Ceramic precursor batch compositions for increased stiffening onset temperature using organic additive heteroatom polyols

Patent metadata

Field	Value
Publication number	US-9233880-B2
Application number	US-201313836338-A
Country	US
Kind code	B2
Filing date	Mar 15, 2013
Priority date	Oct 30, 2012
Publication date	Jan 12, 2016
Grant date	Jan 12, 2016

Abstract

A ceramic precursor batch composition comprising inorganic ceramic-forming ingredients, a binder, an aqueous solvent and a heteroatom polyol agent. The heteroatom polyol agent can be represented by X(R) where X is at least one of S, N, and P, and R is at least two of CH 3 , CH 2 CH 2 OH, CH 2 CH 2 CH 2 OH, CH 2 (CHOH)CH 3 , C(CH 2 OH) 1-3 , CH 2 OH, CH(CH 2 OH)CHOH, C(O)(CHOH) 1-4 CH 2 OH, and CH 2 CH 2 CH 2 OCH 3 . The presence of the heteroatom polyol agent provides a composition with a lower viscosity and/or a greater batch stiffening temperature (T onset ) allowing for increased rates of extrusion. Methods for producing a ceramic honeycomb body using this ceramic precursor batch composition are also provided.

First claim

What is claimed is:

1. A method of producing a ceramic honeycomb body, comprising:
adding a cellulose-based binder, an aqueous-based solvent, and a heteroatom polyol agent to inorganic ceramic-forming ingredients, wherein the heteroatom polyol agent is optionally mixed with the aqueous-based solvent prior to adding to the inorganic ceramic-forming ingredients, wherein the heteroatom polyol agent is represented by X(R) where X is at least one of S and P, and R is at least two of —CH 2 CH 2 OH, CH 2 CH 2 CH 2 OH, CH 2 (CHOH)CH 3 , C(CH 2 OH) 1-3 , CH 2 OH, CH(CH 2 OH)CHOH, and C(O)(CHOH) 1-4 CH 2 OH, or at least one of C(CH 2 OH) 2-3 , CH(CH 2 OH)CHOH, and C(O)(CHOH) 1-4 CH 2 OH combined with at least one of CH 3 and CH 2 CH 2 CH 2 OCH 3 ;
mixing the inorganic ceramic-forming ingredients, the binder, the solvent, and the heteroatom polyol agent to form a precursor batch;
forming the precursor batch into a green honeycomb body; and
firing the green honeycomb body to produce the ceramic honeycomb body.

2. The method of claim 1 , wherein the heteroatom polyol agent comprises thiodiethanol (“TDE”), 2-[(2-methoxyethyl)sulfanyl]ethanol, 3,3′-thiodipropanol (“TDP”), tris-(2-hydroxyethyl)-sulfonium chloride, 2,2′-sulfinyldiethanol, tetrakis(hydroxymethyl)phosphonium chloride solution, bis[tetrakis(hydroxymethyl)phosphonium]sulfate solution, or combinations thereof.

3. The method of claim 1 , wherein the heteroatom polyol agent comprises thiodiethanol, thiodipropanol, or combinations thereof.

4. The method of claim 1 , wherein the heteroatom polyol agent is added to the precursor batch composition in a concentration of from about 2.5 wt % aqueous solution to about 20 wt % aqueous solution.

5. The method of claim 4 , wherein the amount of heteroatom polyol agent is added to the precursor batch composition in a concentration of from about 8 wt % aqueous solution to about 15 wt % aqueous solution.

6. The method of claim 1 , wherein the cellulose-based binder comprises methylcellulose, ethylhydroxy ethylcellulose, hydroxybutyl methylcellulose, hydroxymethylcellulose, hydroxypropyl methylcellulose, hydroxyethyl methylcellulose, hydroxybutyl methylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, sodium carboxy methylcellulose or combinations thereof.

7. The method of claim 1 , wherein the ceramic-forming ingredients comprise cordierite or aluminum-titanate forming ingredients.

8. The method of claim 1 , further comprising the step of adding up to 60 weight % of a pore forming material to the inorganic ceramic-forming materials wherein the weight % is based on 100% of the inorganic ceramic-forming ingredients.

9. The method of claim 8 , wherein the pore forming material is at least one of starch and graphite.

10. The method of claim 1 , wherein the green honeycomb body is formed by extrusion through a forming die.

11. The method of claim 1 , wherein the precursor batch stiffens during the forming at a gelation temperature.

12. The method of claim 11 , wherein the forming comprises extruding the precursor batch via an extruder screw.

13. The method of claim 1 , wherein the green honeycomb body is dried before firing.

14. A method of producing a ceramic precursor batch, comprising:
adding a cellulose-based binder, an aqueous-based solvent, and a heteroatom polyol agent to inorganic ceramic-forming ingredients to form the ceramic precursor batch, wherein the heteroatom polyol agent is optionally mixed with the aqueous-based solvent prior to adding to the inorganic ceramic-forming ingredients, wherein the heteroatom polyol agent is represented by X(R) where X is at least one of S and P, and R is at least two of CH 2 CH 2 OH, CH 2 CH 2 CH 2 OH, CH 2 (CHOH)CH 3 , C(CH 2 OH) 1-3 , CH 2 OH, CH(CH 2 OH)CHOH, and C(O)(CHOH) 1-4 CH 2 OH or at least one of C(CH 2 OH) 2-3 , CH(CH 2 OH)CHOH, and C(O)(CHOH) 1-4 CH 2 OH combined with at least one of CH 3 and CH 2 CH 2 CH 2 OCH 3 .

15. The method of claim 14 , wherein the heteroatom polyol agent is thiodiethanol (“TDE”), 2-[(2-methoxyethyl)sulfanyl]ethanol, 3,3′-thiodipropanol (“TDP”), tris-(2-hydroxyethyl)-sulfonium chloride, 2,2′-sulfinyldiethanol, tetrakis(hydroxymethyl)phosphonium chloride solution, bis[tetrakis(hydroxymethyl)phosphonium]sulfate solution, or combinations thereof.

16. The method of claim 14 , wherein the heteroatom polyol agent comprises thiodiethanol, thiodipropanol, or combinations thereof.

17. The method of claim 14 , wherein the heteroatom polyol agent is added to the ceramic precursor batch in a concentration of from about 2.5 wt % aqueous solution to about 20 wt % aqueous solution.

18. The method of claim 17 , wherein the heteroatom polyol agent is added to the ceramic precursor batch in a concentration of from about 8 wt % aqueous solution to about 15 wt % aqueous solution.

19. The method of claim 14 , wherein the cellulose-based binder is methylcellulose, hydroxypropyl methylcellulose, or combinations thereof.

Assignees

• Corning Inc
• Corning Inc

Inventors

• Lewis Mark Alan

Classifications

• C04B2235/6021

  Extrusion moulding · CPC title

• C04B35/632

  Organic additives · CPC title

• C04B35/478 Primary

  based on aluminium titanates · CPC title

• C04B2111/00793

  as filters or diaphragms · CPC title

• C04B38/0006 Primary

  Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083) · CPC title