IP Library › Granted Patent US 12,194,449
Granted Patent B2
US 12,194,449 · App. 17/601,594 · Granted Jan 14, 2025

Low bulk density, high geometric surface area honeycomb bodies

Inventors: David Jack Bronfenbrenner (Painted Post, NY); Michael James Lehman (Canisteo, NY)
Assignee: Corning Incorporated
B01J35/56B01D46/2425B01D46/2429B01D46/24491B01D46/2455B01D46/247B01D46/2474B01D46/2482B01D46/2484B01D46/249B01D46/2492B01D46/2498B01J35/31B01J35/61B01J37/0018B01J37/082B01D53/94F01N3/2828F01N2330/06
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Quick Facts
Patent No.
US 12,194,449
App. No.
17/601,594
Granted
Jan 14, 2025
Kind
B2
Abstract

Ceramic honeycomb bodies and methods for then manufacture are provided. The ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in −1 (3.66 mm −1 ), a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.4 mm 2 .

Claims (22)

1. A ceramic honeycomb body comprising:

an inlet face, an outlet face, and a plurality of parallel, elongate, open-ended cells formed by a web of intersecting cell walls having a web thickness (t w ) traversing the ceramic honeycomb body from the inlet face to the outlet face thereof, each cell defining a cell perimeter P and cell area (A cell ), the open-ended cells configured with a cell density in cells per square inch (CPSI) and defining a percentage open frontal area (% OFA) of the ceramic honeycomb body, wherein % OFA=CPSI*A cell , the intersecting cell walls comprising a ceramic material having a density ρ c and a volume percentage porosity (% porosity), wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in −1 , a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.4 mm 2 .

2. The ceramic honeycomb body of claim 1 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in −1 , a mechanical integrity factor (MIF) greater than 0.4%, and a back pressure factor (BPF) greater than 0.4 mm 2 .

3. The ceramic honeycomb body of claim 1 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in −1 , a mechanical integrity factor (MIF) greater than 0.5%, and a back pressure factor (BPF) greater than 0.4 mm 2 .

4. The ceramic honeycomb body of claim 1 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in −1 , a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.45 mm 2 .

5. The ceramic honeycomb body of claim 1 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in −1 , a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.5 mm 2 .

6. The ceramic honeycomb body of claim 1 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 95 in −1 , a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.4 mm 2 .

7. The ceramic honeycomb body of claim 1 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 97 in −1 , a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.4 mm 2 .

8. The ceramic honeycomb body of claim 1 , wherein the cells are rectangular in cross-section.

9. The ceramic honeycomb body of claim 1 , wherein the cells are hexagonal in cross-section.

10. The ceramic honeycomb body of claim 1 , wherein the ceramic material of the intersecting cell walls comprises cordierite.

11. A method of manufacturing a ceramic honeycomb body comprising an inlet face, an outlet face, and a plurality of parallel, elongate, open-ended cells formed by intersecting cell walls having a web thickness (t w ) traversing the ceramic honeycomb body from the inlet face to the outlet face thereof, each cell defining a perimeter P and cell area (A cell ), the open-ended cells comprising a cell density in cells per square inch (CPSI) and defining a percentage open frontal area (% OFA) of the ceramic honeycomb body, wherein % OFA=CPSI*A cell , the intersecting cell walls comprising a ceramic material having a density Pc and a volume percentage porosity (% porosity),

wherein the method comprises forming a mixture of starting materials including a pore forming agent, then extruding the mixture into a green honeycomb body, then firing the green honeycomb body to provide a formed ceramic honeycomb body comprising a predetermined CPSI and a predetermined web thickness so that the formed ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in −1 , a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.4 mm 2 .

12. The method of claim 11 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in −1 , a mechanical integrity factor (MIF) greater than 0.4%, and a back pressure factor (BPF) greater than 0.4 mm 2 .

13. The method of claim 11 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in −1 , a mechanical integrity factor (MIF) greater than 0.5%, and a back pressure factor (BPF) greater than 0.4 mm 2 .

14. The method of claim 11 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in −1 , a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.45 mm 2 .

15. The method of claim 11 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 93 in −1 , a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.5 mm 2 .

16. The method of claim 11 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 95 in −1 , a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.4 mm 2 .

17. The method of claim 11 , wherein the ceramic honeycomb body comprises a bulk density of less than 210 g/L, a geometric surface area (GSA) greater than 97 in −1 , a mechanical integrity factor (MIF) greater than 0.28%, and a back pressure factor (BPF) greater than 0.4 mm 2 .

18. The method of claim 11 , wherein the cells are rectangular in cross-section.

19. The method of claim 11 , wherein the cells are hexagonal in cross-section.

20. The method of claim 11 , wherein the ceramic material of the intersecting cell walls comprises cordierite.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 5, 2021
From: BRONFENBRENNER, DAVID JACK; LEHMAN, MICHAEL JAMES
To: CORNING INCORPORATED
Reel/Frame 057704/0877 →
Continuity (2)
Provisional Application 62835671 · Apr 18, 2019
Related Publication 20220176368A1 · Jun 9, 2022
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