Low-microcracked, porous ceramic honeycombs and methods of manufacturing same
AssigneeCorning Incorporated
InventorsDouglas Munroe Beall, Isabelle Marie Melscoet-Chauvel, Gregory Albert Merkel, Tinghong Tao, David John Thompson
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Abstract
Substantially non-microcracked, porous, cordierite ceramic honeycomb bodies are provided. Although exhibiting moderately high thermal expansion (CTE) between 7×10−7 to 16×10−7/° C. (25-800° C.), the honeycomb bodies exhibit relatively high thermal shock parameter (TSP), such as TSR≧525° C. by virtue of a high MOR/E ratio, and/or low Eratio=ERT/E1000° C. and well interconnected porosity, as witnessed by a relatively high pore connectivity factor (PCF). A method of manufacturing the honeycomb ceramic structure is also provided.
Claims22
A porous ceramic honeycomb structure, comprising:
- a primary cordierite ceramic phase exhibiting low microcracking and cordierite crystallite orientation and having a room temperature elastic modulus (ERT), room temperature modulus of rupture strength (MORRT), and high temperature (500-900° C.) thermal expansion coefficient (CTEH) such that a thermal shock parameter (TSP) of the structure calculated as:
- TSP=MORRT/[ERT][CTEH]
- is at least 400° C.;
- CTE (25-800° C.)≦15×10−7/° C.;
- a total porosity ≧46%;
- and
- wherein low microcracking is characterized by an Eratio≦1.05, wherein Eratio=EH/ERT and (EH) is a high temperature (1000° C.) elastic modulus.
Dependencies are inferred from the claim text.