Method of filling a substrate having a selected plurality of channels with a granular material

Patent metadata

Field	Value
Publication number	US-9834475-B2
Application number	US-201514643562-A
Country	US
Kind code	B2
Filing date	Mar 10, 2015
Priority date	Apr 24, 2014
Publication date	Dec 5, 2017
Grant date	Dec 5, 2017

Abstract

The method is for use with a substrate having a plurality of parallel channels extending therethrough. In the method, the steps comprise: filling a selected plurality of the channels with a granular material; and consolidating the granular material through heat. The selected plurality of channels is selected to produce a wall that separates the substrate into: a first portion having a first plurality of the parallel channels extending therethrough; and a second portion having a second plurality of the parallel channels extending therethrough.

First claim

What is claimed is:

1. A method of forming a substrate having a plurality of parallel channels extending there through, the method comprising the steps of:
mixing from about 65 to 85% by weight of fly-ash with from about 15 to 35% by weight of a heat sensitive binder to form a granular material;
filling a selected plurality of the channels with the granular material; and
consolidating the granular material through heat,
the selected plurality being selected to produce a wall that separates the substrate into:
a first portion having a first plurality of the parallel channels extending there through; and
a second portion having a second plurality of the parallel channels extending there through.

2. A method according to claim 1 , wherein the granular material is sintered to produce the wall.

3. A method according to claim 1 , wherein the granular material consists essentially of:
from 65 to 85% by weight of fly-ash comprising cenospheres,
from 15 to 35% by weight of a heat sensitive binder selected from the group consisting of boric acid and anhydrous boron oxide.

4. A method according to claim 1 , wherein the granular material consists essentially of:
from about 80% by weight of said fly ash;
about 20% by weight of said heat sensitive binder.

5. The method according to claim 1 , wherein the binder is boric acid.

6. The method according to claim 1 , wherein the granular material has a density of from 25 to 30 lb/ft 3 .

7. The method according to claim 1 , wherein the granular material has a median particle size of approximately 50 microns and a particle size ranging from 10 to 160 microns.

8. The method according to claim 1 , wherein the filling step involves pouring the granular material into the selected plurality of the cells.

9. The method of claim 1 , wherein said granular material is heated to between about 300° C. and 750° C. before filling the selected plurality of channels and fired to above about 850° C. after filling said selected plurality of channels.

10. The method of claim 9 , wherein said firing is above 900° C.

11. The method of claim 10 , wherein said firing is for at least 12 hours.

12. The method of claim 1 , wherein said substrate comprises a catalytic converter.

Assignees

• Lacasse Maurice
• Desrosiers Luc
• Pyrotek Inc

Inventors

• Lacasse Maurice
• Desrosiers Luc

Classifications

• C04B14/202

  Vermiculite · CPC title

• Y02W30/92

  Cross-Sectional Technologies · mapped topic

• C04B38/0067

  characterised by the density of the end product · CPC title

• C04B30/00 Primary

  Compositions for artificial stone, not containing binders · CPC title

• C04B38/06

  by burning-out added substances {by burning natural expanding materials or by sublimating or melting out added substances} · CPC title