Methods of making plugged honeycomb bodies with cement patties
A method of plugging a honeycomb body includes mixing a plugging mixture at a mixing temperature, wherein the plugging mixture comprises a plurality of inorganic particles, inorganic binder, organic binder, and water; dispensing the plugging mixture into a patty mold at a dispensing temperature; cooling the plugging mixture within the patty mold to a cooled temperature, such that a cement patty is formed; and pressing the cement patty into a plurality of channels in a honeycomb body, wherein the mixing temperature and the dispensing temperature are above a hydration point temperature of the organic binder in the plugging mixture, and the cooled temperature is below the hydration point temperature of the organic binder in the plugging mixture.
1. A method of forming a plugging cement patty, comprising:
mixing a plurality of inorganic particles, an inorganic binder, an organic binder, and a liquid at a mixing temperature greater than a hydration point temperature of the organic binder to form a plugging mixture comprising a viscosity in a range from about 1 cP to about 100 cP;
dispensing the plugging mixture at a dispensing temperature greater than the hydration point temperature; and
cooling the plugging mixture to a cooled temperature less than the hydration point temperature to increase the viscosity of the plugging mixture and form the plugging cement patty.
2. The method of claim 1 , wherein a viscosity of the plugging mixture at the cooled temperature is from about 1,500,000 cP to about 10,000,000 cP.
3. The method of claim 1 , wherein a viscosity of the plugging mixture at the cooled temperature is from about 3,000,000 cP to about 5,000,000 cP.
4. The method of claim 1 , wherein the organic binder comprises methylcellulose.
5. The method of claim 4 , wherein the plurality of inorganic particles comprises cordierite.
6. The method of claim 5 , wherein the inorganic binder comprises colloidal silica.
7. The method of claim 1 , wherein the mixing comprises subjecting the plugging mixture to a pressure less than 1 atmosphere during the mixing.
8. The method of claim 1 , wherein the mixing comprises bringing the liquid to the mixing temperature prior to mixing the plurality of inorganic particles, the inorganic binder, and the organic binder with the liquid.
9. A method of forming a plugging cement patty for plugging a honeycomb body, comprising the steps of:
mixing a plugging mixture comprising cordierite, colloidal silica, organic binder, and water at a mixing temperature greater than a hydration point temperature of the organic binder such that a viscosity of the plugging mixture at the mixing temperature is in a range from about 1 cP to about 100 cP;
dispensing the plugging mixture into a patty mold at a dispensing temperature greater than the hydration point temperature of the organic binder such that the viscosity of the plugging mixture at the dispensing temperature is in the range from about 1 cP to about 100 cP; and
cooling the plugging mixture within the patty mold to a cooled temperature less than the hydration point temperature of the organic binder to increase a viscosity of the plugging mixture and form the plugging cement patty.
10. The method of claim 9 , wherein a weight percentage of the organic binder as a super addition relative to a combined total weight of the cordierite in the plugging mixture is from about 0.5 wt. % to about 6 wt. %.
11. The method of claim 9 , wherein the weight percentage of the organic binder as a super addition relative to the combined total weight of the cordierite in the plugging mixture is from about 0.75 wt. % to about 3.0 wt. %.
12. The method of claim 9 , wherein the weight percentage of the organic binder as a super addition relative to the combined total weight of the cordierite in the plugging mixture is about 1.5 wt. %.
13. The method of claim 9 , wherein the organic binder comprises methylcellulose.
14. The method of claim 9 , wherein the step of cooling the plugging mixture to the cooled temperature further comprises the step of subjecting the plugging mixture to a cooling bath having a temperature below the cooled temperature.
15. The method of claim 9 , wherein a viscosity of the plugging mixture at the cooled temperature is from about 3,000,000 cP to about 5,000,000 cP.
16. A method of plugging a honeycomb body comprising the steps of:
mixing a plugging mixture comprising a plurality of inorganic particles, an inorganic binder, an organic binder, and water at a mixing temperature greater than a hydration point temperature of the organic binder such that a viscosity of the plugging mixture is in a range from about 1 cP to about 100 cP;
dispensing the plugging mixture into a patty mold at a dispensing temperature greater than the hydration point temperature of the organic binder;
cooling the plugging mixture within the patty mold to a cooled temperature below the hydration point temperature to increase a viscosity of the plugging mixture and form a plugging cement patty, the cooling comprising cooling the patty mold to the cooled temperature prior to the dispensing; and
pressing the plugging cement patty into a plurality of channels in the honeycomb body.
17. The method of claim 16 , wherein the hydration point temperature of the organic binder in the plugging mixture is from about 20° C. to about 100° C.
18. The method of claim 16 , wherein the hydration point temperature of the organic binder in the plugging mixture is from about 25° C. to about 60° C.
19. The method of claim 16 , wherein the organic binder comprises methylcellulose.