초록 ▼

A method of manufacturing a honeycomb body is disclosed having the steps of mixing inorganic source materials, a nut shell pore former, and forming aids to form a plasticized batch, wherein the nut shell pore former has a particle size distribution with 20 μm≦dp50≦70 μm, and forming the plasticized

A method of manufacturing a honeycomb body is disclosed having the steps of mixing inorganic source materials, a nut shell pore former, and forming aids to form a plasticized batch, wherein the nut shell pore former has a particle size distribution with 20 μm≦dp50≦70 μm, and forming the plasticized batch into the honeycomb body having a plurality of channels formed by intersecting walls. Green honeycombs and porous ceramic honeycombs produced by the method are also disclosed.

대표청구항 ▼

1. A method of manufacturing a honeycomb body, comprising the steps of: mixing inorganic source materials, a pore former, and forming aids to form a plasticized batch, wherein the pore former includes nut shells having a particle size distribution with 30 μm≦dp50≦50 μm wherein dp50 is a median parti

1. A method of manufacturing a honeycomb body, comprising the steps of: mixing inorganic source materials, a pore former, and forming aids to form a plasticized batch, wherein the pore former includes nut shells having a particle size distribution with 30 μm≦dp50≦50 μm wherein dp50 is a median particle size diameter wherein 50% of the particle volume has a smaller particle diameter, wherein the nut shells exhibit a particle size distribution with dp10≧10 μm wherein dp10 is a particle diameter where 10% of the particle volume has a smaller particle diameter, and wherein the nut shells exhibit a value of dpf≦0.54 wherein dpf=dp50−dp10/dp50, andforming the plasticized batch into the honeycomb body having a plurality of channels formed by intersecting walls. 2. The method of manufacturing of claim 1 wherein the pore former comprises walnut shells. 3. The method of manufacturing of claim 2 wherein the pore former comprises English walnut shells. 4. The method of manufacturing of claim 1 wherein the pore former is selected from the group consisting of pecan shells, black walnut shells, and English walnut shells. 5. The method of manufacturing of claim 1 wherein the nut shells exhibit a particle size distribution wherein dp10≧15 μm. 6. The method of manufacturing of claim 1 wherein the nut shells exhibit a particle size distribution with dp90≦100 μm wherein dp90 is a particle diameter where 90% of the particle volume has a smaller particle diameter. 7. The method of manufacturing of claim 6 further comprising dp90≦90 μm. 8. The method of claim 1 wherein the nut shells have a median particle size between 35 μm and 45 μm. 9. The method of claim 1 wherein the nut shells are provided in the plasticized batch in an amount between 5-80 wt. % of the inorganic source materials by superaddition. 10. The method of claim 1 wherein the pore former comprises the nut shells in combination with a second pore former. 11. The method of claim 10 wherein the second pore former is a graphite pore former. 12. The method of claim 1 further comprising a step of firing the honeycomb body to produce a cordierite ceramic honeycomb having: % P 45%,d50≧10 μm,df≦0.6 wherein df=d50−d10/d50, andCTE≦25×10−7/° C. from 25-800° C. 13. The method of claim 1 further comprising a step of firing the honeycomb body to produce an aluminum titanate ceramic honeycomb having: % P≧45%,d50≧10 μm,df≦0.6 wherein df=d50−d10/d50, andCTE≦15×10−7/° C. from 25-1000° C. 14. The method of claim 1 further comprising a step of firing the honeycomb body to produce a ceramic honeycomb having 10 μm≦d50≦30 μm. 15. The method of claim 1 further comprising a step of firing the honeycomb body to produce a ceramic honeycomb having df≦0.5 wherein df=d50−d10/d50. 16. The method of claim 1 further comprising a step of firing the ceramic honeycomb body to produce a ceramic honeycomb having df≦0.4 wherein df=d50−d10/d50.