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Low shrinkage plugging mixture for ceramic filter, plugged honeycomb filter and method of manufacturing same

A mixture and filter technology, applied in membrane filters, ceramic products, chemical instruments and methods, etc., can solve the problems of volume expansion, low net drying shrinkage, etc.

Inactive Publication Date: 2010-03-31
CORNING INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

The non-foaming volume change agent undergoes volume expansion during drying resulting in low net drying shrinkage

Method used

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  • Low shrinkage plugging mixture for ceramic filter, plugged honeycomb filter and method of manufacturing same
  • Low shrinkage plugging mixture for ceramic filter, plugged honeycomb filter and method of manufacturing same
  • Low shrinkage plugging mixture for ceramic filter, plugged honeycomb filter and method of manufacturing same

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0084] Example 1: Evaluation of potato starch as volume expansion agent

[0085] Two exemplary cordierite-based plugging mixtures of the present invention were prepared containing potato starch as the volume change agent, and these mixtures were compared with conventional cordierite plugging binders containing graphite pore formers instead of potato starch volume change agents Compare and evaluate. Table 1 below shows the specific formulations used for the various plugging mixtures:

[0086] Table 1

[0087] components MPS comparative example Invention example Invention example

[0088] (μm) A 1 2

[0089] Inorganic components wt% wt% wt%

[0090] Talc 23.5 40.7 40.7 40.7

[0091] Alumina A 3.4 14.8 --- ---

[0092] Alumina B 6.8 --- 14.8 14.8

[0093] Kaolin 3.2 16.0 16.0 16.0

[0094] Hydrated alumina A 4.6 16.0 --- ---

[0095] Hydrated alumina B 9.0 --- 16.00 16.00

[0096] Silica 26.2 12.5 12.5 12.5

[0097] Total inorganic components 100.0 1...

Embodiment 2

[0122] Example 2: Evaluation of microspheres as volume expansion agents

[0123] Four exemplary cordierite-based plugging binder mixtures of the present invention were prepared containing various levels of Microspheres as non-foaming volume change agents were evaluated in comparison to conventional cordierite plugging binders using graphite porogens instead of microsphere volume change agents. Table 3 below shows the specific formulations used for the various plugging mixtures:

[0124] Table 3 - Plug Binder Composition

[0125] components MPS comparative example Invention example Invention example Invention example Invention example

[0126] (μm) B 3 4 5 6

[0127] Inorganic components wt% wt% wt% wt% wt%

[0128] Talc 23.5 40.7 40.7 40.7 40.7 40.7

[0129] Alumina 3.4 14.8 14.8 14.8 14.8 14.8

[0130] Kaolin 3.2 16.0 16.0 16.0 16.0 16.0

[0131] Hydrated alumina 4.6 16.0 16.0 16.0 16.0 16.0

[0132] Silica 23.4 12.5 12.5 12.5 12.5 12.5

[0...

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Abstract

Disclosed are plugging mixtures for forming a ceramic honeycomb wall flow filter. The plugging mixtures exhibit a reduced percentage of volumetric shrinkage during the drying process and generally comprise an inorganic ceramic powder batch composition; an organic binder; a liquid vehicle; and a non-foaming volume transformation agent. Also disclosed are methods for forming plugged ceramic wall flow filters from such plugging mixtures and honeycomb articles produced therefrom.

Description

[0001] This application claims priority to US Provisional Application Serial No. 60 / 918,950, filed March 20, 2007, entitled "Low Shrinkage Plugging Compounds for Ceramic Filters, Plugged Honeycomb Filters and Methods of Making Same." field of invention [0002] This invention relates to the preparation of porous ceramic honeycomb structures, and more particularly to improved materials and methods for sealing selected channels of porous ceramic honeycomb to form plugged ceramic honeycomb filters. Background technique [0003] Ceramic wall flow filters are increasingly used to remove particulate matter from exhaust gas streams from diesel or other internal combustion engines. This filter is known as a Diesel Particulate Filter (DPF). A number of methods are known for producing such filters using a honeycomb structure with channels of porous forming ceramics. The most common approach is to place plugs of sealing material in the individual channels of the structure, blocking di...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): C04B38/00C04B35/195B01D46/24C04B35/478F01N3/022C04B111/34
CPCC04B2235/3418C04B38/0012C04B2111/34C04B2103/0051B01D2279/30C04B2235/3218B01D2046/2433B01D46/2455C04B2235/349C04B35/195C04B2235/3217B01D46/244B01D46/2425B01D46/2482C04B35/478C04B38/08C04B38/0655B01D46/2459B01D46/2451B01D46/247
Inventor S·L·查特拉尼L·E·费里I·M·梅尔斯科特-查威尔
Owner CORNING INC
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