# US 7,744,669 B2 · Plugging material for aluminum titanate ceramic wall flow filter manufacture

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- Number: US 7,744,669 B2
- Document ID: US7744669B2
- Status: Granted
- Kind: B2
- Application number: 11/486,699
- Filed: 2006-07-14
- Published: 2008-01-17
- Granted: 2010-06-29
- Earliest claimed: 2006-07-14
- Assignees: Corning Incorporated
- Inventors: Robert John Paisley; Patrick David Tepesch
- Web page: https://patentgrep.com/patent/US7744669B2

## CPC

- C04B 35/478: based on aluminium titanates
- C04B 35/6263: {characterised by their solids loadings, i.e. the percentage of solids}
- C04B 35/6303: {Inorganic additives}
- C04B 38/0012: {characterised by the material used for sealing or plugging (some of) the channels of the honeycombs}
- B01D 2279/30: for treatment of exhaust gases from IC Engines
- C04B 2111/00793: {as filters or diaphragms}
- C04B 2235/3206: Magnesium oxides or oxide-forming salts thereof
- C04B 2235/3208: Calcium oxide or oxide-forming salts thereof, e.g. lime
- C04B 2235/3213: Strontium oxides or oxide-forming salts thereof
- C04B 2235/3215: Barium oxides or oxide-forming salts thereof
- C04B 2235/3218: Aluminium (oxy)hydroxides, e.g. boehmite, gibbsite, alumina sol
- C04B 2235/322: Transition aluminas, e.g. delta or gamma aluminas
- C04B 2235/3224: Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
- C04B 2235/3225: Yttrium oxide or oxide-forming salts thereof
- C04B 2235/3227: Lanthanum oxide or oxide-forming salts thereof
- C04B 2235/3231: Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
- C04B 2235/3232: Titanium oxides or titanates, e.g. rutile or anatase
- C04B 2235/3258: Tungsten oxides, tungstates, or oxide-forming salts thereof
- C04B 2235/3272: Iron oxides or oxide forming salts thereof, e.g. hematite, magnetite
- C04B 2235/3284: Zinc oxides, zincates, cadmium oxides, cadmiates, mercury oxides, mercurates or oxide forming salts thereof
- C04B 2235/3298: Bismuth oxides, bismuthates or oxide forming salts thereof, e.g. zinc bismuthate
- C04B 2235/3418: Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
- C04B 2235/349: Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
- C04B 2235/425: Graphite
- C04B 2235/5436: micrometer sized, i.e. from 1 to 100 micron
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)

## Abstract

Disclosed are plugging mixtures for a ceramic wall flow filter, comprising an aluminum titanate precursor reactive batch composition including an alumina source, a silica source, and a titania source; a sintering aid; an organic binder; and a liquid vehicle. Also disclosed are ceramic wall flow filters comprised of end plugs formed from the plugging mixtures of the present invention and methods for the manufacture thereof.

## Claims

### Claim 1

A method for manufacturing a porous ceramic wall flow filter having a ceramic honeycomb structure and a plurality of channels bounded by porous ceramic walls, with selected channels each incorporating a plug sealed to the channel wall, comprising the steps of:
providing a fired honeycomb structure having a plurality of channels bounded by parallel walls, wherein the honeycomb structure was formed from a first aluminum titanate batch composition and fired at a peak firing temperature in the range of 1350° C. to 1500° C.,
selectively plugging at least one predetermined channel with a plugging mixture comprising an aluminum titanate batch composition different from the first aluminum titanate batch composition of the fired honeycomb structure; a sintering aid; an organic binder; and a liquid vehicle; to form a selectively plugged honeycomb structure; and
firing the selectively plugged honeycomb structure under conditions effective to fire the plugging mixture and form a fired plug in the at least one selectively plugged channel, wherein the conditions effective to fire the plugging mixture comprise firing at a temperature at least about 50° C. lower than the peak firing temperature.

### Claim 2 (depends on 1)

The method of claim 1, wherein the fired honeycomb structure is a fired aluminum titanate ceramic honeycomb structure.

### Claim 3 (depends on 1)

The method of claim 1, wherein the conditions effective to fire the plugging mixture are effective to convert the plugging mixture into an aluminum titanate ceramic composition.

### Claim 4 (depends on 1)

The method of claim 1, wherein the conditions effective to fire the plugging mixture further comprise firing the selectively plugged honeycomb structure at a maximum firing temperature in the range of from 1350° C. to 1500° C.

### Claim 5 (depends on 1)

The method of claim 1, wherein the conditions effective to fire the plugging mixture further comprise firing the selectively plugged honeycomb structure at a maximum firing temperature in the range of from 1375° C. to 1425° C.