Honeycomb body having layered plugs and method of making the same

Patent metadata

Field	Value
Publication number	US-11459924-B2
Application number	US-201515508791-A
Country	US
Kind code	B2
Filing date	Sep 2, 2015
Priority date	Sep 3, 2014
Publication date	Oct 4, 2022
Grant date	Oct 4, 2022

Abstract

A porous ceramic honeycomb body (10) including intersecting walls that form channels (22) extending axially from a first end face to a second end face and layered plugs (62) comprised of a first layer (64) disposed on channel walls and a second layer (66) disposed inward toward an axial center of each respective channel on the first layer. The plugs seal at least one of a first portion of the channels at the first end face and a second portion of channels at the second end face of the porous ceramic honeycomb body.

First claim

What is claimed is:

1. A porous ceramic honeycomb body, comprising:
intersecting walls that form channels extending axially from a first end face to a second end face; and
plugs to seal at least one of a first portion of the channels at the first end face and a second portion of the channels at the second end face, the plugs comprising:
a first layer disposed on the walls of respective channels, and a second layer disposed inward toward a central axis of each respective channel on the first layer, such that the first layer peripherally surrounds the second layer and spaces the second layer away from contact with the intersecting walls,
wherein the first layer has a tip portion positioned distalmost from the respective end face and extending across each respective channel, the tip portion covering an axial end of the second layer.

2. The porous ceramic honeycomb body of claim 1 , wherein the first layer comprises a first composition and the second layer comprises a second composition.

3. The porous ceramic honeycomb body of claim 2 , wherein the second composition is different from the first composition.

4. The porous ceramic honeycomb body of claim 3 , wherein:
the first composition comprises a first dispersion of silica particles and a first inorganic particle component,
the second composition comprises a second dispersion of silica particles and a second inorganic particle component,
wherein the first inorganic particle component comprises an average particle size less than the second inorganic particle component, and
wherein the first dispersion of silica comprises a first average particle size smaller than a second average particle size of the second dispersion of silica particles.

5. The porous ceramic honeycomb body of claim 4 , wherein the first dispersion of silica particles comprises a multimodal particle size distribution.

6. The porous ceramic honeycomb body of claim 2 , wherein the first composition comprises a first colloidal silica composition that is gelled and the second composition comprises a second colloidal silica composition that is not gelled.

7. The porous ceramic honeycomb body of claim 2 , wherein the first composition comprises a transitory component capable of removal through at least one of thermal treatment and chemical treatment.

8. The porous ceramic honeycomb body of claim 1 , wherein at least one of the first layer and the second layer comprises a catalytically active component or a chemically active component of the plug structure.

9. The porous ceramic honeycomb body of claim 8 , wherein the catalytically active component is catalytically active in a NOx reducing reaction and the chemically active component is chemically active in hydrocarbon reduction reaction.

10. The porous ceramic honeycomb body of claim 1 , wherein the first layer comprises a first property and the second layer comprises a second property different from the first property.

11. The porous ceramic honeycomb body of claim 1 , wherein the first layer comprises a first porosity and the second layer comprises a second porosity different from the first porosity.

12. The porous ceramic honeycomb body of claim 1 , wherein the first layer comprises a first coefficient of thermal expansion protection (CP 1 ) and the second layer comprises a second coefficient of thermal expansion protection (CP 2 ) different from the first coefficient of thermal expansion protection (CP 1 ),
wherein the walls comprise a coefficient of thermal expansion (CTE 3 ) that increases locally when at least one of the first layer and the second layer is disposed thereon.

13. The porous ceramic honeycomb body of claim 12 , wherein CP 2 <CP 1 , wherein greater coefficient of thermal expansion protection refers to a smaller increase in the wall CTE 3 .

14. The porous ceramic honeycomb body of claim 1 , wherein the second layer comprises more than one layer, the more than one layers disposed inwardly toward the central axis of the respective channel from the preceding layer.

15. The porous ceramic honeycomb body of claim 1 , wherein the plugs are disposed in the respective channels spaced apart from the respective end face.

16. The porous ceramic honeycomb body of claim 1 , wherein the first layer and the second layer are exposed at respective axial ends thereof positioned proximalmost to the respective end face.

17. A method of plugging a porous ceramic honeycomb body comprising intersecting walls that form channels extending axially from a first end face to a second end face, the method comprising:
disposing a first layer patty on a second layer patty;
disposing the second layer patty on a support;
pressing the support and the porous ceramic honeycomb body together in an axial direction a predetermined distance to inject the first layer and the second layer in at least one of a first portion of the channels at the first end face and a second portion of the channels at the second end face to form plugs to seal the at least one of the first portion of the channels at the first end face and the second portion of the channels at the second end face, the plugs comprising a first layer of the first layer patty composition disposed on the walls of respective channels, and a second layer of the second layer patty composition disposed inward toward a central axis of each respective channel on the first layer, such that the first layer peripherally surrounds the second layer and spaces the second layer away from contact with the intersecting walls, wherein the first layer has a tip portion positioned distalmost from the respective end face and extending across each respective channel, the tip portion covering an axial end of the second layer.

18. The method of plugging a porous ceramic honeycomb body of claim 17 , further comprising disposing a mask on at least one of the first end face and the second end face prior to pressing the support and the porous ceramic honeycomb body together.

19. The method of plugging a porous ceramic honeycomb body of claim 18 , further comprising sealing the support and the mask forming a reservoir containing the first layer patty on the second layer patty prior to pressing the support and the porous ceramic honeycomb body together.

20. The method of plugging a porous ceramic honeycomb body of claim 17 , further comprising:
retracting the support and the porous ceramic honeycomb body; and
passing a parting member between the support and the at least one of the first end face and the second end face.

21. The method of plugging a porous ceramic honeycomb body of claim 17 , wherein
disposing a first layer patty on a second layer patty further comprises forming the second layer patty by disposing at least one additional layer patty on a third layer patty.

22. The method of plugging a porous ceramic honeycomb body of claim 17 , wherein the first layer patty comprises a first composition and the second layer patty comprises a second composition.

Assignees

• Corning Inc

Inventors

• Bubb Keith Norman
• Chapman Thomas Richard
• Drury Kenneth Joseph
• St Clair Todd Parrish
• Warren Courtney Spencer

Classifications

• C04B2235/3873

  Silicon nitrides, e.g. silicon carbonitride, silicon oxynitride · CPC title

• F01N2330/06

  Ceramic, e.g. monoliths · CPC title

• Y02T10/12

  Improving ICE efficiencies · CPC title

• C04B2235/3236

  Alkaline earth titanates · CPC title

• B01D46/2474

  of the walls along the length of the honeycomb · CPC title