Method of coating porous ceramic structures with .gamma.-alumina

• US 4,746,537 A
• Filed: 07/13/1987
• Issued: 05/24/1988
• Est. Priority Date: 01/09/1985
• Status: Expired due to Fees

• Current Assignee: Nippondenso Co., Ltd. (DENSO Corporation)
• Original Assignee: Nippondenso Co., Ltd. (DENSO Corporation)
• Inventors: Takeuchi, Akira, Takeuchi, Yukihisa, Yoshida, Hitoshi
• Primary Examiner(s): Childs, Sadie L.
• Application Number:
  US07/073,344
• Time in Patent Office: 316 Days
• Field of Search: 427/37, 427/180, 427/181, 427/199, 427/230, 427/237, 427/376.2, 55/DIG. 5
• US Class Current: 427/564
• CPC Class Codes: B01D 53/86 Catalytic processes
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 37/0215 Coating
• CPC Class Codes: B01J 37/347 Ionic or cathodic spraying; Electric discharge
• CPC Class Codes: C04B 41/5031 Alumina
• CPC Class Codes: C04B 41/87 Ceramics

Abstract

A method of applying γ-alumina to a porous ceramics structure includes the steps of: causing fine particles of γ-alumina together with a carrier gas to flow through pores in the porous ceramics structure so as to deposit the γ-alumina fine particles on the surfaces of the skeleton of the porous ceramics structure, and heating the structure with the γ-aluminum particles deposited thereto to a predetermined temperature thereby fixing the γ-alumina particles. The fine particles of γ-alumina are formed by causing an arc discharge between the surface of molten aluminum and an aluminum electrode so as to generate vapor of aluminum, and oxidizing the aluminum vapor by an oxidizing gas which may be Ar-O₂ carrier gas which is made to flow through the pores in the porous ceramics structure.

Claims

1. A method of coating a porous ceramics structure with γ

-alumina comprising the steps of;

generating an arc discharge between the surface of aluminum in molten state and an aluminum electrode so as to generate aluminum vapor;

oxidizing said aluminum vapor to form fine particles of γ

-alumina;

causing both the γ

-alumina fine particles and a carrier gas comprising an oxidizing gas containing oxygen to flow through pores of said porous ceramics structure so that said γ

-alumina fine particles are deposited in three-dimensional and columnar form on the surface of the skeleton of said structure around said pores; and

heating said structure with said γ

-alumina fine particles deposited thereto to a predetermined temperature thereby fixing said γ

-alumina fine particles to the surface of said skeleton.

2. A method of coating a porous ceramics structure according to claim 1, wherein said porous ceramics structure has a multiplicity of inlet passages, multiplicity of outlet passages and partition walls by which said inlet and outlet passages are separated from each other.

3. A method of coating a porous ceramics structure according to claim 2, wherein said partition wall is constituted by a three-dimensional network-type skeleton and pores defined by said skeleton.

4. A method of coating a porous ceramics structure according to claim 3, wherein said oxidizing gas is air or a mixture gas containing mainly argon and oxygen.

5. A method of coating a porous ceramics structure according to claim 3, wherein a thin ceramics film is formed on the surface of said skeleton and which also fills the pores existing on the surface of said skeleton.