Corning Incorporated

James Albert Boorom

Gregory A Merkel

Lin He

Robert John Paisley

Disclosed is a honeycomb ceramic article that exhibits a primary crystalline phase of cordierite having a coefficient of thermal expansion (CTE), wherein CTE&#x3c;1.5&#xd7;10/&#xb0; C. over the temperature range of about 25&#xb0; C. to about 800&#xb0; C.; a total porosity, P, of at least 28%, a transverse I-ratio, I, of less than 0.92; and a pore size distribution wherein at least 60% of the total pore volume is comprised of pores having diameters between 0.5 &#x3bc;m and 5.0 &#x3bc;m. Also provided is a ceramic honeycomb article comprising a phase of cordierite and exhibiting a mean CTE &#x3c;1.0&#xd7;10/&#xb0; C. (from 25 to 800&#xb0; C.) in at least one direction, and 28%&#x2266;P&#x2266;33%. Methods of manufacturing ceramic articles comprising the aforementioned cordierite compositions are also disclosed.

Low CTE cordierite honeycomb article and method of manufacturing same

A method for plugging a selected subset of cell channels of a honeycomb structure having a multiplicity of mutually adjoining cell channels which have open ends at and extend throughout the structure between opposing end faces thereof. The method includes (a) loading a powdered plugging material into open end portions of cell channels at one end face of the honeycomb structure, wherein the powdered plugging material passes the length of the cell channels to settle at opposing end portions of the cell channels; (b) compacting the powdered plugging material in the cell channels at the one end face of the honeycomb structure; (c) scanning the one end face of the honeycomb structure to locate the selected subset of cell channels to be plugged; (d) generating in response to the scanning step first signals indicating the location of the selected subset of cell channels; (e) generating in response to the first signals second signals for positioning a laser with respect to the selected subset of cell channels; (f) positioning the laser with respect to the selected subset of cell channels, wherein the laser generates energy which adherently bonds the compacted plugging material to surrounding cell walls to form plugs thereat; and, (g) removing the remaining compacted plugging material from all but the selected subset of cell channels which have been plugged.

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Coopers Plains, NY, United States of America

James Albert Boorom