US 12,286,915 B2
High porosity ceramic honeycomb structure and method of manufacturing
Douglas Munroe Beall, Painted Post, NY (US); Achim Karl-Erich Heibel, Corning, NY (US); and David John Thompson, Savona, NY (US)
Assigned to Corning Incorporated, Corning, NY (US)
Filed by CORNING INCORPORATED, Corning, NY (US)
Filed on Jul. 6, 2023, as Appl. No. 18/218,788.
Application 18/218,788 is a continuation of application No. 16/085,089, granted, now 11,739,670, previously published as PCT/US2017/022859, filed on Mar. 17, 2017.
Claims priority of provisional application 62/309,754, filed on Mar. 17, 2016.
Prior Publication US 2023/0358154 A1, Nov. 9, 2023
Int. Cl. F01N 3/022 (2006.01); B01D 46/24 (2006.01); C04B 35/195 (2006.01); C04B 35/636 (2006.01); C04B 38/00 (2006.01); F01N 3/035 (2006.01); C04B 111/00 (2006.01)
CPC F01N 3/0222 (2013.01) [B01D 46/2425 (2013.01); B01D 46/2429 (2013.01); B01D 46/24491 (2021.08); B01D 46/24492 (2021.08); B01D 46/2455 (2013.01); B01D 46/2474 (2013.01); B01D 46/2482 (2021.08); B01D 46/2484 (2021.08); C04B 35/195 (2013.01); C04B 35/6365 (2013.01); C04B 38/0009 (2013.01); F01N 3/035 (2013.01); C04B 2111/00793 (2013.01); C04B 2111/0081 (2013.01); C04B 2235/3217 (2013.01); C04B 2235/349 (2013.01); C04B 2235/5436 (2013.01); C04B 2235/6562 (2013.01); C04B 2235/6567 (2013.01); C04B 2235/9607 (2013.01); F01N 2330/06 (2013.01); F01N 2330/30 (2013.01); F01N 2330/48 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A method of manufacturing a ceramic honeycomb structure, comprising:
forming a cordierite precursor batch composition mixture comprising a combination of constituent materials comprising:
inorganic particles comprised of magnesia source particles, silica source particles, and alumina source particles, the inorganic particles having a median particle diameter less than or equal to about 10 μm, wherein the magnesia source particles or the alumina source particles comprise spinel particles and the amount of silica source is about 13% to about 24% by weight of the inorganic particles, and
at least one starch-based pore former having a median particle diameter greater than or equal to about 10 μm;
forming the mixture of ceramic precursor batch composition and at least one starch-based pore former into a green body having a honeycomb web structure of intersecting walls; and
firing the green ceramic body to yield the ceramic honeycomb structure comprising a predominant cordierite crystalline phase.