Corning Incorporated

Isabelle Marie Melscoet-Chauvel

Gregory A Merkel

Douglas Munroe Beall

Tinghong Tao

Steven Bolaji Ogunwumi

David John Thompson

George Halsey Beall

Jianguo Wang

Patrick David Tepesch

Dell Joseph St Julien

William Peter Addiego

Christopher John Warren

Substantially non-microcracked, porous, cordierite ceramic honeycomb bodies are provided. Although exhibiting moderately high thermal expansion (CTE) between 7&#xd7;10to 16&#xd7;10/&#xb0; C. (25-800&#xb0; C.), the honeycomb bodies exhibit relatively high thermal shock parameter (TSP), such as TSR&#x2267;525&#xb0; C. by virtue of a high MOR/E ratio, and/or low E=E/E. and well interconnected porosity, as witnessed by a relatively high pore connectivity factor (PCF). A method of manufacturing the honeycomb ceramic structure is also provided.

Low-microcracked, porous ceramic honeycombs and methods of manufacturing same

Cordierite ceramic articles with high volume percent porosities of at least 64% but less than 80% have controlled median pore sizes and mean coefficients of thermal expansion that impart substantially improved modulus of rupture strengths (MOR) and thermal shock resistance (TSR) to the ceramic articles.

High porosity filters for 4-way exhaust gas treatment

Disclosed are ceramic honeycomb articles, which are composed predominately of a crystalline phase cordierite composition. The ceramic honeycomb articles possess a microstructure characterized by a unique combination of relatively high total porosity of less than 54%, and relatively narrow pore size distribution having a dpore diameter of not less than 8 &#x3bc;m, a dpore diameter of not greater than 35 &#x3bc;m, and a value of d=(d&#x2212;d)/dof less than 0.50. The articles exhibit high thermal durability and high filtration efficiency coupled with low pressure drop across the filter. Such ceramic articles are particularly well suited for filtration applications, such as diesel exhaust filters or DPFs. Also disclosed are methods for manufacturing the ceramic articles of the present invention.

Narrow pore size distribution cordierite ceramic honeycomb articles and methods for manufacturing same

Substantially non-microcracked, porous, cordierite ceramic honeycomb bodies are provided. Although exhibiting moderately high thermal expansion (CTE) between 7&#xd7;10to 16&#xd7;10/&#xb0; C. (25-800&#xb0; C.), the honeycomb bodies exhibit relatively high thermal shock parameter (TSP), such as TSR&#x2267;525&#xb0; C. by virtue of a high MOR/E ratio, and/or low E=E/Eand well interconnected porosity, as witnessed by a relatively high pore connectivity factor (PCF). A method of manufacturing the honeycomb ceramic structure is also provided.

The present invention provides materials and methods for the manufacture of high porosity ceramic exhaust filters employing relatively low amounts of pore formers, the filters combining efficient diesel particulate filtration with effective support for exhaust emissions control catalysts. Cordierite-forming ceramic batches comprising non-hydrated transition alumina powders of relatively large particle size provide high porosities with well-controlled pore sizes and with low filter thermal expansion coefficients and good mechanical strengths.

High porosity cordierite ceramic honeycomb article and method

An aluminum titanate-based ceramic article having a composition comprising u (AlO&#x2014;TiO)+v (R)+w (3AlO&#x2014;2SiO)+x (AlO)+y (SiO)+z (1.1SrO-1.5AlO-13.6SiO&#x2014;TiO)+a (FeO&#x2014;TiO)+b (MgO-2TiO), where, R is SrO&#x2014;AlO-2SiOor 11.2SrO-10.9AlO-24.1SiO&#x2014;TiO, where u, v, w, x, y, z, a and b are weight fractions of each component such that (u+v+w+x+y+z+a+b=1), and 0.5&#x3c;u&#x2266;0.95, 0.01&#x3c;v&#x2266;0.5, 0.01&#x3c;w&#x2266;0.5, 0&#x2266;x&#x2266;0.5, 0&#x2266;y&#x2266;0.1, 0&#x2266;z&#x2266;0.5, 0&#x3c;a&#x2266;0.3, and 0&#x2266;b&#x2266;0.3. A method of forming the ceramic article is provided. The ceramic article is useful in automotive emissions control systems, such as diesel exhaust filtration.

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Painted Post, NY, United States of America

Isabelle Marie Melscoet-Chauvel