EP0043694A1
Expired / Lapsed
EP
⏱️ 0.0 years remaining
Particulate filter and material for producing the same
Assignee: Corning Glass Works
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Filing: 1981-07-01
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Granted: —
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Expires: 2001-07-01
Abstract
Abstract Apparatus for filtering solid particulates from suspension in fluid streams (especially carbon particulates from exhaust gas of diesel engines) comprising a honeycomb filter with thin porous walls defining cells extending therethrough, with the transverse cross-sectional shapes of the cells forming a repeating pattern of geometric shapes without corner angles of less than 30° and with alternate cells forming an inlet group and an outlet group. The inlet group is open at the inlet face and closed adjacent the outlet face. The outlet group is closed adjacent the inlet face and open at the outlet face. Each cell of each group shares cell walls only with cells of the other group. The walls may have a volume of substantially uniform interconnected open porosity. Further described are impervious, unglazed, sintered ceramic products of primarily cordierite crystal phase, exhibiting low coefficient of thermal expansion and having analytical molar composition of about 1.7-2.4 RO . 1.9-2.4 Al 2 O 3 . 4.5-5.2 Si0 2 , as well as a foamable particulate cement capable of forming sintered cordierite foamed ceramic masses, consisting essentially, by weight, of 1-40% cordierite grog, 99 - 60% ceramic base material and foaming agent, such as SiC, useful as materials for the apparatus.
Inventors
- 👤 Irwin Morris Lachman
- 👤 Rodney Irving Frost
- 👤 Robert John Paisley
- 👤 Wayne Harold Pitcher, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-10-30 12:48
CPC Classifications
B; B01; B01D; B01D39/00; B01D39/14; B01D39/20; B01D39/2068; B01D39/2072; B01D39/2075; B01D46/00; B01D46/24; B01D46/2403; B01D46/2407; C; C04; C04B; C04B35/00; C04B35/01; C04B35/16; C04B35/18; C04B35/195; C04B37/00; C04B37/003; C04B37/005; C04B38/00; C04B38/0006; C04B38/02; F; F01; F01N; F01N3/00; F01N3/02; F01N3/021; F01N3/0211; F01N3/022; F01N3/0222; C04B2235/00; C04B2235/65; C04B2235/656; C04B2235/6567; C04B2237/00; C04B2237/02; C04B2237/04; C04B2237/06; C04B2237/062; C04B2237/30; C04B2237/32; C04B2237/34; C04B2237/341; F01N2330/00; F01N2330/06; F01N2350/00; F01N2350/02; F02; F02B; F02B3/00; F02B3/06; Y; Y02; Y02T; Y02T10/00; Y02T10/10; Y02T10/12
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
179 words
Apparatus for filtering solid particulates from suspension in fluid streams, which comprises a filter of honeycomb structure having a matrix of thin porous walls defining a plurality of cells extending longitudinally and mutually parallel therethrough between inlet and outlet end faces of the structure, the walls containing substantially uniform interconnected open porosity of a volume and size sufficient to enable the fluid to flow completely through the walls and to restrain most or all of the particulates from passing completely through the walls, the transverse cross-sectional shapes of the cells forming a substantially uniformly repeating pattern of geometric shapes without corner angles of less than 30°, an inlet group of the cells open at the inlet end face and closed adjacent to the outlet end face, an outlet group of the cells closed adjacent to the inlet end face and open at the outlet end face, each cell of the inlet group sharing cell walls only with cells of the outlet group, and each cell of the outlet group sharing cell walls only with cells of the inlet group.
Claim 2
Dependent Claim
179 words
Apparatus for filtering solid particulates from suspension in fluid streams, which comprises a filter of honeycomb structure having a matrix of thin porous walls defining a plurality of cells extending longitudinally and mutually parallel therethrough between inlet and outlet end faces of the structure, the walls containing substantially uniform interconnected open porosity of a volume and size sufficient to enable the fluid to flow completely through the walls and to restrain most or all of the particulates from passing completely through the walls, the transverse cross-sectional shapes of the cells forming a substantially uniformly repeating pattern of geometric shapes without corner angles of less than 30°, an inlet group of the cells open at the inlet end face and closed adjacent to the outlet end face, an outlet group of the cells closed adjacent to the inlet end face and open at the outlet end face, each cell of the inlet group sharing cell walls only with cells of the outlet group, and each cell of the outlet group sharing cell walls only with cells of the inlet group.
Claim 3
Dependent Claim
41 words
Apparatus as claimed in claim 1 wherein the volume of open porosity and the mean diameter of the pores forming the open porosity lie within the area defined by the boundary lines connecting points 1-2-3-4 in Figure 4 of the drawings.
Claim 4
Dependent Claim
22 words
Apparatus as claimed in claim 1 or 2 wherein the walls within each transverse sector of the structure have substantially uniform thickness.
Claim 5
Dependent Claim
19 words
Apparatus as claimed in claim 1 or 2 wherein the walls throughout the structure have a substantially uniform thickness.
Claim 6
Dependent Claim
24 words
Apparatus as claimed in claim 1 or 2 wherein the transverse cross-sectional geometric shapes of the cells are of quadrilateral, triangular, or square configuration.
Claim 7
Dependent Claim
62 words
Apparatus as claimed in claim 1 or 2, wherein the walls are not greater than about 1.5 mm thick and contain interconnected open porosity of at least about 25% by volume formed by pores with a mean pore diameter of at least about 1 pm, and the structure has a transverse cross-sectional cell density of at least about 1.5 cells/cm 2 .
Claim 8
Dependent Claim
17 words
Apparatus as claimed in claim 6 wherein the walls are not greater than about 0.635 mm thick.
Claim 9
Dependent Claim
30 words
Apparatus as claimed in claim 6 or 7 wherein the open porosity is at least about 35% by volume and the mean pore diameter is at least about 3.5 µm.
Claim 10
Dependent Claim
18 words
Apparatus as claimed in claim 8 wherein the cell density is at least about 7.75 cells/cm 2 .
Claim 11
Dependent Claim
18 words
Apparatus as claimed in claim 9 wherein the geometric shapes of the cells are either square or triangles.
Claim 12
Dependent Claim
34 words
Apparatus as claimed in claim 6 wherein pore diameter of the pores forming the open porosity lie within the area defined by the boundary lines connecting points 1-5-6-4 in Figure 4 of the drawings.
Claim 13
Dependent Claim
36 words
Apparatus as claimed in claim 1, 2 or 11 wherein the walls have a thickness in the range of about 0.05-1.27 mm and the cell density is in the range of about 2-93 cells/cm 2 .
Claim 14
Dependent Claim
17 words
Apparatus as claimed in claim 12 wherein the walls are not less than about 0.3 mm thick.
Claim 15
Dependent Claim
39 words
Apparatus as claimed in any one of the preceding claims, used as part of a diesel engine exhaust gas system, interposed across the exhaust gas path, with the inlet face of the filter facing upstream of the gas path.
Claim 16
Dependent Claim
17 words
Apparatus as claimed in claim 14, dispersed in a housing through which passes the exhaust gas path.
Claim 17
Dependent Claim
81 words
Apparatus as claimed in any one of claims 1-13, used in a molten metal filtration chamber comprising a first portion for containing unfiltered molten metal, a second portion for containing filtered molten metal, a passage for flow of the molten metal from the first portion to the second portion, and the passage containing the filter interposed across the molten metal flow path through the passage with the inlet end face of the filter facing upstream of the molten metal flow path.
Claim 18
Dependent Claim
106 words
Apparatus as claimed in any one of claims 1-13, used in a heat exchange assembly comprising a..heat exchange chamber having two separate fluid flow paths therethrough, a pair of ducts for passing hotter first fluid to and carrying cooled first fluid from one fluid flow path, a pair of ducts for passing cooler second fluid to and carrying heated second fluid from the other fluid flow path, a heat exchange wheel interposed and rotatable across the two fluid flow paths within the chamber, and the wheel comprising the filter with the inlet and outlet faces thereof facing the fluid flow directions from and to the ducts.
Claim 19
Dependent Claim
18 words
Apparatus as claimed in any one of the preceding claims wherein the filter is fabricated of ceramic material.
Claim 20
Dependent Claim
106 words
An impervious, unglazed, sintered manganese-containing ceramic material for making the apparatus of any one of the preceding claims, having its major and primary crystal phase being cordierite crystal structure, having an analytical molar composition of about 1.7-2.4 RO 1.9-2.4 Al 2 O3 · 4.5-5.2 Si0 2 and made of mineral batch composition selected from: (a) wholly raw ceramic material wherein RO comprises, as mole % of RO, about 55-95% MnO, and 4-45% MgO, and (b) at least about 50 wt % prereacted cordierite material and the balance thereof being raw ceramic material, and wherein RO comprises, as mole of RO, about 5-40% MnO and 60-95% MgO.
Claim 21
Dependent Claim
20 words
The ceramic material as claimed in claim 19 wherein the selected mineral batch composition is the wholly raw ceramic material.
Claim 22
Dependent Claim
21 words
The ceramic material as claimed in claim 20 wherein RO comprises about 74-90 mole % MnO and 10-26 mole % MgO.
Claim 23
Dependent Claim
31 words
The ceramic material as claimed in claim 19 wherein the selected mineral batch composition is at least about 50 wt.% prereacted cordierite material and the balance thereof being raw ceramic material.
Claim 24
Dependent Claim
23 words
The ceramic material as claimed in claim 22 wherein the prereacted cordierite material is about 50-95 wt % of the mineral batch composition.
Claim 25
Dependent Claim
20 words
The ceramic material as claimed in claim 23 wherein RO comprises about 6-15 mole % MnO and 85-94 mole %Mgo.
Claim 26
Dependent Claim
26 words
The ceramic material as claimed in claim 22, 23 or 24 wherein the prereacted cordierite material is about 80-90 wt. % of the mineral batch composition.
Claim 27
Dependent Claim
28 words
The ceramic material as claimed in claim 19 wherein the analytical molar composition is about 1.9-2.1 RO . 1.9-2.1 Al 2 O 3 · 4.9-5.1 SiO 2 .
Claim 28
Dependent Claim
183 words
A foamable particulate ceramic cement capable of forming a sintered cordierite foamed ceramic mass, for use as a bond in the apparatus of any one of claims 1-13, consisting essentially, by weight, of: 1-40% cordierite grog, 99-60% ceramic base material and an effective amount of a foaming agent to effect foaming of the cement upon firing to produce the foamed ceramic mass, the base material being raw ceramic material that has an analytical molar composition consisting essentially of about: 1.7-2.4 MO . 1.2-2.4 Al 2 O 3 - 4.5-5.4 Si0 2 wherein MO comprises, as mole % of MO, about O-55% MgO and at least 45% MnO, and the grog being ceramic material that has been previously fired and comminuted, and that has an analytical molar composition consisting essentially of about: 1.7-2.4 RO . 1.9-2.4 Al 2 O 3 · 4.5-5.2 SiO2 wherein RO comprises, as mole % of RO, MnO in an amount of O% up to a mole % that is about 20 mole % lower than the mole % of MO that is MnO and the balance is substantially MgO.
Claim 29
Dependent Claim
31 words
Cement as claimed in claim 27 wherein the foaming agent is SiC in an amount of at least 0.25% and up to about 5% by weight of grog plus base material.
Claim 30
Dependent Claim
26 words
Cement as claimed in claim 28 wherein the grog is at least 5 wt % and the base material is not more than 95 wt. %.
Claim 31
Dependent Claim
60 words
Cement as claimed in claim 28 wherein the analytical molar composition of the base material is about: 1.7-2.4 MO . 1.9-2.4 Al 2 O 3 · 4.5-5.2 SiO 2 the grog is 5-20 wt %, the base material is 95-80 Wt %, SiC is at least 1 wt. % and MO comprises not more than about 15 mole % MgO.
Claim 32
Dependent Claim
40 words
Cement of claim 30 wherein the analytical molar composition of the grog is about: 1.8-2.1 RO . 1.9-2.1 Al 2 O 3 · 4.9-5.2 SiO 2 , MO is wholly MnO and SiC is not more than 2 wt %.
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