Ceramic Honeycomb Plug Cement for Water-Resistant Channel Sealing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional methods for plugging ceramic honeycomb channels involve organic binders that decompose at high temperatures or release soluble materials into treatment solutions, limiting their effectiveness.

Innovation Solution

A cement composition comprising inorganic particles, an inorganic binder, an organic binder, and a crosslinking agent that reacts with both, allowing for plugging without high-temperature firing and reducing material release into treatment solutions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional organic binder plug materials are used in green honeycomb bodies, then the plugging process is simple, but the organic binder decomposes at high temperatures greater than 400°C and reduces plug effectiveness

Engineering Contradiction:

Improveplugging process simplicityVSAvoidplug effectiveness

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention changes the chemical composition parameters of the plug material by using inorganic binders (alumina, silica, magnesia) instead of organic binders, and by incorporating specific inorganic particles with controlled size distributions. This parameter change allows the plug to withstand high firing temperatures without decomposition, resolving the contradiction between manufacturing simplicity and plug effectiveness at high temperatures.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite plug material comprising multiple inorganic components (inorganic binder, inorganic particles, and optional organic binder in controlled amounts) that combines the advantages of high-temperature stability with adequate binding properties. This composite structure maintains plug integrity during firing while allowing for simple application processes.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional plug materials with water-soluble components are used, then the plugging process is straightforward, but the dried plug material releases material into treatment solutions, limiting solution reuse

Engineering Contradiction:

Improveplugging process straightforwardnessVSAvoidtreatment solution reusability

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The invention changes the chemical composition of the plug material by eliminating water-soluble organic components and using exclusively inorganic binders and particles. This parameter change prevents dissolution and release of plug materials into treatment solutions, allowing for complete solution reuse and resolving the contradiction between manufacturing simplicity and substance loss.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If high-temperature firing is used to cure plug materials, then the plug structure is stable, but the organic binder decomposes and reduces plug effectiveness

Engineering Contradiction:

Improveplug structure stabilityVSAvoidplug effectiveness

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The invention changes the thermal stability parameter by replacing organic binders with inorganic binders that have high decomposition temperatures. The inorganic binder system maintains plug structure stability through sintering and chemical bonding at firing temperatures, while avoiding the decomposition issues of organic materials, thus resolving the contradiction between structural stability and effectiveness.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If organic binders are used in plug materials, then the green body can be easily formed, but the binders decompose at temperatures greater than 400°C

Engineering Contradiction:

Improvegreen body formabilityVSAvoiddecomposition temperature

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The invention changes the thermal property parameter by substituting organic binders with inorganic binders that exhibit stable behavior at high temperatures. The inorganic binder system provides adequate green strength for forming while maintaining integrity through firing temperatures, resolving the contradiction between ease of formation and temperature resistance.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The cement composition forms stable, water-resistant plugs that maintain integrity during treatment processes, enhancing the reuse and uniformity of treatment solutions.

Implementation Method 1

a crosslinking agent, wherein the crosslinking agent is capable of reacting with the inorganic binder and the organic binder

Methodology Applied

Scientific EffectChemical bonding: Chemical Bonding

Implementation Method 2

heating the plugged honeycomb body to evaporate at least a portion of the liquid vehicle from the cement composition to form a plug material

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS12521697B2Cement plug composition for application to a ceramic honeycomb body and method of forming plugged ceramic honeycomb body with the same

Publication Date: 2026.01.13 CORNING INC

AI summary

A cement composition for plugging a honeycomb body, a plugged honeycomb body, and methods of plugging a honeycomb body are provided. The cement composition includes a source of inorganic particles, an inorganic binder, an organic binder, and a crosslinking agent that is capable of reacting with the inorganic binder and the organic binder. The cement composition can be dried without firing to form water-resistant plugs in a honeycomb body.