US4772580A
Expired / Lapsed
US
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Catalyst carrier of cordierite honeycomb structure and method of producing the same
Assignee: Garmin Switzerland GmbH
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Filing: 1986-12-01
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Granted: 1988-09-20
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Expires: 2006-12-01
Abstract
Abstract Catalyst carriers made of cordierite honeycomb structures having low thermal expansion, porosities of not exceeding 30%, high strengths and thin partition walls with high cell density or low cell density are provided by using very fine particles of kaoline and talc which are considered heretofore disadvantageous for producing such catalyst carriers. The catalyst carriers are useful in a broader use field than conventional ones, particularly as catalyst carriers for purifying exhaust gases exited from automobile engines.
Inventors
- 👤 Toshiyuki Hamanaka
- 👤 Keiichiro Watanabe
- 👤 Takashi Harada
- 👤 Seiichi Asami
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 15:47
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/01; C04B35/16; C04B35/18; C04B35/195; B; B01; B01J; B01J35/00; B01J35/50; B01J35/56; B01J35/57; C04B38/00; C04B38/0006; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24149
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
112 words
A method of producing a cordierite catalyst carrier having a honeycomb structure comprising: preparing a batch including talc particles having an average particle diameter of not greater than 7 μm, kaolin particles having an average particle diameter not greater than 2 μm and not greater than 1/3 of the average particle diameter of the talc particles and other raw materials for producing the cordierite; adding an organic binder and a plasticizer to the batch to form an admixture; kneading said admixture to plasticize same to an extrudable consistency; extruding said admixture to form a honeycomb structure; drying the extruded honeycomb structure; and firing the honeycomb structure at a temperature of 1350°-1440° C.
Claim 2
Independent Claim
112 words
A method of producing a cordierite catalyst carrier having a honeycomb structure comprising: preparing a batch including talc particles having an average particle diameter of not greater than 7 μm, kaolin particles having an average particle diameter not greater than 2 μm and not greater than 1/3 of the average particle diameter of the talc particles and other raw materials for producing the cordierite; adding an organic binder and a plasticizer to the batch to form an admixture; kneading said admixture to plasticize same to an extrudable consistency; extruding said admixture to form a honeycomb structure; drying the extruded honeycomb structure; and firing the honeycomb structure at a temperature of 1350°-1440° C.
Claim 3
Dependent Claim
20 words
The method of claim 1, wherein said talc particles have an average particle diameter of not greater than 5 μm.
Claim 4
Dependent Claim
20 words
The method of claim 1, wherein said kaolin particles have an average particle diameter of not greater than 1 μm.
Claim 5
Dependent Claim
37 words
The method of claim 1, wherein at least one material selected from the group consisting of alumina particles and aluminum hydroxide particles having an average particle diameter not greater than 2 μm is added to the batch.
Claim 6
Dependent Claim
20 words
The method of claim 4, wherein said talc particles have an average particle diameter of not greater than 5 μm.
Claim 7
Dependent Claim
20 words
The method of claim 4, wherein said kaolin particles have an average particle diameter of not greater than 1 μm.
Claim 8
Dependent Claim
17 words
The method of claim 4, wherein said alumina has a Na 2 O content not exceeding 0.12%.
Claim 9
Dependent Claim
21 words
The method of claim 4, wherein said kaolin particles are prepared by grinding calcined kaoline in a wet type ball mill.
Claim 10
Dependent Claim
15 words
The method of claim 1, wherein highly pure amorphous silica is added to the batch.
Claim 11
Dependent Claim
20 words
The method of claim 9, wherein said talc particles have an average particle diameter of not greater than 5 μm.
Claim 12
Dependent Claim
20 words
The method of claim 9, wherein said kaolin particles have an average particle diameter of not greater than 1 μm.
Claim 13
Dependent Claim
17 words
The method of claim 9, wherein said alumina has a Na 2 O content not exceeding 0.12%.
Claim 14
Dependent Claim
21 words
The method of claim 9, wherein said kaolin particles are prepared by grinding calcined kaoline in a wet type ball mill.
Claim 15
Dependent Claim
22 words
The method of claim 9, wherein said highly pure amorphous silica is added to the batch in an amount not exceeding 8%.
Claim 16
Dependent Claim
131 words
A cordierite catalyst carrier having a honeycomb structure comprising: a chemical composition in weight percent of 42-56% of SiO 2 , 30-45% of Al 2 O 3 and 12-16% of MgO as main components; a crystalline phase consisting mainly of cordierite; a porosity of not greater than 30%; an axis A which corresponds to a longitudinal direction of a plurality of channels in said honeycomb structure, wherein the coefficient of thermal expansion in the direction of axis A is not greater than 0.8×10 -6 /°C. in a temperature range of 40°-800° C.; and an axis B which corresponds to a transverse direction of said channels, wherein the coefficient of thermal expansion in the direction of axis B is not greater than 1.0×10 -6 /°C. in a temperature range of 40°-800° C.
Claim 17
Dependent Claim
131 words
A cordierite catalyst carrier having a honeycomb structure comprising: a chemical composition in weight percent of 42-56% of SiO 2 , 30-45% of Al 2 O 3 and 12-16% of MgO as main components; a crystalline phase consisting mainly of cordierite; a porosity of not greater than 30%; an axis A which corresponds to a longitudinal direction of a plurality of channels in said honeycomb structure, wherein the coefficient of thermal expansion in the direction of axis A is not greater than 0.8×10 -6 /°C. in a temperature range of 40°-800° C.; and an axis B which corresponds to a transverse direction of said channels, wherein the coefficient of thermal expansion in the direction of axis B is not greater than 1.0×10 -6 /°C. in a temperature range of 40°-800° C.
Claim 18
Dependent Claim
15 words
The structure of claim 15, which further comprises a porosity of not greater than 25%.
Claim 19
Dependent Claim
49 words
The structure of claim 15, which further comprises a difference between the coefficient of thermal expansion in the direction of axis A and the coefficient of thermal expansion in the direction of axis B which is not greater than 0.2×10 -6 /°C. in a temperature range of 40°-800° C.
Claim 20
Dependent Claim
25 words
The structure of claim 13, which further comprises a compressive strength in the direction of axis A of not less than 200 kg/cm 2 .
Claim 21
Dependent Claim
18 words
The structure of claim 15, which further comprises a partition wall thickness of not greater than 437 μm.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-09-20 | 1992-03-21 | 1992-09-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-09-20 | 1996-03-21 | 1996-09-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-09-20 | 2000-03-21 | 2000-09-20 | $7700.00 | Window Closed / Lapsed |