US5322537A
Expired / Lapsed
US
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Exhaust gas filter and method for making the same
Assignee: Panasonic Holdings Corp
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Filing: 1993-04-26
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Granted: 1994-06-21
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Expires: 2013-04-26
Abstract
Abstract An exhaust gas filter for internal combustion engines and having a honeycomb structure comprises a ceramic fiber and an inorganic binder. The ceramic fiber consists essentially of Al2O3 and SiO2. The inorganic binder includes Al2O3 and SiO2 to bind the ceramic fiber. The inorganic binder is of a single glass phase or of a mixed phase of a glass phase and a crystal phase both having the same crystal structure in the temperature range of 20 DEG to 1200 DEG C. In the inorganic binder, a crystal such as quartz which produces abnormal expansion due to crystal phase transition is excluded, and occurrence of cracking is prevented.
Inventors
- 👤 Kenichi Nakamura
- 👤 Kunio Kimura
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 20:43
CPC Classifications
F; F01; F01N; F01N3/00; F01N3/02; F01N3/021; F01N3/022; F01N3/0222; B; B01; B01D; B01D39/00; B01D39/14; B01D39/20; B01D39/2068; B01D39/2082; B01D39/2086; B01D46/00; B01D46/24; C; C04; C04B; C04B35/00; C04B35/01; C04B35/16; C04B35/18; C04B35/71; C04B35/78; C04B35/80; C04B38/00; C04B38/0006; C04B2111/00; C04B2111/00474; C04B2111/00793; F01N2330/00; F01N2330/06; Y; Y02; Y02T; Y02T10/00; Y02T10/10; Y02T10/12; Y10; Y10S; Y10S55/00; Y10S55/05; Y10S55/30
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
78 words
An exhaust gas filter comprising: a ceramic fiber including Al 2 O 3 and SiO 2 , and an inorganic binder including Al 2 O 3 and SiO 2 for binding to said ceramic fiber, wherein said inorganic binder is of a single phase of glass or of a mixed phase of a glass phase and a crystal phase, said crystal phase having a crystal structure which is invariant in the temperature range of 20° to 1200° C.
Claim 2
Dependent Claim
78 words
An exhaust gas filter comprising: a ceramic fiber including Al 2 O 3 and SiO 2 , and an inorganic binder including Al 2 O 3 and SiO 2 for binding to said ceramic fiber, wherein said inorganic binder is of a single phase of glass or of a mixed phase of a glass phase and a crystal phase, said crystal phase having a crystal structure which is invariant in the temperature range of 20° to 1200° C.
Claim 3
Dependent Claim
23 words
The exhaust gas filter of claim 1, wherein said ceramic fiber includes one compound selected from the group consisting of aluminosilicate and aluminoborosilicate.
Claim 4
Dependent Claim
15 words
The exhaust gas filter of claim 1, wherein said ceramic fiber comprises a crystal nucleus.
Claim 5
Dependent Claim
17 words
The exhaust gas filter of claim 3, wherein said crystal nucleus is Cr 2 O 3 .
Claim 6
Dependent Claim
27 words
The exhaust gas filter of claim 1, wherein said inorganic binder includes at least one compound selected from the group consisting of alkaline and alkaline earth metals.
Claim 7
Dependent Claim
56 words
An exhaust gas filter comprising a ceramic fiber including Al 2 O 3 and SiO 2 , and an inorganic binder which includes complex oxides including Al 2 O 3 , SiO 2 and potassium, to bind said ceramic fiber, wherein said inorganic binder comprises a mixed phase of a glass phase and a mullite phase.
Claim 8
Dependent Claim
56 words
An exhaust gas filter comprising a ceramic fiber including Al 2 O 3 and SiO 2 , and an inorganic binder which includes complex oxides including Al 2 O 3 , SiO 2 and potassium, to bind said ceramic fiber, wherein said inorganic binder comprises a mixed phase of a glass phase and a mullite phase.
Claim 9
Independent Claim
165 words
A method of manufacturing an exhaust gas filter comprising the steps of: 1) preparing a mixture including raw materials of ceramic powder, 2) manufacturing a honeycomb structure with a porous wall, an inlet for an exhaust gas leading to said porous wall, and an outlet for an exhaust gas after passing through said porous wall from said mixture, and 3) sintering the honeycomb structure, wherein said ceramic raw material powder comprises a ceramic fiber with Al 2 O 3 and SiO 2 as the main constituents, and an inorganic binder material powder comprising complex oxides including Al 2 O 3 , SiO 2 and at least oxides from the group consisting of alkaline and alkaline earth metal, and wherein the sintering is carried out at a temperature range in which said inorganic binder material powder changes to a single glass phase or to a mixed phase with a crystal phase having a crystal structure which is invariant in the temperature range of 20°to 1200° C.
Claim 10
Independent Claim
165 words
A method of manufacturing an exhaust gas filter comprising the steps of: 1) preparing a mixture including raw materials of ceramic powder, 2) manufacturing a honeycomb structure with a porous wall, an inlet for an exhaust gas leading to said porous wall, and an outlet for an exhaust gas after passing through said porous wall from said mixture, and 3) sintering the honeycomb structure, wherein said ceramic raw material powder comprises a ceramic fiber with Al 2 O 3 and SiO 2 as the main constituents, and an inorganic binder material powder comprising complex oxides including Al 2 O 3 , SiO 2 and at least oxides from the group consisting of alkaline and alkaline earth metal, and wherein the sintering is carried out at a temperature range in which said inorganic binder material powder changes to a single glass phase or to a mixed phase with a crystal phase having a crystal structure which is invariant in the temperature range of 20°to 1200° C.
Claim 11
Dependent Claim
27 words
The method of manufacturing an exhaust gas filter of claim 7, wherein said ceramic fiber further contains Cr 2 O 3 of 1.5 to 3.5 weight %.
Claim 12
Dependent Claim
19 words
The method of manufacturing an exhaust gas filter of claim 7, wherein said inorganic binder material powder includes sericite.
Claim 13
Dependent Claim
31 words
The method of manufacturing an exhaust gas filter of claim 7, wherein said inorganic binder material powder includes potassium of 1.8 to 3.2 weight % in terms of K 2 O.
Claim 14
Independent Claim
154 words
A method of manufacturing an exhaust gas filter comprising the steps of: 1) preparing a mixture including ceramic material powder. 2) manufacturing a honeycomb structure with a porous wall, an inlet for an exhaust gas leading to said porous wall, and an outlet for an exhaust gas after passing through said porous wall from said mixture, and 3) sintering the honeycomb structure, wherein said mixture includes aluminosilicate fiber, sericite clay, and organic binder, and wherein said step of manufacturing a honeycomb structure comprises the steps of making a planar sheet and corrugated sheet with said mixture, gluing said planar sheet to said corrugated sheet so that cavities are formed, pouring paste for plug-forming into said cavities, said paste including aluminosilicate fiber, sericite clay, and organic binder, and combining and winding said planar sheet and said corrugated sheet into a cylindrical form, wherein said sintering is carried out at a temperature range of 1400°-1500° C.
Claim 15
Independent Claim
154 words
A method of manufacturing an exhaust gas filter comprising the steps of: 1) preparing a mixture including ceramic material powder. 2) manufacturing a honeycomb structure with a porous wall, an inlet for an exhaust gas leading to said porous wall, and an outlet for an exhaust gas after passing through said porous wall from said mixture, and 3) sintering the honeycomb structure, wherein said mixture includes aluminosilicate fiber, sericite clay, and organic binder, and wherein said step of manufacturing a honeycomb structure comprises the steps of making a planar sheet and corrugated sheet with said mixture, gluing said planar sheet to said corrugated sheet so that cavities are formed, pouring paste for plug-forming into said cavities, said paste including aluminosilicate fiber, sericite clay, and organic binder, and combining and winding said planar sheet and said corrugated sheet into a cylindrical form, wherein said sintering is carried out at a temperature range of 1400°-1500° C.
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