Skinning of ceramic honeycomb bodies

Patent metadata

Field	Value
Publication number	US-11220466-B2
Application number	US-202017071652-A
Country	US
Kind code	B2
Filing date	Oct 15, 2020
Priority date	Mar 18, 2014
Publication date	Jan 11, 2022
Grant date	Jan 11, 2022

Abstract

A ceramic honeycomb body having a skin that does not block partial cells extending from an inlet face to an outlet face at an outer periphery portion of the body. A method of making the ceramic honeycomb body having the skin includes disposing a sheet on an outer peripheral wall of a honeycomb core having an outer surface spaced apart from interiors of the partial cells and skinning the body having the sheet disposed thereon. Subsequent curing in the method bonds the skin to cell walls of the body spaced apart from interiors of the partial cells.

First claim

The invention claimed is:

1. A method of forming a honeycomb body from a honeycomb core that comprises intersecting walls that form cell channels extending from a first end face to a second end face of the honeycomb core, the method comprising:
disposing a filling material on an outer peripheral surface of the honeycomb core to fill peripheral partial cell channels at the outer peripheral surface while outer most portions of the intersecting walls of the peripheral partial cell channels are exposed,
disposing skin batch on the filling material and on the outer most portions of the intersecting walls, wherein the filling material prevents the skin batch from filling the peripheral partial cell channels; and
curing the skin batch to form a cured skin and to bond the cured skin to the outer most portions of the intersecting walls of the honeycomb core to form the honeycomb body, such that the cured skin forms an outer wall of each of the peripheral partial cell channels,
wherein curing the skin batch comprises sacrificing at least a portion of the filling material to open each peripheral partial cell channel from the first end face to the second end face.

2. The method of claim 1 , wherein disposing the filling material on the outer peripheral surface comprises cleaning away at least some of the filling material in order to expose the outer most portions of the intersecting walls.

3. The method of claim 1 , wherein curing the skin batch comprises heating the skin batch.

4. The method of claim 1 , wherein curing the skin batch comprises heating the skin batch to a temperature of at least 50° C.

5. The method of claim 1 , wherein the filling material comprises a material that is a paste at room temperature and volatizes at a temperature suitable for drying, curing, calcining, or firing.

6. The method of claim 1 , wherein the filling material comprises wax or naphthalene.

7. The method of claim 1 , further comprising firing and contouring the honeycomb core prior to disposing the filling material on the outer peripheral surface.

8. The method of claim 1 , wherein disposing the skin batch on the filling material and on the outer most portions of the intersecting walls comprises at least one of doctor blade skinning and axial skinning.

9. The method of claim 1 , wherein the intersecting walls are porous.

10. The method of claim 1 , wherein the cured skin comprises a cold set cement.

11. The method of claim 1 , wherein the cured skin comprises a fired or sintered ceramic.

12. The method of claim 1 , wherein disposing the skin batch on the filling material and on the outer most portions of the intersecting walls comprises disposing multiple layers of skin batch.

13. The method of claim 12 , wherein the multiple layers comprise different compositions.

14. The method of claim 1 , wherein the skin batch comprises an inorganic fibrous reinforcing material.

Assignees

• Corning Inc

Inventors

• Gunasekaran Natarajan
• Patil Mallanagouda Dyamanagouda

Classifications

• B01D46/2444

  of the outer peripheral sealing · CPC title

• C04B41/5089

  Silica sols, alkyl, ammonium or alkali metal silicate cements · CPC title

• C04B38/0006 Primary

  Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083) · CPC title

• Y10T428/24149

  Honeycomb-like · CPC title

• C04B41/81

  Coating or impregnation · CPC title