US3923940A — Process for the manufacture of ceramic honeycomb …

Claim 1

Independent Claim 234 words

A PROCESS FOR THE MANUFACTURE OF A CERAMIC HONEY COMB STRUCTURE WHICH COMPRISES THE STEPS: A. PROVIDING COMBUSTIBLE RODS OR TUBES OF DIFFICULT TO GET WETTED MATERIAL SELECTED FROM THE GROUP CONSISTING OF PLASTICS, WOOD AND PAPER, B. APPLYING WATER-ABSORBENT PAPER TO SAID COMBUSTIBLE RODS OR TUBES HAVING A DESIRED CROSS SECTIONAL SHAPE, C. COATING SAID PAPER APPLIED, COMBUSTIBLE RODS OR TUBES INDIVIDUALLY WITH AT LEAST ONE KIND OF A CERAMICS-FORMING MATERIAL IN SLURRY FROM HAVING A WATER CONTENT FROM ABOUT 25% TO ABOUT 60% BY WEIGHT TO FORM AT LEAST ONE LAYER THEREOF ON THE PAPER-APPLIED RODS OR TUBES, (1) SAID CERAMICS-FORMING MATERIAL CONSISTING ESSENTIALLY OF AT LEAST ONE MEMBER SELECTED FROM THE GROUP CONSISTING OF ALUMINOSILICATE, ALKALINE EARTH METALISILICATES, SILIMANITE, MAGNESIUM SILICATE, MAGNESIA, ZIRCON, ZIRCONIA, PETALITE, SPODUMENE, CORDIERITE, CORUNDUM, MULLITE, ALUMINUM PHOSPHATE, SPINEL, CARBORUNDUM AND GLASS-CERAMICS; D. SAID PAPER ON SAID RODS OR TUBES BEING EFFECTIVE TO FORM A UNIDFORM COATING OF CERAMIC MATERIAL ON SAID PAPER-APPLIED, COMBUSTIBLE RODS OR TUBES, E. ARRANGING AT LEAST TWO OF THE COATED, PAPER-APPLIED RODS OR TUBES SO THAT THEY CONTACT WITH EACH OTHER AND TOGETHER FORM A DESIRED HONEYCOMB STRUCTURE BLANK; F. DRYING THE BLANK; AND THEN G. HEATING THE DRIED BLANK TO ITS SINTERING TEMPERATURE IN AN OXIDIZING ATMOSPHERE TO MAKE IT SINTERED AND SIMULTANEOUSLY BURN AWAY THE BASE COMBUSTIBLE RODS OR TUBES AND THE BASE, WATER-ABSORBENT PAPER THERBY MANUFACTURING THE CERAMIC HONEYCOMB STRUCTURE.

Claim 2

Dependent Claim 234 words

A PROCESS FOR THE MANUFACTURE OF A CERAMIC HONEY COMB STRUCTURE WHICH COMPRISES THE STEPS: A. PROVIDING COMBUSTIBLE RODS OR TUBES OF DIFFICULT TO GET WETTED MATERIAL SELECTED FROM THE GROUP CONSISTING OF PLASTICS, WOOD AND PAPER, B. APPLYING WATER-ABSORBENT PAPER TO SAID COMBUSTIBLE RODS OR TUBES HAVING A DESIRED CROSS SECTIONAL SHAPE, C. COATING SAID PAPER APPLIED, COMBUSTIBLE RODS OR TUBES INDIVIDUALLY WITH AT LEAST ONE KIND OF A CERAMICS-FORMING MATERIAL IN SLURRY FROM HAVING A WATER CONTENT FROM ABOUT 25% TO ABOUT 60% BY WEIGHT TO FORM AT LEAST ONE LAYER THEREOF ON THE PAPER-APPLIED RODS OR TUBES, (1) SAID CERAMICS-FORMING MATERIAL CONSISTING ESSENTIALLY OF AT LEAST ONE MEMBER SELECTED FROM THE GROUP CONSISTING OF ALUMINOSILICATE, ALKALINE EARTH METALISILICATES, SILIMANITE, MAGNESIUM SILICATE, MAGNESIA, ZIRCON, ZIRCONIA, PETALITE, SPODUMENE, CORDIERITE, CORUNDUM, MULLITE, ALUMINUM PHOSPHATE, SPINEL, CARBORUNDUM AND GLASS-CERAMICS; D. SAID PAPER ON SAID RODS OR TUBES BEING EFFECTIVE TO FORM A UNIDFORM COATING OF CERAMIC MATERIAL ON SAID PAPER-APPLIED, COMBUSTIBLE RODS OR TUBES, E. ARRANGING AT LEAST TWO OF THE COATED, PAPER-APPLIED RODS OR TUBES SO THAT THEY CONTACT WITH EACH OTHER AND TOGETHER FORM A DESIRED HONEYCOMB STRUCTURE BLANK; F. DRYING THE BLANK; AND THEN G. HEATING THE DRIED BLANK TO ITS SINTERING TEMPERATURE IN AN OXIDIZING ATMOSPHERE TO MAKE IT SINTERED AND SIMULTANEOUSLY BURN AWAY THE BASE COMBUSTIBLE RODS OR TUBES AND THE BASE, WATER-ABSORBENT PAPER THERBY MANUFACTURING THE CERAMIC HONEYCOMB STRUCTURE.

Claim 3

Dependent Claim 45 words

A process according to claim 1, wherein the ceramics-forming material includes as a flux a member selected from the group consisting of feldspar, talc and limestone, and as a sticking agent a member selected from the group consisting of carboxymethylcellulose, polyvinyl acetate and polyvinyl alcohol.

Claim 4

Dependent Claim 52 words

A process according to claim 1, wherein the dried blank is heated to its sintering temperature at a heating rate of not higher than approximately 80*C/hr before being heated to approximately 400*C and then at a heating rate of not higher than approximately 120*C/hr after having been heated to said approximately 400*C.

Claim 5

Dependent Claim 54 words

A process according to claim 1 wherein between the steps of coating said rods or tubes and forming said honeycomb structure blank, the following steps are included: drying each of said coated rods or tubes, and further coating each of the dried coated rods or tubes with a ceramic forming material in slurry form.

Claim 6

Dependent Claim 222 words

A process for the manufacture of a ceramic honeycomb structure which comprises the steps of: a. providing incombustible rods or tubes, b. applying water-absorbent paper to said incombustible rods or tubes having a desired cross-sectional shape, c. coating said paper-applied incombustible rods or tubes individually with at least one kind of a ceramics-forming material in slurry form having a water content from about 25% to about 60% by weight to form at least one layer thereof on the paper-applied rods or tubes, said ceramics-forming material consisting essentially of at least one member selected from the group consisting of aluminosilicate, alkaline earth metalsilicates, sillimanite, magnesium silicate, magnesia, zircon, zirconia, petalite, spodumene, cordierite, corundum, mullite, aluminum phosphate, spinel carborundum and glass-ceramics. d. said paper on said rods or tubes being effective to form a uniform coating of ceramic material on said paper-applied, incombustible rods or tubes, e. arranging at least two of the coated, paper-applied rods or tubes so that they contact with each other and together form a desired honeycomb-like mass; f. drying the mass and removing therefrom the base incombustible rods or tubes without damaging the mass to obtain a desired honeycomb structure blank; and then g. heating the dried blank to its sintering temperature to make it sintered thereby manufacturing the ceramic honeycomb structure and simultaneously burn away the water-absorbent paper.

Claim 7

Dependent Claim 222 words

A process for the manufacture of a ceramic honeycomb structure which comprises the steps of: a. providing incombustible rods or tubes, b. applying water-absorbent paper to said incombustible rods or tubes having a desired cross-sectional shape, c. coating said paper-applied incombustible rods or tubes individually with at least one kind of a ceramics-forming material in slurry form having a water content from about 25% to about 60% by weight to form at least one layer thereof on the paper-applied rods or tubes, said ceramics-forming material consisting essentially of at least one member selected from the group consisting of aluminosilicate, alkaline earth metalsilicates, sillimanite, magnesium silicate, magnesia, zircon, zirconia, petalite, spodumene, cordierite, corundum, mullite, aluminum phosphate, spinel carborundum and glass-ceramics. d. said paper on said rods or tubes being effective to form a uniform coating of ceramic material on said paper-applied, incombustible rods or tubes, e. arranging at least two of the coated, paper-applied rods or tubes so that they contact with each other and together form a desired honeycomb-like mass; f. drying the mass and removing therefrom the base incombustible rods or tubes without damaging the mass to obtain a desired honeycomb structure blank; and then g. heating the dried blank to its sintering temperature to make it sintered thereby manufacturing the ceramic honeycomb structure and simultaneously burn away the water-absorbent paper.

Claim 8

Dependent Claim 45 words

A process according to claim 5, wherein the ceramics-forming material includes as a flux a member selected from the group consisting of feldspar, talc and limestone, and as a sticking agent a member selected from the group consisting of carboxymethylcellulose, polyvinyl acetate and polyvinyl alcohol.

Claim 9

Dependent Claim 52 words

A process according to claim 5, wherein the dried blank is heated to its sintering temperature at a heating rate of not higher than approximately 80*C/hr before being heated to approximately 400*C and then at a heating rate of not higher than approximately 120*C/hr after having been heated to said approximately 400*C.

Claim 10

Dependent Claim 53 words

A process according to claim 5 wherein between the steps of coating said rods or tubes and forming said honeycomb-like mass, the following steps are included: drying each of said coated rods or tubes, and further coating each of the dried coated rods or tubes with a ceramic forming material in slurry form.

Claim 11

Dependent Claim 51 words

A process according to claim 1 wherein said step of arranging at least two of the coated, paper-applied rods or tubes so that they contact each other comprises confining a plurality of said coated, paper-applied rods or tubes within a confined area corresponding to the configuration of the desired honeycomb structure.

Claim 12

Dependent Claim 26 words

A process according to claim 9 wherein said confining step comprises applying a compressive force to said plurality of coated, paper-applied rods in said confined area.

Claim 13

Dependent Claim 51 words

A process according to claim 5 wherein said step of arranging at least two of the coated, paper-applied rods or tubes so that they contact each other comprises confining a plurality of said coated, paper-applied rods or tubes within a confined area corresponding to the configuration of the desired honeycomb structure.

Claim 14

Dependent Claim 26 words

A process according to claim 11 wherein said confining step comprises applying a compressive force to said plurality of coated, paper-applied rods in said confined area.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1978-12-01	1979-06-02	1979-12-02	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1982-12-01	1983-06-02	1983-12-02	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1986-12-01	1987-06-02	1987-12-02	$7700.00	Window Closed / Lapsed

Process for the manufacture of ceramic honeycomb structures

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