Ceramic cement mixture and ceramic honeycomb with ceramic cement skin
A cement composition for application to a ceramic substrate, such as a cement skin composition for application to a ceramic honeycomb body is provided. The cement composition includes a first source of inorganic particles having a mean particle diameter <50 nm, wherein the first source of inorganic particles is present at about <15% (by dry weight), a second source of inorganic particles having a mean particle diameter of from about 50 nm to about 700 nm, wherein the second source of inorganic particles is present at from about 5% to about 15% (by dry weight), and a water-soluble organic binder. An inorganic fibrous material can be present at about <15% (based on dry weight). The amount of at least one of the first source of inorganic particles or the inorganic fibrous material is greater than 0% (by dry weight).
1 . A cement composition for application to a ceramic substrate, comprising:
a first source of inorganic particles having a mean particle diameter <50 nm, wherein an amount of the first source of inorganic particles is greater than 0% and about ≤12% (by dry weight);
a second source of inorganic particles having a mean particle diameter of from about 50 nm to about 700 nm, wherein an amount of the second source of inorganic particles is from about 5% to about 15% (by dry weight);
an inorganic fibrous material, wherein an amount of the inorganic fibrous material is about ≤15% (based on dry weight); and
a water-soluble organic binder.
2 . The cement composition of claim 1 , wherein an amount of the first source of inorganic particles is greater than 0% and about ≤9% (by dry weight).
3 . The cement composition of claim 1 , wherein the first source of inorganic particles has a mean particle diameter <20 nm.
4 . The cement composition of claim 1 , wherein the first source of inorganic particles comprises colloidal silica, colloidal alumina, or a combination thereof.
5 . The cement composition of claim 1 , wherein the second source of inorganic particles comprises at least one of silica, alumina, titania, spinel, and zirconia particles.
6 . The cement composition of claim 1 , wherein the second source of inorganic particles has a mean particle diameter of from about 100 nm to about 500 nm.
7 . The cement composition of claim 1 , further comprising:
a pH modifier, a rheology modifier, or a combination thereof.
8 . The cement composition of claim 7 , wherein the pH modifier comprises one of sodium hydroxide and potassium hydroxide.
9 . The cement composition of claim 7 , wherein the rheology modifier comprises a smectite clay.
10 . The cement composition of claim 1 , wherein the composition is substantially free of inorganic fibrous material.
11 . The cement composition of claim 1 , further comprising:
a third source of inorganic particles comprising inorganic particles in which at least 90% of the inorganic particles are retained by a mesh sieve having sieve openings <1 μm.
12 . The cement composition of claim 11 , wherein the third source of inorganic particles comprises fused silica, cordierite, aluminum titanate, alumina, silicon carbide, or combinations thereof.
13 . The cement composition of claim 1 , wherein the inorganic fibrous material comprises an alkaline earth silicate, wollastonite, or mullite.
14 . The cement composition of claim 1 , wherein the inorganic fibrous material comprises an aspect ratio of longest axis to shortest axis of >5:1.
15 . The cement composition of claim 1 , wherein the water-soluble organic binder comprises at least one of methylcellulose, cellulose ether, ethylcellulose, polyvinyl alcohol, polyethylene oxide, xanthum gum, or latex.
16 . A cement composition for application to a ceramic substrate, comprising:
a first source of inorganic particles having a mean particle diameter <50 nm, wherein an amount of the first source of inorganic particles is about ≤15% (by dry weight);
a second source of inorganic particles having a mean particle diameter of from about 50 nm to about 700 nm, wherein an amount of the second source of inorganic particles is from about 5% to about 15% (by dry weight);
a third source of inorganic particles comprising inorganic particles in which at least 90% of the inorganic particles are retained by a mesh sieve having sieve openings <1 μm;
an inorganic fibrous material, wherein an amount of the inorganic fibrous material is about ≤15% (based on dry weight); and
a water-soluble organic binder,
wherein the amount of at least one of the first source of inorganic particles or the inorganic fibrous material is greater than 0% (by dry weight).
17 . The cement composition of claim 16 , wherein the second source of inorganic particles comprises at least one of silica, alumina, titania, spinel, and zirconia particles.
18 . The cement composition of claim 16 , wherein the second source of inorganic particles has a mean particle diameter of from about 100 nm to about 500 nm.
19 . The cement composition of claim 16 , wherein the third source of inorganic particles has a particle diameter >1 μm and an amount of the third source of inorganic particles is about >50% (by dry weight).
20 . The cement composition of claim 16 , wherein the third source of inorganic particles comprises fused silica, cordierite, aluminum titanate, alumina, silicon carbide, or combinations thereof.