Compositions and methods for plugging honeycomb bodies with reduced plug depth variability

Patent metadata

Field	Value
Publication number	US-2016264472-A1
Application number	US-201615163429-A
Country	US
Kind code	A1
Filing date	May 24, 2016
Priority date	Aug 30, 2012
Publication date	Sep 15, 2016
Grant date	—

Abstract

A composition for applying to a honeycomb body includes a refractory filler, an organic binder, an inorganic binder, and a liquid vehicle, wherein the refractory filler, the particle size distribution of the refractory filler, the organic binder, and the inorganic binder are selected such that, when the composition is applied to plug a plurality of channels of the honeycomb body, the plug depth variability is reduced.

First claim

What is claimed is:

1 . A composition for applying to a honeycomb body having a plurality of parallel channels, the composition comprising:
a refractory filler having a particle size distribution; an organic binder; an inorganic binder; and a liquid vehicle; wherein the inorganic binder comprises a polydisperse colloidal silica.

2 . The composition of claim 1 , wherein the refractory filler comprises at least one inorganic powder selected from the group consisting of cordierite, mullite, aluminum titanate, silicon carbide, silicon nitride, calcium aluminate, beta-eucryptite, and beta-spodumene.

3 . The composition of claim 2 , wherein the refractory filler has a median particle size (D 50 ) of from 10 to 50 microns.

4 . The composition of claim 1 , wherein the polydisperse colloidal silica comprises a surface area of less than or equal to about 150 m 2 /g.

5 . The composition of claim 1 , wherein the composition sets at a temperature of less than 200° C.

6 . The composition of claim 1 , wherein the inorganic binder comprises non-gelled colloidal silica.

7 . The composition of claim 1 , wherein the polydisperse colloidal silica consists of a disperse colloidal silica comprising a first particle size distribution and a second particle size distribution greater than the first particle size distribution.

8 . The composition of claim 7 , wherein the first particle size distribution comprises a D 50 of greater than about 10 nm and less than about 40 nm and the second particle size distribution comprises a D 50 of greater than about 40 nm and less than about 300 nm.

9 . The composition of claim 8 , wherein at least 15 wt % of the first particle size distribution comprises a D 50 of no greater than about 25 nm and at least 15 wt % of the second particle size distribution comprises a D 50 of no less than about 50 nm.

10 . The composition of claim 8 , wherein the weight percent of the first particle size distribution and the second particle size distribution constitutes greater than 35 wt % of the particles in the polydisperse colloidal silica.

11 . A method for applying a plugging composition to a honeycomb body having a plurality of parallel channels, the method comprising:
applying to the honeycomb body, a composition comprising: a refractory filler having a particle size distribution; an organic binder; an inorganic binder; and a liquid vehicle; wherein the inorganic binder comprises a polydisperse colloidal silica.

12 . The method of claim 11 , further comprising setting the composition at a temperature of less than 200° C.

13 . The method of claim 11 , wherein the polydisperse colloidal silica consists of a disperse colloidal silica comprising a first particle size distribution comprising a D 50 of less than about 25 nm and a second particle size distribution greater comprising a D 50 of greater than about 40 nm.

14 . The method of claim 11 , wherein the polydisperse colloidal silica comprises a surface area of less than or equal to about 150 m 2 /g.

Assignees

• Corning Inc

Inventors

• Bubb Keith Norman
• Cecce Anthony Joseph
• Cronin Allison Elizabeth
• Sarma Huthavahana Kuchibhotla
• Warren Courtney Spencer

Classifications

• C04B2235/3418

  Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint · CPC title

• C04B35/195 Primary

  Alkaline earth aluminosilicates, e.g. cordierite {or anorthite} · CPC title

• B01D46/2459

  of the plugs · CPC title

• C04B2235/48

  Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins · CPC title

• C04B2235/3481

  Alkaline earth metal alumino-silicates other than clay, e.g. cordierite, beryl, micas such as margarite, plagioclase feldspars such as anorthite, zeolites such as chabazite · CPC title