Ceramic structures having hydrophobic coatings
AssigneeCorning Incorporated
InventorsMax P. Bliss, Dana C. Bookbinder, Robert J. Paisley, Christopher J. Warren
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Abstract
Provided is a catalyst support structure for use as either a NOx catalyst support or as a DPF having a hydrophobic coating. The hydrophobic coating affords a catalyst support structure exhibiting reduced or low absorption when exposed to both liquid catalytic coating or other aqueous media and thus protecting the catalyst support structure from cracking and spalling during drying. Methods are also provided for making a catalyst support structure with a hydrophobic coating.
Claims14
A catalyst support structure comprising a multicellular ceramic-body which includes:
- (i) an external skin portion,
- (ii) a hydrophobic coating, the hydrophobic coating resulting in a coated ceramic body exhibiting a low absorption of liquid catalytic coating mixtures and aqueous media utilized in application of the liquid catalytic coating mixtures, wherein the hydrophobic coating is formed directly on the external skin portion of the ceramic body, and
- (ii) a catalytic coating on the hydrophobic coating.
A method of producing a coated catalyst support structure having an external hydrophobic coating, the method comprising:
- a. providing a fired multicellular ceramic body;
- b. applying an external skin coating to the fired multicellular ceramic body;
- c. applying a hydrophobic passivating coating to the external skin coating and/or to the entire coated multicellular ceramic body;
- d. applying a catalyst coating to the coated multicellular ceramic body;
- e. drying the catalyst-coated multicellular ceramic body;
- and
- f. calcining the dried catalyst coated multicellular ceramic body.
Dependencies are inferred from the claim text.