Ceramic body, ceramic catalyst body and related manufacturing methods

A ceramic body for use in a fluid stream, comprising:

• a porous base material composed of a constituent element;
• and
• acicular particles formed on a surface of the porous base material and composed of a component different from the constituent element of the porous base material, wherein:
• the porous base material has a porosity equal to or greater than 30%.

A ceramic body for use in a fluid stream, comprising:

• a porous base material composed of a constituent element;
• and
• acicular particles formed on a surface of the porous base material and composed of a component different from the constituent element of the porous base material, wherein:
• the acicular particles have an aspect ratio equal to or greater than 5.

A ceramic body for use in a fluid stream, comprising:

• a porous base material composed of a constituent element;
• and
• acicular particles formed on a surface of the porous base material and composed of a component different from the constituent element of the porous base material, wherein:
• the ceramic body has a specific surface area equal to or greater than 1 m2/g.

A method of manufacturing a ceramic body, comprising the steps of:

• preparing a slurry containing acicular particle source material;
• preparing a porous base material;
• applying the slurry onto a surface of the porous base material;
• firing the porous base material, whose surface is coated with the slurry, to cause acicular particles to develop on the surface of the porous base material;
• and
• covering a part of or a whole of surfaces of the acicular particles with a constituent element different from that of the acicular particles.

A ceramic body for use in an exhaust gas purifying catalyst or a filter, comprising:

• a cordierite porous body made of a cordierite;
• and
• acicular particles formed on a surface of the cordierite porous body and composed of a component different from the cordierite, wherein:
• the acicular particles have surfaces partly or entirely formed with coated layers.

A ceramic body for use in an exhaust gas purifying catalyst or a filter, comprising:

• a cordierite porous body made of a cordierite;
• and
• acicular particles formed on a surface of the cordierite porous body and composed of a component different from the cordierite, wherein:
• the cordierite porous body has a porosity equal to or greater than 30%.

A ceramic body for use in an exhaust gas purifying catalyst or a filter, comprising:

• a cordierite porous body made of a cordierite;
• and
• acicular particles formed on a surface of the cordierite porous body and composed of a component different from the cordierite, wherein:
• the acicular particles have an aspect ratio equal to or greater than 5.

A ceramic body for use in an exhaust gas purifying catalyst or a filter, comprising:

• a cordierite porous body made of a cordierite;
• and
• acicular particles formed on a surface of the cordierite porous body and composed of a component different from the cordierite, wherein:
• the ceramic body has a specific surface area equal to or greater than 1 m2/g.

A ceramic catalyst body for use as an exhaust gas purifying catalyst, comprising:

• a cordierite honeycomb structural body composed of a porous body made of a cordierite;
• and
• polycrystalline acicular mullite particles, formed on a surface of the cordierite porous body, each of which has an unleveled pattern and supports thereon a catalyst, wherein:
• the acicular mullite particles have surfaces partly or entirely formed with coated layers.

A ceramic catalyst body for use as an exhaust gas purifying catalyst, comprising:

• a cordierite honeycomb structural body composed of a porous body made of a cordierite;
• and
• polycrystalline acicular mullite particles, formed on a surface of the cordierite porous body, each of which has an unleveled pattern and supports thereon a catalyst, wherein:
• the porous body has a porosity equal to or greater than 30%.

A ceramic catalyst body for use as an exhaust gas purifying catalyst, comprising:

• a cordierite honeycomb structural body composed of a porous body made of a cordierite;
• and
• polycrystalline acicular mullite particles, formed on a surface of the cordierite porous body, each of which has an unleveled pattern and supports thereon a catalyst, wherein:
• the polycrystalline acicular mullite particles have an aspect ratio equal to or greater than 5.

A ceramic catalyst body for use as an exhaust gas purifying catalyst, comprising:

• a cordierite honeycomb structural body composed of a porous body made of a cordierite;
• and
• polycrystalline acicular mullite particles, formed on a surface of the cordierite porous body, each of which has an unleveled pattern and supports thereon a catalyst, wherein:
• the ceramic catalyst body has a specific surface area equal to or greater than 1 m2/g.

A method of manufacturing a ceramic catalyst body, comprising the steps of:

• preparing a slurry composed of a solution dispersed with acicular mullite particles;
• preparing a cordierite porous base material;
• applying the slurry onto a surface of the cordierite porous base material;
• firing the cordierite porous base material, whose surface is coated with the slurry, to cause acicular mullite particles to develop on the surface of the cordierite porous base material for thereby providing a catalyst carrier having a surface formed with the acicular mullite particles;
• applying a part of or a whole of surfaces of the acicular mullite particles with a component different from the acicular mullite particles;
• and
• supporting a catalyst on the catalyst carrier.