Method for making a honeycomb structure comprising coating a honeycomb body with cement skin layers

Patent metadata

Field	Value
Publication number	US-9833927-B2
Application number	US-201514714979-A
Country	US
Kind code	B2
Filing date	May 18, 2015
Priority date	Nov 29, 2012
Publication date	Dec 5, 2017
Grant date	Dec 5, 2017

Abstract

Disclosed is a ceramic honeycomb structure comprising a honeycomb body and a multilayered outer layer formed of a thick core layer applied and rapidly dried and a thin clad layer dried more gently to form a crack free dual skin layer. The core layer may have properties that are closer to those of the ceramic honeycomb body in service than the clad layer that may provide a tough outer shell to withstand handling and assembly.

First claim

What is claimed is:

1. A method of making a honeycomb structure, comprising:
coating the periphery of a honeycomb body with a first cement mixture to form a first coat cement mixture;
drying the first coat cement mixture to form a first skin layer;
coating the first skin layer with a second cement mixture to form a second coat cement mixture; and
drying the second coat cement mixture on the periphery of the honeycomb body to form a second skin layer and the honeycomb structure,
wherein
the first skin layer comprises a first porosity, a first modulus of rupture, and a first modulus of elasticity, and
the second skin layer comprises a second porosity less than the first porosity, a second modulus of rupture greater than the first modulus of rupture, and a second modulus of elasticity greater than the first modulus of elasticity.

2. The method according to claim 1 , wherein
drying the first coat cement mixture comprises exposing the first coat cement mixture to at least one of high temperature air, forced air, microwave, RF, and IR radiation, and
drying the second cement mixture comprises exposing the second coat cement mixture to at least one of high temperature air, forced air microwave, RF, and IR radiation.

3. The method according to claim 1 , wherein
drying the first coat cement mixture comprises exposing the first coat cement mixture to high temperature forced air in a temperature range of 25 to 200° C., and
drying the second cement mixture comprises exposing the second coat cement mixture to high temperature air in a temperature range of 25 to 140° C.

4. The method according to claim 3 , wherein
drying the first coat cement mixture comprises exposing the first coat cement mixture to high temperature forced air in a temperature range of 100 to 200° C. for less than 90 min, and
drying the second cement mixture comprises exposing the second coat cement mixture to high temperature air in a temperature range of 25 to 60° C. for less than 60 min.

5. The method according to claim 1 , wherein
coating the periphery of the honeycomb body with a first cement mixture comprises applying the first cement mixture at a thickness of 0.10 mm to 5.0 mm, and
coating the first skin layer with a second cement mixture comprises applying the second cement mixture at a thickness of 0.10 mm to 5.0 mm.

6. The method according to claim 5 , wherein
coating the periphery of the honeycomb body with a first cement mixture comprises applying the first cement mixture at a thickness of 0.10 mm to 3.00 mm, and
coating the first skin layer with a second cement mixture comprises applying the second cement mixture at a thickness of 0.10 mm to 1.00 mm.

7. The method according to claim 1 , wherein
coating the periphery of the honeycomb body comprises at least one of an axial application of the first cement mixture, a doctor blade application of the first cement mixture, a spray casting of the first cement mixture, a tape casting of the first cement mixture, a spin coating of the first cement mixture, and
coating the first skin layer with the second cement mixture comprises at least one of an axial application of the second cement mixture, a doctor blade application of the second cement mixture, a spray casting of the second cement mixture, a tape casting of the second cement mixture, and a spin coating of the second cement mixture.

8. The method according to claim 1 , wherein
a coefficient of thermal expansion of the first skin layer is substantially equal to a thermal expansion coefficient of the honeycomb body, and
a coefficient of thermal expansion of the second skin layer is greater than the coefficient of thermal expansion of the first skin layer.

Assignees

• Corning Inc

Inventors

• Chapman Thomas Richard
• George Jacob
• Hagg Ralph Henry
• Halder Amit
• Sarma Huthavahana Kuchibhotla

Classifications

• C04B41/009

  characterised by the material treated · CPC title

• C04B41/52

  Multiple coating or impregnating {multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation} · CPC title

• B28B11/241

  using microwave heating means · CPC title

• C04B41/89

  for obtaining at least two superposed coatings having different compositions · CPC title

• Y10T428/24149

  Honeycomb-like · CPC title