Cement compositions for applying to honeycomb bodies

Patent metadata

Field	Value
Publication number	US-9828298-B2
Application number	US-27497208-A
Country	US
Kind code	B2
Filing date	Nov 20, 2008
Priority date	Nov 30, 2007
Publication date	Nov 28, 2017
Grant date	Nov 28, 2017

Abstract

Disclosed are cement compositions for applying to honeycomb bodies as a plugging cement composition, segment cement, or even as an after-applied artificial skin or coating. The cement compositions generally comprise an inorganic powder batch mixture; an organic binder; a liquid vehicle; and a gelled inorganic binder. Also disclosed are honeycomb bodies having the disclosed cement compositions applied thereto, and methods for making same.

First claim

What is claimed is:

1. A cement composition for applying to a porous microcracked fired ceramic honeycomb body, comprising:
an inorganic powder, wherein the inorganic powder comprises cordierite;
an organic binder;
a liquid vehicle; and
a gelled inorganic binder comprising gelled colloidal silica,
wherein the gelled colloidal silica is present in an amount greater than about 9% by weight of the composition and less than about 20% by weight of the composition, calculated on a dry weight basis.

2. The cement composition of claim 1 , wherein the inorganic powder batch composition comprises ceramed refractory powder.

3. The cement composition of claim 1 , further comprising a gelling agent.

4. The cement composition of claim 3 , further comprising a pH adjusting gelling agent.

5. The cement composition of claim 4 , wherein the pH adjusting gelling agent comprises an acid, a base, or a combination of an acid and a base.

6. The cement composition of claim 4 , wherein the pH adjusting gelling agent comprises an acid selected from hydrochloric acid, sulfuric acid, nitric acid, citric acid, and acetic acid.

7. The cement composition of claim 5 , wherein the pH adjusting gelling agent comprises a base selected from ammonium hydroxide, sodium hydroxide, and triethanolamine.

8. The cement composition of claim 3 , wherein the gelling agent comprises an ion increasing gelling agent.

9. The cement composition of claim 8 , wherein the ion increasing gelling agent comprises a water soluble salt.

10. The cement composition of claim 9 , wherein the water soluble salt comprises magnesium, calcium, or sodium.

11. The cement composition of claim 8 , wherein the ion increasing gelling agent comprises triethanolamine.

12. The cement composition of claim 1 , further comprising a rheology modifier.

13. The cement composition of claim 12 , wherein the rheology modifier comprises polyvinyl alcohol.

14. The cement composition of claim 1 , wherein:
the organic binder comprises a cellulose material; and
the liquid vehicle comprises water.

15. A segmented porous microcracked fired ceramic honeycomb body, comprising:
at least two porous microcracked fired ceramic honeycomb structures, each structure defining a plurality of cell channels bounded by cell channel walls; and
a cement composition bonding the at least two fired ceramic honeycomb structures, wherein the cement composition comprises:
an inorganic powder;
an organic binder;
a gelled inorganic binder comprising gelled colloidal silica; and
a liquid vehicle.

16. A porous microcracked fired ceramic honeycomb body, comprising:
a porous microcracked fired ceramic honeycomb structure defining a plurality of cell channels bounded by cell channel walls; and
an after applied surface coating applied to a peripheral region of the porous microcracked fired ceramic honeycomb structure, wherein the surface coating is formed from a composition comprising:
an inorganic powder;
an organic binder;
a gelled inorganic binder comprising gelled colloidal silica; and
a liquid vehicle.

17. A porous microcracked fired ceramic honeycomb body, comprising:
a porous microcracked fired ceramic honeycomb structure defining a plurality of cell channels bounded by porous cell channel walls;
wherein at least a portion of the plurality of cell channels comprise plugs, and wherein the plugs are formed from a cement composition comprising:
an inorganic powder;
an organic binder;
a gelled inorganic binder comprising gelled colloidal silica; and
a liquid vehicle.

18. The porous microcracked fired ceramic honeycomb claim 17 , wherein a first portion of the plurality of cell channels comprise plugs sealed to the respective channel walls at or near a first end and a second portion of the plurality of cell channels comprise plugs sealed to the respective channel walls at or near a second end.

19. A method for minimizing microcrack filling in a porous microcracked fired ceramic honeycomb body, comprising the steps of:
providing a porous microcracked fired ceramic honeycomb structure defining a plurality of cell channels bounded by cell channel walls; and
applying a cement composition to the porous microcracked fired ceramic honeycomb structure, said cement composition comprising:
an inorganic powder;
an organic binder;
a gelled inorganic binder comprising gelled colloidal silica; and
a liquid vehicle.

20. The method of claim 19 , further comprising a step of firing the porous microcracked fired ceramic honeycomb structure under conditions effective to form at least one of:
a ceramic plug in one or more cell channels, and
a ceramic surface coating about a periphery of the honeycomb structure.

21. The cement composition of claim 1 , further comprising gelling agents triethanolamine and citric acid.

22. The cement composition of claim 1 , wherein the gelled colloidal silica is present in an amount greater than about 9% by weight of the composition and less than about 15% by weight of the composition, calculated on a dry weight basis.

Assignees

• Deneka Thomas James
• Michels Crystal Lynn
• Tepesch Patrick David
• Wight Jr John Forrest
• Corning Inc

Inventors

• Deneka Thomas James
• Michels Crystal Lynn
• Tepesch Patrick David
• Wight Jr John Forrest

Classifications

• C04B41/85

  with inorganic materials · CPC title

• C04B2111/00793

  as filters or diaphragms · CPC title

• C04B28/24

  containing alkyl, ammonium or metal silicates; containing silica sols {(reaction mixtures resulting in mineral polymers C04B28/006; polymeric reaction products of alkali metal silicates with isocyanates C08G18/3895)} · CPC title

• C04B41/009

  characterised by the material treated · CPC title

• C04B41/5089 Primary

  Silica sols, alkyl, ammonium or alkali metal silicate cements · CPC title