US 11,890,609 B2
Honeycomb bodies with improved skin CTE and isostatic strength and methods of making the same
Jacob George, Horseheads, NY (US); Mallanagouda Dyamanagouda Patil, Corning, NY (US); and Elizabeth Margaret Wheeler, Lindley, NY (US)
Assigned to Corning Incorporated, Corning, NY (US)
Filed by Corning Incorporated, Corning, NY (US)
Filed on Sep. 11, 2020, as Appl. No. 17/017,979.
Claims priority of provisional application 62/899,478, filed on Sep. 12, 2019.
Prior Publication US 2021/0077989 A1, Mar. 18, 2021
Int. Cl. B01J 21/04 (2006.01); B01J 21/06 (2006.01); B01J 21/08 (2006.01); B01J 21/12 (2006.01); B01J 21/20 (2006.01); B01J 23/10 (2006.01); B01J 23/92 (2006.01); B01J 38/48 (2006.01); B01J 38/62 (2006.01); B01J 38/66 (2006.01); B01D 39/20 (2006.01); B01D 46/24 (2006.01); B01D 53/94 (2006.01)
CPC B01J 38/485 (2013.01) [B01D 39/2068 (2013.01); B01D 46/2418 (2013.01); B01D 53/94 (2013.01); B01J 21/04 (2013.01); B01J 21/063 (2013.01); B01J 21/066 (2013.01); B01J 21/08 (2013.01); B01J 21/12 (2013.01); B01J 21/20 (2013.01); B01J 23/10 (2013.01); B01J 23/92 (2013.01); B01J 38/62 (2013.01); B01J 38/66 (2013.01); B01D 2255/9155 (2013.01); B01D 2279/30 (2013.01)] 21 Claims
OG exemplary drawing
 
1. A method for treating a honeycomb body, the honeycomb body comprising a skin surrounding a matrix of cells defined by a plurality of intersecting walls, the method comprising:
applying a buffer solution to an exterior surface of the skin, the buffer solution comprising a first pH, wherein a porous inorganic material of the skin comprises a plurality of micro-cracks, and wherein applying the buffer solution to the skin comprises introducing the buffer solution into the plurality of micro-cracks, wherein the buffer solution comprises one or more of: ammonium chloride, ammonium nitrate, ammonium acetate, ammonium hydroxide, potassium phosphate, sodium hydroxide, boric acid, potassium chloride, sodium chloride, potassium carbonate, potassium borate, potassium hydroxide, hydrochloric acid, or potassium acid phthalate; and
coating the exterior surface of the skin with an oxide slurry and depositing inorganic particles of the oxide slurry in pores of the porous inorganic material of the skin to increase a first density of the skin relative to a second density of a porous inorganic material of the matrix, the inorganic particles comprising particles of an oxide or a precursor of the oxide, wherein the oxide comprises alumina, silica, titania, zirconia, ceria, or aluminum silicate;
wherein the density of the skin after coating is 30% to 60% greater than a density of the porous inorganic material of the matrix,
wherein the oxide slurry comprises a second pH different from the first pH, and
wherein the oxide slurry and the buffer solution form a gel that inhibits the inorganic particles of the oxide or the precursor of the oxide from entering the plurality of micro-cracks.