High porosity cordierite honeycomb articles
AssigneeCorning Incorporated
InventorWilliam Peter Addiego
Life of this patent
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Abstract
Methods of making a porous cordierite ceramic honeycomb article are provided. In example methods, a batch composition includes a quantity of non-crosslinked pore former provided as a superaddition of about 20% or less of a dry weight of a quantity of inorganic components. Batch compositions are also provided that include a quantity of clay and other substantially nonfibrous inorganic components sufficient to yield an article including cordierite. Example batch compositions can include clay having a median particle size of about 7 μm or less and/or provided in an amount that is 10% or less of the dry weight of the quantity of inorganic components.
Claims13
A method of making a porous cordierite ceramic honeycomb article, comprising the steps of:
- providing a batch composition including a quantity of noncrosslinked pore former and a quantity of substantially nonfibrous inorganic components, wherein the quantity of pore former comprises a superaddition of about 20% or less of a dry weight of the quantity of inorganic components;
- forming the batch composition into a green body;
- and
- firing the green body to produce a porous ceramic honeycomb article including cordierite, wherein the porous ceramic honeycomb article includes a porosity of at least 50% with pores including a median pore size of less than about 12 μm;
- wherein the quantity of substantially nonfibrous inorganic components comprises relatively coarse silica and relatively fine silica;
- wherein the relatively coarse silica comprises silica having 95% of particles with sizes less than about 75 μm and with a median particle size of about 35 μm or less;
- and
- wherein the relatively fine silica comprises silica having 95% of particles with sizes less than about 40 μm and with a median particle size of about 15 μm or less.
Dependencies are inferred from the claim text.