IT)+116 (CTE)−26 (d90)−28 (% porosity), and
• CTE from 25 to 800° C. of not more than 9×10−7/° C.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, or
• MT>2660
• wherein
• MA=3645 (IA)−106 (CTE)+19 (d90)+17 (% porosity),
• MT=4711 (IT)+116 (CTE)−26 (d90 )−28 (% porosity),
• CTE from 25 to 800° C. of not more than 9×10−7/° C., and
• a mean CTE (10−7/° C.) from 25 to 800° C. in the axial direction that is greater than the quantity defined as 34.4 (IA)−8.7.

A porous cordierite ceramic honeycomb article, comprising:

• MA<2220, or
• MT>2660
• wherein
• MA=3645 (IA)−106 (CTE)+19 (d90)+17 (% porosity),
• MT=4711 (IT)+116 (CTE)−26 (d90)−28 (% porosity),
• CTE from 25 to 800° C. of not more than 9×10−7/° C., and
• a mean CTE (10−7/° C.) from 25 to 800° C. in the axial direction that is greater than the quantity defined as 40.0−40.6 (IT).

A method of manufacturing a porous ceramic cordierite honeycomb article, comprising the steps of:

• mixing inorganic raw materials containing talc, an alumina-forming source, a silica-forming source, and 0-18 wt. % of a kaolin or calcined kaolin containing not more than 8 wt. % of a fine kaolin source having a median particle diameter of less than 7 μm, or if greater than 8 wt. % of the fine kaolin source then using a slow ramp rate during firing, with processing aids and optionally a pore forming agent to form a plasticized mixture,
• forming the plasticized mixture into a honeycomb structure, and
• firing the honeycomb structure to form the porous ceramic cordierite honeycomb article having a porosity <54% wherein if greater than 8 wt. % fine kaolin source is used, then the slow ramp rate includes a heating rate from 1200 to 1300° C. of not more than 20° C./hr, and
• wherein the alumina-forming source includes, in part, a highly derpersible power having a median particle of less then 1 μm which comprises not more than 10 wt. % of the inorganic raw materials.

A method of manufacturing a porous ceramic cordierite honeycomb article, comprising the steps of:

• mixing inorganic raw materials containing talc, an alumina-forming source, a silica-forming source, and 0-18 wt. % of a kaolin or calcined kaolin containing not more than 8 wt. % of a fine kaolin source having a median particle diameter of less than 7 μm, or if greater than 8 wt. % of the fine kaolin source then using a slow ramp rate during firing, with processing aids and optionally a pore forming agent to form a plasticized mixture,
• forming the plasticized mixture into a honeycomb structure, and
• firing the honeycomb structure to form the porous ceramic cordierite honeycomb article having a porosity <54% wherein if greater than 8 wt. % fine kaolin source is used, then the slow ramp rate includes a heating rate from 1200 to 1300° C. of not more than 20° C./hr, and
• wherein the talc includes an XRD talc morphology Index of between 0.6 and 1.0.

A method of manufacturing a porous ceramic cordierite honeycomb article, comprising the steps of:

• mixing inorganic raw materials containing talc, an alumina-forming source, a silica-forming source, and 0-18 wt. % of a kaolin or calcined kaolin containing not more than 8 wt. % of a fine kaolin source having a median particle diameter of less than 7 μm, or if greater than 8 wt. % of the fine kaolin source then using a slow ramp rate during firing, with processing aids and optionally a pore forming agent to form a plasticized mixture,
• forming the plasticized mixture into a honeycomb structure, and
• firing the honeycomb structure to form the porous ceramic cordierite honeycomb article having a porosity <54% wherein if greater than 8 wt. % fine kaolin source is used, then the slow ramp rate includes a heating rate from 1200 to 1300° C. of not more than 20° C./hr, and
• wherein the porous ceramic cordierite honeycomb article comprises:
• MA<2000, or
• MT>2900
• wherein
• MA=3645 (IA)−106 (CTE)+19 (d90)+17 (% porosity),
• MT=4711 (IT)+116 (CTE)−26 (d90)−28 (% porosity).

A method of manufacturing a porous ceramic cordierite honeycomb article, comprising the steps of:

• mixing inorganic raw materials containing talc, an alumina-forming source, a silica-forming source, and 0-18 wt. % of a kaolin or calcined kaolin containing not more than 8 wt. % of a fine kaolin source having a median particle diameter of less than 7 μm, or if greater than 8 wt. % of the fine kaolin source then using a slow ramp rate during firing, with processing aids and optionally a pore forming agent to form a plasticized mixture,
• forming the plasticized mixture into a honeycomb structure, and
• firing the honeycomb structure to form the porous ceramic cordierite honeycomb article having a porosity <54% wherein if greater than 8 wt. % fine kaolin source is used, then the slow ramp rate includes a heating rate from 1200 to 1300° C. of not more than 20° C./hr, and
• wherein the porous ceramic cordierite honeycomb article comprises d90≦33 μm.