Multi- wall thickness, thin-walled honeycomb bodies, and extrusion dies and methods therefor

Patent metadata

Field	Value
Publication number	US-2021362370-A1
Application number	US-201816954250-A
Country	US
Kind code	A1
Filing date	Dec 16, 2018
Priority date	Dec 22, 2017
Publication date	Nov 25, 2021
Grant date	—

Abstract

A thin-walled honeycomb body (100) having a plurality of repeating cell structures (110) formed of intersecting porous thick walls (112V, 112H) and thin walls (114V, 114H). Each repeating cell structure (110) is bounded on its periphery by the thick walls (112V, 122H) of a first transverse thickness (Tk) and the thin walls (114V, 114H) have a second transverse thickness (Tt) that subdivides each repeating cell structure (110) into between 7 and 36 individual cells (108). In the thin-walled honeycomb body (100), the first transverse thickness (Tk) of the thick walls (112V, 112H) is less than or equal to 0.127 mm (0.005 inch) and the second transverse thickness (Tt) of the thin walls (114V, 114H) is less than or equal to 0.0635 mm (0.0025 inch), and Tk>Tt. Honeycomb extrusion dies and methods of manufacturing the thin-walled honeycomb body (100) having thick walls (112V, 112H) and thin walls (114V, 114H) are provided.

First claim

1 . A thin-walled honeycomb body, comprising:
a plurality of cells provided by a matrix of intersecting porous walls forming a plurality of repeating cell structures, wherein (i) each repeating cell structure comprises thick walls of a first transverse thickness (Tk) and thin walls of a second transverse thickness (Tt), (ii) each repeating cell structure is subdivided into between 7 and 36 individual cells by thin walls, (iii) each repeating cell structure is bound on a periphery by thick walls, (iv) the thin walls interconnect with the thick walls and with each other, (v) the first transverse thickness (Tk) of the thick walls is less than or equal to 0.005 inch (0.127 mm), and (vi) the second transverse thickness (Tt) of the thin walls is less than or equal to 0.0025 inch (0.0635 mm) and less than the first transverse thickness (Tk).

2 . The thin-walled honeycomb body of claim 1 , wherein the first transverse thickness (Tk) of the thick walls is less than or equal to 0.004 inch (0.102 mm).

3 . The thin-walled honeycomb body of claim 1 , wherein the second transverse thickness (Tt) of the thin walls is less than or equal to 0.002 inch (0.0508 mm).

4 . The thin-walled honeycomb body of claim 1 , wherein the second transverse thickness (Tt) of the thin walls is less than or equal to 0.0015 inch (0.038 mm).

5 . The thin-walled honeycomb body of claim 1 , comprising a cell density of greater than or equal to 600 cpsi.

6 - 7 . (canceled)

8 . The thin-walled honeycomb body of claim 1 ,
wherein each repeating cell structure comprises an R×C configuration, of 3×3, 3×4, 3×5, 3×6, 4×4, 4×5, 4×6, 5×5, 5×6, or 6×6, and wherein R is a number of rows and C is a number of columns of the individual cells in each repeating cell structure.

9 . The thin-walled honeycomb body of claim 1 , comprising a cell density of greater than or equal to 900 cpsi, the first transverse thickness (Tk) of the thick walls is less than or equal to 0.004 inch (0.102 mm), and the second transverse thickness (Tt) of the thin walls is less than or equal to 0.0015 inch (0.0381 mm).

10 . (canceled)

11 . The thin-walled honeycomb body of claim 1 , wherein each repeating cell structure has a 4×4 configuration and each of the individual cells in the repeating cell structure has a rectangular perimeter shape in transverse cross-section.

12 . The thin-walled honeycomb body of claim 1 , wherein each repeating cell structure has a 5×5 configuration and each of the individual cells in the repeating cell structure has a rectangular perimeter shape in transverse cross-section.

13 . The thin-walled honeycomb body of claim 1 , wherein each repeating cell structure has a 6×6 configuration and each of the individual cells in the repeating cell structure has a rectangular perimeter shape in transverse cross-section.

14 . The honeycomb body of claim 1 , wherein the periphery of each repeating cell structure is rectangular in transverse cross-section.

15 . (canceled)

16 . The thin-walled honeycomb body of claim 1 , wherein the individual cells of each repeating cell structure have a hexagonal perimeter shape in transverse cross-section.

17 - 18 . (canceled)

19 . The thin-walled honeycomb body of claim 1 , comprising an average wall thickness of less than or equal to 0.003 inch (0.0762 mm).

20 . (canceled)

21 . The thin-walled honeycomb body of claim 1 , comprising an average wall thickness of less than or equal to 0.0020 inch (0.0508 mm).

22 - 24 . (canceled)

25 . The thin-walled honeycomb body of claim 1 , comprising 0.0025 inch (0.0635 mm)≤Tk−Tt≤0.0035 inch (0.0889 mm).

26 . The thin-walled honeycomb body of claim 1 , wherein each repeating cell structure comprises an R×C configuration, wherein R is a number of rows and C is a number of columns of the individual cells in each repeating cell structure.

27 - 28 . (canceled)

29 . The thin-walled honeycomb body of claim 1 , wherein each repeating cell structure comprises a cell structure with an R×C configuration, wherein R is a number of rows and C is a number of columns of individual cells in the repeating cell structure, and wherein R is between 3 and 6, and C is between 3 and 6.

30 . (canceled)

31 . A honeycomb extrusion die, comprising:
a die body comprising an outlet face forming a plurality of repeating pin structures defining intersecting thick slots of a first slot thickness (Sk) and thin slots of a second slot thickness (St), wherein (i) each repeating pin structure is bounded on a periphery by the thick slots, (ii) each repeating pin structure is subdivided into between 7 and 36 individual pins by the thin slots, (iii) the thin slots interconnect with the thick slots and with each other, and (iv) the first slot thickness (Sk) is less than or equal to 0.0056 inch (0.142 mm) and the second slot thickness (St) is less than or equal to 0.0028 inch (0.0711 mm) provided that Sk>St.

32 . A method of manufacturing a thin-walled honeycomb body, comprising:
providing a honeycomb extrusion die comprising an outlet face forming a plurality of repeating pin structures defining intersecting thick slots of a first slot thickness (Sk) and thin slots of a second slot thickness (St), wherein (i) each repeating pin structure is bounded on a periphery by the thick slots, (ii) each repeating pin structure is subdivided into between 7 and 36 individual pins by the thin slots, and (iii) the first slot thickness (Sk) is less than or equal to 0.0056 inch (0.142 mm) and the second slot thickness (St) is less than or equal to 0.0028 inch (0.0711 mm) provided that Sk>St; and extruding a ceramic-forming material through the honeycomb extrusion die to produce the thin-walled honeycomb body.

33 . The method of manufacturing a honeycomb body of claim 31 , comprising firing the green honeycomb body to produce the thin-walled honeycomb body having a first transverse thickness (Tk) of thick walls less than or equal to 0.005 inch (0.127 mm) and a second transverse thickness (Tt) of thin walls less than or equal to 0.0025 inch (0.0635 mm), wherein the thick walls are thicker than the thin walls.

34 - 35 . (canceled)

Assignees

• Corning Inc

Inventors

• Akarapu Ravindra Kumar
• Halder Amit
• Jain Priyank Paras
• Li Weidong

Classifications

• B01J35/57

  Honeycombs · CPC title

• B01D2279/30

  for treatment of exhaust gases from IC Engines · CPC title

• F01N3/2828 Primary

  Ceramic multi-channel monoliths, e.g. honeycombs · CPC title

• B29C48/11

  comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped · CPC title

• F01N2330/30

  Honeycomb supports characterised by their structural details · CPC title