Methods of making plugged honeycomb bodies with cement patties

Patent metadata

Field	Value
Publication number	US-12145892-B2
Application number	US-201917296399-A
Country	US
Kind code	B2
Filing date	Nov 15, 2019
Priority date	Nov 30, 2018
Publication date	Nov 19, 2024
Grant date	Nov 19, 2024

Abstract

A method of plugging a honeycomb body includes mixing a plugging mixture at a mixing temperature, wherein the plugging mixture comprises a plurality of inorganic particles, inorganic binder, organic binder, and water; dispensing the plugging mixture into a patty mold at a dispensing temperature; cooling the plugging mixture within the patty mold to a cooled temperature, such that a cement patty is formed; and pressing the cement patty into a plurality of channels in a honeycomb body, wherein the mixing temperature and the dispensing temperature are above a hydration point temperature of the organic binder in the plugging mixture, and the cooled temperature is below the hydration point temperature of the organic binder in the plugging mixture.

First claim

What is claimed is:

1. A method of forming a plugging cement patty, comprising:
mixing a plurality of inorganic particles, an inorganic binder, an organic binder, and a liquid at a mixing temperature greater than a hydration point temperature of the organic binder to form a plugging mixture comprising a viscosity in a range from about 1 cP to about 100 cP;
dispensing the plugging mixture at a dispensing temperature greater than the hydration point temperature; and
cooling the plugging mixture to a cooled temperature less than the hydration point temperature to increase the viscosity of the plugging mixture and form the plugging cement patty.

2. The method of claim 1 , wherein a viscosity of the plugging mixture at the cooled temperature is from about 1,500,000 cP to about 10,000,000 cP.

3. The method of claim 1 , wherein a viscosity of the plugging mixture at the cooled temperature is from about 3,000,000 cP to about 5,000,000 cP.

4. The method of claim 1 , wherein the organic binder comprises methylcellulose.

5. The method of claim 4 , wherein the plurality of inorganic particles comprises cordierite.

6. The method of claim 5 , wherein the inorganic binder comprises colloidal silica.

7. The method of claim 1 , wherein the mixing comprises subjecting the plugging mixture to a pressure less than 1 atmosphere during the mixing.

8. The method of claim 1 , wherein the mixing comprises bringing the liquid to the mixing temperature prior to mixing the plurality of inorganic particles, the inorganic binder, and the organic binder with the liquid.

9. A method of forming a plugging cement patty for plugging a honeycomb body, comprising the steps of:
mixing a plugging mixture comprising cordierite, colloidal silica, organic binder, and water at a mixing temperature greater than a hydration point temperature of the organic binder such that a viscosity of the plugging mixture at the mixing temperature is in a range from about 1 cP to about 100 cP;
dispensing the plugging mixture into a patty mold at a dispensing temperature greater than the hydration point temperature of the organic binder such that the viscosity of the plugging mixture at the dispensing temperature is in the range from about 1 cP to about 100 cP; and
cooling the plugging mixture within the patty mold to a cooled temperature less than the hydration point temperature of the organic binder to increase a viscosity of the plugging mixture and form the plugging cement patty.

10. The method of claim 9 , wherein a weight percentage of the organic binder as a super addition relative to a combined total weight of the cordierite in the plugging mixture is from about 0.5 wt. % to about 6 wt. %.

11. The method of claim 9 , wherein the weight percentage of the organic binder as a super addition relative to the combined total weight of the cordierite in the plugging mixture is from about 0.75 wt. % to about 3.0 wt. %.

12. The method of claim 9 , wherein the weight percentage of the organic binder as a super addition relative to the combined total weight of the cordierite in the plugging mixture is about 1.5 wt. %.

13. The method of claim 9 , wherein the organic binder comprises methylcellulose.

14. The method of claim 9 , wherein the step of cooling the plugging mixture to the cooled temperature further comprises the step of subjecting the plugging mixture to a cooling bath having a temperature below the cooled temperature.

15. The method of claim 9 , wherein a viscosity of the plugging mixture at the cooled temperature is from about 3,000,000 cP to about 5,000,000 cP.

16. A method of plugging a honeycomb body comprising the steps of:
mixing a plugging mixture comprising a plurality of inorganic particles, an inorganic binder, an organic binder, and water at a mixing temperature greater than a hydration point temperature of the organic binder such that a viscosity of the plugging mixture is in a range from about 1 cP to about 100 cP;
dispensing the plugging mixture into a patty mold at a dispensing temperature greater than the hydration point temperature of the organic binder;
cooling the plugging mixture within the patty mold to a cooled temperature below the hydration point temperature to increase a viscosity of the plugging mixture and form a plugging cement patty, the cooling comprising cooling the patty mold to the cooled temperature prior to the dispensing; and
pressing the plugging cement patty into a plurality of channels in the honeycomb body.

17. The method of claim 16 , wherein the hydration point temperature of the organic binder in the plugging mixture is from about 20° C. to about 100° C.

18. The method of claim 16 , wherein the hydration point temperature of the organic binder in the plugging mixture is from about 25° C. to about 60° C.

19. The method of claim 16 , wherein the organic binder comprises methylcellulose.

Assignees

• Corning Inc

Inventors

• Bubb Keith Norman

Classifications

• C04B38/0012

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

• C04B28/24

  containing alkyl, ammonium or metal silicates; containing silica sols {(reaction mixtures resulting in mineral polymers C04B28/006; polymeric reaction products of alkali metal silicates with isocyanates C08G18/3895)} · CPC title

• C04B26/285

  Cellulose or derivatives thereof (C04B26/24 takes precedence) · CPC title

• C04B14/303

  Alumina · CPC title

• B28B11/006

  Making hollow articles or partly closed articles · CPC title