Porous cordierite ceramic honeycomb article with improved strength and method of manufacturing same

US7520911B2 · kind B2 · utility

Assignee

• CORNING INCORPORATED · US

Inventors

• Douglas Munroe Beall · Corning, US
• Gregory Albert Merkel · Corning, US
• David J. Thompson · Oak Grove, US

Key dates

• Filing date: Nov 30, 2005
• Grant date: Apr 21, 2009
• Expiry date: Apr 27, 2027

Classification

• Technology area (CPC Y): Emerging Cross-Sectional Technologies
• CPC primary: Y10T428/24149
• WIPO field: Chemical engineering
• WIPO sector: Chemistry

Abstract

A porous cordierite ceramic honeycomb article with increased mechanical strength and thermal shock resistance. The porous cordierite ceramic honeycomb article has MA<2220, or MT>2660 whereinMA=3645(IA)−106(CTE)+19(d90)+17(% porosity),MT=4711(IT)+116(CTE)−26(d90)−28(% porosity),and a CTE≦9×10−7/° C. in at least one direction. A method of manufacturing is also disclosed wherein the inorganic raw material mixture contains talc, an alumina-forming source, a silica-forming source, and 0-18 wt. % of a kaolin or calcined kaolin containing not more than 8 wt. % of a fine kaolin source having a median particle diameter of less than 7 μm, wherein the fired porous ceramic cordierite honeycomb article has a porosity<54% . Alternatively, if greater than 8 wt. % of the fine kaolin source is used, then a slow ramp rate is utilized from 1200° C. to 1300° C. of not more than 20° C./hr.