Honey comb assembly

• US 10,443,461 B2
• Filed: 04/02/2014
• Issued: 10/15/2019
• Est. Priority Date: 04/03/2013
• Status: Active Grant

• Current Assignee: Dinex A/S
• Original Assignee: Dinex A/S
• Inventors: Wolff, Thomas
• Primary Examiner(s): Orlando, Amber R
• Application Number:
  US14/781,743
• Publication Number:
  US 20160061076A1
• Time in Patent Office: 2,022 Days
• CPC Class Codes: B01D 46/2418 Honeycomb filters used for filtering exhaust gases of an internal combustion engine F01N3/022; ceramic honeycomb structures per se C04B38/0006
• CPC Class Codes: C04B 14/005 Inorganic fillers with a shape other than granular or fibrous carbon nanotubes C04B14/026
• CPC Class Codes: C04B 14/041 Aluminium silicates other than clay
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/30 Oxides other than silica ferrites C04B14/363
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/304 Magnesia
• CPC Class Codes: C04B 14/324 Silicon carbide
• CPC Class Codes: C04B 14/328 Silicon nitride
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 16/02 Cellulosic materials cellulosic waste materials, e.g. sawdust, rice husks, C04B18/24
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 2111/00793 as filters or diaphragms
• CPC Class Codes: C04B 24/2623 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/383 Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/34 containing cold phosphate binders
• CPC Class Codes: C04B 28/348 the starting mixture also containing one or more reactive oxides
• CPC Class Codes: C04B 38/0019 characterised by the material used for joining separate subunits
• CPC Class Codes: C04B 40/0263 Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: F01N 13/16 Selection of particular materials
• CPC Class Codes: F01N 2330/06 : Ceramic, e.g. monoliths
• CPC Class Codes: F01N 3/0222 : the structure being monolithic, e.g. honeycombs
• CPC Class Codes: F01N 3/2828 : Ceramic multi-channel monoliths, e.g. honeycombs

Abstract

The present invention relates to a composition comprising a non-oxide silicon containing component, a water soluble phosphate component, a metal oxide ceramic component, a polysaccharide component and water to 100% w/w. This composition can be transformed into a cement that holds individual honey comb filter segments of a honey comb filter together.

Claims

1. A hardened cement composition consisting of a non-oxide inorganic silicon containing component and metaphosphates,

wherein the non-oxide inorganic silicon containing component comprises an inorganic powder having a bimodal particle size distribution consisting of coarse particles and fine particles, the coarse particles having a mean particle diameter size in the range from 20-150 μ

m and the fine particles having a mean particle diameter size in the range from 1-20 μ

m; and

wherein the metaphosphates bind the coarse particles and the fine particles together to form the hardened cement composition.

2. An article of manufacture comprising:

a first porous ceramic honey comb filter segment;

a second porous ceramic honey comb filter segment; and

a layer of the hardened cement composition of claim 1 between the first and second porous ceramic honey comb filter segments, wherein the cement holds together the first and second porous ceramic honey comb filter segments.

3. The hardened cement composition of claim 1, wherein the cement is hardened at a temperature sufficiently high to transform substantially all phosphate components into the metaphosphates.

4. The hardened cement composition of claim 1, wherein the cement is hardened at the temperature of about 800°

C.-1000°

C.

5. The article of manufacture of claim 2, wherein the hardened cement composition has a thermal conductivity equal to or greater than a thermal conductivity of the first and second honey comb filter segments.

6. The article of manufacture of claim 2, wherein the hardened cement composition has a specific heat capacity per unit volume equal to or greater than a specific heat capacity per unit volume of the first and second honey comb filter segments.

7. The article of manufacture of claim 2, wherein the hardened cement composition has a coefficient of thermal expansion substantially similar to a coefficient of thermal expansion of the first and second honey comb filter segments.

8. The hardened cement composition of claim 1, wherein the inorganic power is silicon carbide or silicon nitride or mixtures thereof.

9. The hardened cement composition of claim 8, wherein the silicon carbide is alpha-silicon carbide.

10. The hardened cement composition of claim 1, wherein the metaphosphates are aluminum metaphosphates.