Ceramic cement mixture and ceramic honeycomb with ceramic cement skin

Patent metadata

Field	Value
Publication number	US-12522545-B2
Application number	US-202117919338-A
Country	US
Kind code	B2
Filing date	Apr 27, 2021
Priority date	Apr 30, 2020
Publication date	Jan 13, 2026
Grant date	Jan 13, 2026

Abstract

A cement composition for application to a ceramic substrate, such as a cement skin composition for application to a ceramic honeycomb body is provided. The cement composition includes a first source of inorganic particles having a mean particle diameter <50 nm, wherein the first source of inorganic particles is present at about <15% (by dry weight), a second source of inorganic particles having a mean particle diameter of from about 50 nm to about 700 nm, wherein the second source of inorganic particles is present at from about 5% to about 15% (by dry weight), and a water-soluble organic binder. An inorganic fibrous material can be present at about <15% (based on dry weight). The amount of at least one of the first source of inorganic particles or the inorganic fibrous material is greater than 0% (by dry weight).

First claim

What is claimed is:

1 . A cement composition for application to a ceramic substrate, comprising:
a first source of inorganic particles having a mean particle diameter <50 nm, wherein an amount of the first source of inorganic particles is greater than 0% and about ≤12% (by dry weight); a second source of inorganic particles having a mean particle diameter of from about 50 nm to about 700 nm, wherein an amount of the second source of inorganic particles is from about 5% to about 15% (by dry weight); an inorganic fibrous material, wherein an amount of the inorganic fibrous material is about ≤15% (based on dry weight); and a water-soluble organic binder.

2 . The cement composition of claim 1 , wherein an amount of the first source of inorganic particles is greater than 0% and about ≤9% (by dry weight).

3 . The cement composition of claim 1 , wherein the first source of inorganic particles has a mean particle diameter <20 nm.

4 . The cement composition of claim 1 , wherein the first source of inorganic particles comprises colloidal silica, colloidal alumina, or a combination thereof.

5 . The cement composition of claim 1 , wherein the second source of inorganic particles comprises at least one of silica, alumina, titania, spinel, and zirconia particles.

6 . The cement composition of claim 1 , wherein the second source of inorganic particles has a mean particle diameter of from about 100 nm to about 500 nm.

7 . The cement composition of claim 1 , further comprising:
a pH modifier, a rheology modifier, or a combination thereof.

8 . The cement composition of claim 7 , wherein the pH modifier comprises one of sodium hydroxide and potassium hydroxide.

9 . The cement composition of claim 7 , wherein the rheology modifier comprises a smectite clay.

10 . The cement composition of claim 1 , wherein the composition is substantially free of inorganic fibrous material.

11 . The cement composition of claim 1 , further comprising:
a third source of inorganic particles comprising inorganic particles in which at least 90% of the inorganic particles are retained by a mesh sieve having sieve openings <1 μm.

12 . The cement composition of claim 11 , wherein the third source of inorganic particles comprises fused silica, cordierite, aluminum titanate, alumina, silicon carbide, or combinations thereof.

13 . The cement composition of claim 1 , wherein the inorganic fibrous material comprises an alkaline earth silicate, wollastonite, or mullite.

14 . The cement composition of claim 1 , wherein the inorganic fibrous material comprises an aspect ratio of longest axis to shortest axis of >5:1.

15 . The cement composition of claim 1 , wherein the water-soluble organic binder comprises at least one of methylcellulose, cellulose ether, ethylcellulose, polyvinyl alcohol, polyethylene oxide, xanthum gum, or latex.

16 . A cement composition for application to a ceramic substrate, comprising:
a first source of inorganic particles having a mean particle diameter <50 nm, wherein an amount of the first source of inorganic particles is about ≤15% (by dry weight); a second source of inorganic particles having a mean particle diameter of from about 50 nm to about 700 nm, wherein an amount of the second source of inorganic particles is from about 5% to about 15% (by dry weight); a third source of inorganic particles comprising inorganic particles in which at least 90% of the inorganic particles are retained by a mesh sieve having sieve openings <1 μm; an inorganic fibrous material, wherein an amount of the inorganic fibrous material is about ≤15% (based on dry weight); and a water-soluble organic binder, wherein the amount of at least one of the first source of inorganic particles or the inorganic fibrous material is greater than 0% (by dry weight).

17 . The cement composition of claim 16 , wherein the second source of inorganic particles comprises at least one of silica, alumina, titania, spinel, and zirconia particles.

18 . The cement composition of claim 16 , wherein the second source of inorganic particles has a mean particle diameter of from about 100 nm to about 500 nm.

19 . The cement composition of claim 16 , wherein the third source of inorganic particles has a particle diameter >1 μm and an amount of the third source of inorganic particles is about >50% (by dry weight).

20 . The cement composition of claim 16 , wherein the third source of inorganic particles comprises fused silica, cordierite, aluminum titanate, alumina, silicon carbide, or combinations thereof.

Assignees

• Corning Inc

Inventors

• Patil Mallanagouda Dyamanagouda
• Tanner Cameron Wayne
• Zimmermann James William

Classifications

• C04B2103/0094

  Agents for altering or buffering the pH; Ingredients characterised by their pH · CPC title

• C04B2103/0079

  Rheology influencing agents · CPC title

• C04B22/062

  of the alkali or alkaline-earth metals · CPC title

• C04B22/0093

  Aluminates · CPC title

• C04B20/0048

  Fibrous materials · CPC title