Honeycomb filter plugging and apparatus for honeycomb filter plugging

Patent metadata

Field	Value
Publication number	US-10940420-B2
Application number	US-201615577531-A
Country	US
Kind code	B2
Filing date	May 25, 2016
Priority date	May 29, 2015
Publication date	Mar 9, 2021
Grant date	Mar 9, 2021

Abstract

A method for forming a plugged honeycomb article includes feeding a ceramic precursor material through an extrusion die, the extrusion die having a plurality of pins, a plurality of cavities bounded by adjacent pins, and alternating end-faces of the plurality of pins include extensions extending from an outlet of the extrusion die in an extrusion direction. The method further includes extruding the ceramic precursor material through the extrusion die to form a web structure comprising a plurality of cell walls and channels bounded by adjacent cell walls, supporting the web structure that has been extruded through the extrusion die, and providing movement between the extrusion die and the web structure in at least one direction substantially orthogonal to the extrusion direction while the extensions are positioned in at least a portion of the channels.

First claim

What is claimed is:

1. A method for forming a plugged honeycomb article, the method comprising:
feeding a ceramic precursor material through an extrusion die, the extrusion die comprising a plurality of pins, a plurality of cavities bounded by adjacent pins, and alternating end-faces of the plurality of pins comprise extensions extending from an outlet of the extrusion die in an extrusion direction beyond end-faces of pins that do not comprise extensions, wherein the ceramic precursor material is extruded through the plurality of cavities;
extruding the ceramic precursor material through the extrusion die to form a web structure comprising a plurality of cell walls and channels bounded by adjacent cell walls;
supporting the web structure that has been extruded through the extrusion die; and
providing movement between the extrusion die and the web structure in at least one direction substantially orthogonal to the extrusion direction while the extensions are positioned in at least a portion of the channels,
wherein the movement in the orthogonal direction laterally deforms the cell walls so that alternating channels are plugged.

2. The method of claim 1 , wherein the ceramic precursor material is fed through the extrusion die at a rate from greater than or equal to about 5 mm/s to less than or equal to about 255 mm/s.

3. The method of claim 1 , wherein providing movement between the extrusion die and the web structure comprises providing periodic movement between the extrusion die and the web structure as the ceramic precursor material is extruded through the extrusion die such that alternating channels are periodically plugged along a length of the alternating channels.

4. The method of claim 3 , wherein an interval comprising no movement between the extrusion die and the web structure is present between each periodic movement.

5. The method of claim 4 , wherein the interval creates a plugged region having a length from greater than or equal to about 2 mm to less than or equal to about 30 mm.

6. The method of claim 1 , wherein providing movement between the extrusion die and the web structure comprises providing an offset circular motion at a speed of from greater than or equal to about 30 rpm to less than or equal to about 1000 rpm.

7. The method of claim 1 , wherein providing movement between the extrusion die and the web structure comprises holding the web structure stationary and moving the extrusion die laterally relative to the web structure.

8. The method of claim 1 , wherein providing movement between the extrusion die and the web structure comprises holding the extrusion die stationary and moving the web structure laterally relative to the extrusion die.

9. The method of claim 1 , further comprising:
cutting the web structure at an axial location where the cell walls have been plugged and at an axial location where the cell walls have not been plugged, thereby forming a honeycomb article comprising alternating plugged and unplugged channels on a first axial end surface and unplugged channels on a second axial end surface.

10. The method of claim 9 , further comprising:
drying the web structure after the movement has been provided;
dipping the second axial end surface into a plugging material;
drawing the plugging material into a portion of channels that are unplugged at the first axial end surface, thereby plugging alternating channels on the second axial end surface of the honeycomb article;
drying the honeycomb article; and
sintering the honeycomb article to form a ceramic honeycomb article.

11. The method of claim 10 , wherein the plugging material is drawn into a portion of the channels that are unplugged at the first axial end surface by creating a vacuum across the channels that are unplugged at the first axial end surface.

12. The method of claim 10 , wherein the plugging material is drawn into the portion of channels at a depth of from greater than or equal to about 1 mm to less than or equal to about 20 mm.

13. The method of claim 1 , wherein an open frontal area of the plugged honeycomb article is from greater than or equal to about 35% to less than or equal to about 95%.

14. The method of claim 1 , wherein a pressure drop across the plugged honeycomb article is from greater than or equal to about 25 KPa to less than or equal to about 40 KPa.

15. An apparatus for forming a plugged honeycomb article, the apparatus comprising:
an extrusion die, the extrusion die comprising a plurality of pins and a plurality cavities between the plurality of pins, wherein alternating pins of the plurality of pins comprise extensions extending from an outlet of the extrusion die in an extrusion direction, and wherein the alternating pins comprising extensions extend beyond pins that do not comprise extensions in the extrusion direction;
a supporting structure that supports an extrusion of ceramic precursor material exiting the outlet of the extrusion die; and
at least one of the extrusion die and the supporting structure are mechanically coupled to an eccentric system providing movement between the extrusion die and the supporting structure in at least one direction substantially orthogonal to the extrusion direction of the extrusion die.

16. The apparatus of claim 15 , wherein the eccentric system moves the supporting structure relative to the extrusion die.

17. The apparatus of claim 15 , wherein the eccentric system moves the extrusion die relative to the supporting structure.

18. The apparatus of claim 15 , wherein the supporting structure is selected from the group consisting of an air bearing, a set of rollers, and a set of moving belts.

19. The apparatus of claim 15 , wherein the alternating pins comprising extensions extend beyond the pins that do not comprise extensions in the extrusion direction by from greater than or equal to about 2 mm to less than or equal about 10 mm.

Assignees

• Corning Inc

Inventors

• Dannoux Thierry Luc Alain

Classifications

• C04B38/0012 Primary

  characterised by the material used for sealing or plugging (some of) the channels of the honeycombs · CPC title

• B01D46/2484

  Cell density, area or aspect ratio · CPC title

• B01D46/2482

  Thickness, height, width, length or diameter · CPC title

• C04B35/185

  Mullite {3Al2O3-2SiO2} · CPC title

• C04B35/478

  based on aluminium titanates · CPC title