Cement plug composition for application to a ceramic honeycomb body and method of forming plugged ceramic honeycomb body with the same

Patent metadata

Field	Value
Publication number	US-12521697-B2
Application number	US-202117912628-A
Country	US
Kind code	B2
Filing date	Mar 11, 2021
Priority date	Mar 19, 2020
Publication date	Jan 13, 2026
Grant date	Jan 13, 2026

Abstract

A cement composition for plugging a honeycomb body, a plugged honeycomb body, and methods of plugging a honeycomb body are provided. The cement composition includes a source of inorganic particles, an inorganic binder, an organic binder, and a crosslinking agent that is capable of reacting with the inorganic binder and the organic binder. The cement composition can be dried without firing to form water-resistant plugs in a honeycomb body.

First claim

What is claimed is:

1 . A plugged honeycomb body, comprising:
a honeycomb structure comprising a plurality of intersecting porous ceramic walls extending axially between first and second end faces, the ceramic walls defining a plurality of channels; and a plurality of plugs disposed in at least some of the plurality of channels, wherein the plugs are comprised of:
a source of inorganic particles;
an inorganic binder;
an organic binder; and
a crosslinking agent,
wherein the inorganic binder and the organic binder are cross-linked by the crosslinking agent, wherein the crosslinking agent is given by Formula (I):

wherein each of R, R′, and R″ is an aliphatic group, a substituted aliphatic group, an aromatic group, or a substituted aromatic group having a total number of carbon atoms of from 1 to 18, and n is from 1 to 5.

2 . The plugged honeycomb body of claim 1 , wherein the crosslinking agent comprises a formaldehyde derivative.

3 . The plugged honeycomb body of claim 1 , wherein R is an aromatic group or a substituted aromatic group having a total number of carbon atoms of from 3 to 10.

4 . The plugged honeycomb body of claim 1 , wherein each of R′ and R″ is an aliphatic group or a substituted aliphatic group having from 1 to 3 carbon atoms.

5 . The plugged honeycomb body of claim 1 , wherein the crosslinking agent comprises a chemical structure comprising multiple branch chains of methyl ethers and melamine.

6 . The plugged honeycomb structure of claim 1 , wherein the crosslinking agent comprises hexamethoxymethylamine, trimethyloltrimethylmelamine, or hexamethylolmelamine.

7 . The plugged honeycomb body of claim 1 , wherein a ratio of the crosslinking agent to the organic binder is from about 0.5:1 to about 5:1.

8 . The plugged honeycomb body of claim 1 , wherein the source of inorganic particles, the inorganic binder, and the organic binder are cross-linked by the crosslinking agent.

9 . The plugged honeycomb body of claim 1 , wherein a catalyst material is disposed in or on at least a portion of the porous ceramic walls.

10 . The plugged honeycomb body of claim 9 , wherein the catalyst material comprises one or more inorganic components selected from a precious metal, base metal, oxides, and inorganic oxides.

11 . The plugged honeycomb body of claim 9 , wherein the catalyst material comprises one or more organic components selected from octanol, alcohol, isopropyl alcohol, glycol, glycerinum, butyl alcohol, organosilicon, and siloxane.

12 . A method of forming a plugged honeycomb body, the method comprising:
plugging at least a portion of a plurality of channels of a honeycomb structure with a cement composition to form a plugged honeycomb body, the honeycomb structure comprising a plurality of intersecting porous ceramic walls extending axially between first and second end faces, the ceramic walls defining the plurality of channels, the cement composition comprising:
a source of inorganic particles;
an inorganic binder;
an organic binder;
a liquid vehicle; and
a crosslinking agent;
reacting the inorganic binder and the organic binder with the crosslinking agent; and heating the plugged honeycomb body to evaporate at least a portion of the liquid vehicle from the cement composition to form a plug material, wherein the crosslinking agent is given by Formula (I):

wherein each of R, R′, and R″ is an aliphatic group, a substituted aliphatic group, an aromatic group, or a substituted aromatic group having a total number of carbon atoms of from 1 to 18, and n is from 1 to 5.

13 . The method of claim 12 , wherein the crosslinking agent comprises a formaldehyde derivative.

14 . The method of claim 12 , wherein the heating the plugged honeycomb body to evaporate at least a portion of the liquid vehicle comprises heating to a temperature less than a decomposition temperature of the organic binder.

15 . The method of claim 12 , further comprising:
subsequent to heating the plugged honeycomb body, treating the plugged honeycomb body with a catalyst material to deposit the catalyst material at least one of in or on at least a portion of the porous ceramic walls.

16 . The method of claim 12 , wherein a ratio of the crosslinking agent to the organic binder is from about 0.5:1 to about 5:1.

17 . The method of any one of claim 12 , wherein the crosslinking agent comprises hexamethoxymethylamine, trimethyloltrimethylmelamine, or hexamethylolmelamine.

18 . The method of claim 12 , further comprising:
reacting the inorganic particles with the crosslinking agent.

Assignees

• Corning Inc

Inventors

• Hou Weimin
• Li Yang
• Wang Jianguo
• Zhou Qing

Classifications

• B01J21/12 Primary

  Silica and alumina · CPC title

• B01J35/57

  Honeycombs · CPC title

• B01J31/06

  containing polymers {(organometallic polymers B01J31/123; polymer-bound organometallic complexes B01J31/165; coordination polymers B01J31/1691)} · CPC title

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title

• C04B2111/00793

  as filters or diaphragms · CPC title