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US 7,842,371 B2Granted
Washcoat loaded porous ceramics with low backpressure
AssigneeCorning Incorporated
InventorsEric Jean Paul Francois, Guillaume Guzman, Maxime Moreno, Christophe Michel Remy
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Abstract
Disclosed are washcoated ceramic honeycomb filters. The ceramic filters exhibit a relatively high level of washcoat loading while exhibiting minimized levels of backpressure. Also disclosed are methods for manufacturing the washcoated ceramic honeycomb filters. The method comprises providing an cell geometry derived from a predetermined level of washcoat loading to be applied to the ceramic honeycomb article.
Claims17
A porous ceramic article, comprising:
- a honeycomb ceramic structure defining a plurality of cell channels bounded by porous cell channel walls having a porosity % P that extend longitudinally from an upstream inlet end to a downstream outlet end, wherein the plurality of cell channels are present in a cell channel density of “X” cells per square inch;
- and
- a catalyst containing washcoat applied to the porous cell channel walls in a washcoat loading amount “WC” of at least 40 g/l such that the washcoat loading amount “WC” satisfies the relationships of:
- X1=5.95·10−3×WC2+2.44×WC−36.8, and
- X2=−1.46·10−2×WC2+3.89×WC+255,
- wherein X1≦X≦X2;
- wherein the porous cell channel walls have a wall thickness of “Y” that satisfies the relationship Y1≦Y≦Y2;
- wherein Y1=(A·X2)+(B·X)+C,
- wherein Y2=(D·X2)+(E·X)+F;
- wherein:
- A
- =
- 1.10
- ·
- 10
- -
- 12
- ×
- WC
- 4
- -
- 4.25
- ·
- 10
- -
- 10
- ×
- WC
- 3
- +
- 5.92
- ·
- 10
- -
- 8
- ×
- WC
- 2
- -
- 3.23
- ·
- 10
- -
- 6
- ×
- WC
- +
- 1.38
- ·
- 10
- -
- 4
- ;
- B
- =
- -
- 3.95
- ·
- 10
- -
- 10
- ×
- WC
- 4
- +
- 1.4
- ·
- 10
- -
- 7
- ×
- WC
- 3
- -
- 1.89
- ·
- 10
- -
- 5
- ×
- WC
- 2
- +
- 6.32
- ·
- 10
- -
- 4
- ×
- WC
- -
- 5.60
- ·
- 10
- -
- 2
- ;
- C
- =
- 4.18
- ·
- 10
- -
- 6
- ×
- WC
- 3
- -
- 6.11
- ·
- 10
- -
- 4
- ×
- WC
- 2
- +
- 2.08
- ·
- 10
- -
- 1
- ×
- WC
- +
- 3.74
- ;
- D
- =
- -
- 1.04
- ·
- 10
- -
- 12
- ×
- WC
- 4
- +
- 3.94
- ·
- 10
- -
- 10
- ×
- WC
- 3
- -
- 5.33
- ·
- 10
- -
- 8
- ×
- WC
- 2
- +
- 2.83
- ·
- 10
- -
- 6
- ×
- WC
- -
- 1.31
- ·
- 10
- -
- 4
- ;
- E
- =
- 3.97
- ·
- 10
- -
- 10
- ×
- WC
- 4
- -
- 1.41
- ·
- 10
- -
- 7
- ×
- WC
- 3
- +
- 1.65
- ·
- 10
- -
- 5
- ×
- WC
- 2
- -
- 4.63
- ·
- 10
- -
- 4
- ×
- WC
- +
- 1.68
- ·
- 10
- -
- 2
- ;
- and
- F
- =
- -
- 4.65
- ·
- 10
- -
- 8
- ×
- WC
- 4
- +
- 1.65
- ·
- 10
- -
- 5
- ×
- WC
- 3
- -
- 1.75
- ·
- 10
- -
- 3
- ×
- WC
- 2
- +
- 8.98
- ·
- 10
- -
- 2
- ×
- WC
- +
- 8.56
- ;
- and
- wherein % P is in the range of from 40% to 80%.
254 more elements
Dependencies are inferred from the claim text.