Porous ceramic processing using a co-prilled wax and non-ionic surfactant mixture
AssigneeCorning Incorporated
InventorsMichele Fredholm, David Henry, Maxime Moreno
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Abstract
This disclosure is directed to porous ceramic processing; and in particular to a method using selected pore forming materials to avoid high exotherms during the ceramic firing process, and the green bodies formed using the selected pore forming materials. The selected pore forming materials are homogeneous wax/non-ionic surfactant particles formed by a prilling process in which the wax is melted and the non-ionic surfactant is mixed into the wax prior to prilling. The disclosure is useful in the manufacture porous ceramic honeycomb bodies including ceramic honeycomb filter traps.
Claims5
A method for preparing a ceramic body, comprising the steps of:
- providing a ceramic forming batch composition;
- providing a binder material, a liquid and a solid particulate pore former comprising a selected water dispersible wax/non-ionic surfactant material;
- mixing the batch composition with the binder material, the liquid and the pore former to form a plasticized extrudable paste;
- extruding the paste to form an extruded pre-ceramic green body;
- and
- drying the green body to form a dried pre-ceramic green body;
- and
- firing the dried pre-ceramic body to form a ceramic body:
- wherein the water dispersible wax/non-ionic surfactant material is a co-prilled material formed from:
- a wax is selected from the group consisting of natural paraffin waxes, beeswax, polyethylene glycol waxes, polypropylene glycol waxes and waxes made from a combination polyethylene glycol and polypropylene glycol, chemically modified waxes, substituted amide waxes, polymerized α-olefin waxes including combinations of α-olefins, and combinations thereof, and
- a non-ionic surfactant is selected from the group consisting of ethoxylated nonylphenols, ethoxylated octylphenols, PEO-PPO-copolymers, polyoxyethylene sorbitan monooleate, dodecylphenol ethoxylate, dinonylphenol ethoxylate, linear and branched alcohol ethoxylates, tallow amine ethoxylate and combinations thereof.
Dependencies are inferred from the claim text.