Abstract: A porous cellular body comprising primarily a porous sintered glass material is disclosed. The porous sintered glass material primarily includes a first phase and a second phase, the first phase primarily comprising amorphous fused silica and the second phase comprising amorphous fused silica and a sintering aid.

Abstract: A process for producing a honeycomb ceramic article includes providing a green honeycomb body including ceramic-forming materials and organic pore forming materials and subjecting the green honeycomb body to a firing cycle in a kiln in which steam is added to the kiln atmosphere in an amount from about 10% to about 100%, based on volume. Also provided are ceramic articles produced by the process.

Abstract: The present invention describes a high porosity (% P?45%), refractory, ceramic article comprising a cordierite ceramic phase and at least about 0.1 wt. % of a rare earth oxide, such as yttrium oxide or lanthanum oxide. When compared to typical high-porosity cordierite articles, the articles of the present invention may exhibit relatively high strength, relatively low microcracking, relatively high strain tolerance (MOR/E), and/or relatively high thermal shock resistance (TSP).

Abstract: A partial wall-flow filter having some unplugged flow-through channels and some plugged channels. Desirable combinations of filtration efficiency and back pressure may be provided by combinations of t wall?305 urn, MPD?20 ?m, % P?50%, and CD?250 cpsi wherein t wall is the transverse thickness of the porous walls, MPD is a mean pore diameter of the porous walls, % P is the total porosity of the porous walls, and CD is the cell density of the channels. In one embodiment, some of the plugged channels are located adjacent to the inlet end and some are located adjacent to the outlet end. Systems and method including the partial wall-flow filter are also described.

Abstract: The present disclosure provides a flow device including a body disposed in an extrusion apparatus. The body is defined along a plane and has a first side and a second side. The second side is disposed opposite the first side. The flow device also includes a first face formed at the first side and a second face formed at the second side. The body has a thickness defined between the first face and second face. A plurality of feedholes is defined in the body between the first side and the second side. In addition, at least a portion of the first face or second face forms a curvature that extends outwardly from the plane.

Abstract: 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 ?m?dp50?70 ?m, 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.

Abstract: Disclosed are ceramic honeycomb articles which possess a unique microstructure characterized by porosity between 40% and 70%, and the presence of coarse pores exhibiting a depth equivalent to the thickness of the cell wall and a dimensional width, in the plane of the cell wall, exhibiting a diameter that is at least as large as the thickness of the cell wall. The articles exhibits reduced filtration efficiency coupled with low pressure drop across the filter, and a reduced regeneration need. Such ceramic articles are particularly well suited for filtration applications, such as off-road and retro-fit diesel exhaust filters or DPFs. Also disclosed is a method for manufacturing the ceramic article wherein the pore former is capable of forming coarse pores.

Abstract: A particulate filter may comprise an inlet end, an outlet end, and a plurality of parallel channels disposed and configured to flow fluid from the inlet end to the outlet end, the channels being defined by a plurality of porous walls configured to trap particulate matter. The particulate filter may define at least one filtration region including a first group of channels and at least one bypass region including a second group of channels, wherein at least some of the channels in the first group of channels are plugged at an end thereof, wherein the channels in the second group of channels are unplugged, and wherein greater than or equal to about 70% of the plurality of parallel channels are plugged at an end thereof.

Abstract: An exhaust gas after-treatment system (10) for a gasoline engine (12) has a three-way catalyst (14) close-coupled to the gasoline engine, a particulate matter control device (18) positioned downstream of the three-way catalyst, a NOx control system (16) positioned downstream of the particulate matter control device. According to one method of operation, the gasoline engine is operated in a stoichiometric condition upon start-up of the engine, the exhaust gas flow generated by the engine is conducted through the exhaust system, and then the gasoline engine (12) is operated in a lean-burn condition after the NOx control system (16) attains a minimum operating temperature.

Abstract: A particulate filter may comprise an inlet end, an outlet end, and a plurality of channels disposed and configured to flow fluid from the inlet end to the outlet end, wherein the channels are defined by porous walls configured to trap particulate matter. The porous walls may have a cell density less than about 200 cpsi, a wall thickness of less than about 14 mils, a median pore size that ranges from about 13 micrometers to about 20 micrometers, a total porosity greater than about 45%, and a pore size distribution such that pores less than 10 micrometers contribute less than about 10% porosity.

Abstract: The present invention describes a high porosity (% P?45%), refractory, ceramic article comprising a cordierite ceramic phase and at least about 0.1 wt.% of a rare earth oxide, such as yttrium oxide or lanthanum oxide. When compared to typical high-porosity cordierite articles, the articles of the present invention may exhibit relatively high strength, relatively low microcracking, relatively high strain tolerance (MOR/E), and/or relatively high thermal shock resistance (TSP).

Abstract: A porous ceramic honeycomb article includes a primary cordierite phase and an intercrystalline glass phase. In an as-fired condition, the porous ceramic honeycomb article exhibits microcrack parameter Nb3 ?0.06 and an as-fired E500° C./E25° C. ratio ?0.99. The article exhibits a coated microcrack parameter Nb3 ?0.14 and a coated E500° C./E25° C. ratio ?1.06 after the porous ceramic honeycomb article has been washcoated and calcined at a temperature of 550° C. After the article is exposed to a thermal treatment at a temperature ?800° C. following washcoating and calcining, at least a first portion of the porous ceramic honeycomb article has a first treated microcrack parameter Nb3 ?0.18, and a first treated mean coefficient of thermal expansion of not more than 12×10?7/° C. over a temperature range of 25° C. to 800° C. Methods of forming the porous ceramic honeycomb article are also disclosed.

Abstract: A particulate filter may comprise an inlet end, an outlet end, and a plurality of channels disposed and configured to flow fluid from the inlet end to the outlet end, wherein the channels are defined by porous walls configured to trap particulate matter. The porous walls may have a total porosity greater than about 45%, a median pore size ranging from about 13 micrometers to about 20 micrometers, and a pore size distribution such that pores less than 10 micrometers contribute less than about 10% porosity.

Abstract: 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 ?m?dp50?70 ?m, 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.

Abstract: A partial wall-flow filter having some unplugged flow-through channels and some plugged channels. Desirable combinations of filtration efficiency and back pressure may be provided by combinations of t wall?305 urn, MPD?20 ?m, % P?50%, and CD?250 cpsi wherein t wall is the transverse thickness of the porous walls, MPD is a mean pore diameter of the porous walls, % P is the total porosity of the porous walls, and CD is the cell density of the channels. In one embodiment, some of the plugged channels are located adjacent to the inlet end and some are located adjacent to the outlet end. Systems and method including the partial wall-flow filter are also described.

Abstract: Disclosed are porous ceramic honeycomb articles, such as filters, which are composed predominately of a cordierite composition. The ceramic honeycomb articles possess a porous microstructure characterized by a unique combination of relatively high porosity (>45%), and moderately narrow pore size distribution wherein greater than 15% and less than 38% of the total porosity exhibits a pore diameter less than 10 ?m, and low CTE wherein CTE?6.0×10?7/° C. (from 23° C. to 800° C.). The articles exhibit high thermal durability and high filtration efficiency coupled with low pressure drop. Such ceramic articles are particularly well suited for use in filtration applications, such as in diesel exhaust filters. Also disclosed are methods for manufacturing the porous ceramic honeycomb article.

Abstract: A thermally shock resistant ceramic body, such as a porous ceramic honeycomb structure for a wall flow diesel engine exhaust filter or a flow-through ceramic catalyst support, is formed of a composite ceramic material comprising a major first ceramic phase exhibiting good thermal shock resistance and a minor second phase material that substantially reduces the elastic modulus of the composite ceramic material at elevated temperatures.

Abstract: Substantially non-microcracked, porous, cordierite ceramic honeycomb bodies are provided. Although exhibiting moderately high thermal expansion (CTE) between 7×10?7 to 16×10?7/° C. (25-800° C.), the honeycomb bodies exhibit relatively high thermal shock parameter (TSP), such as TSR?525° C. by virtue of a high MOR/E ratio, and/or low Eratio=ERT/E1000° C. and well interconnected porosity, as witnessed by a relatively high pore connectivity factor (PCF). A method of manufacturing the honeycomb ceramic structure is also provided.

Abstract: A particulate filter may comprise an inlet end, an outlet end, and a plurality of parallel channels disposed and configured to flow fluid from the inlet end to the outlet end, the channels being defined by a plurality of porous walls configured to trap particulate matter. The particulate filter may define at least one filtration region including a first group of channels and at least one bypass region including a second group of channels, wherein at least some of the channels in the first group of channels are plugged at an end thereof, wherein the channels in the second group of channels are unplugged, and wherein greater than or equal to about 70% of the plurality of parallel channels are plugged at an end thereof.

Abstract: Disclosed are ceramic honeycomb articles which possess a unique microstructure characterized by porosity between 40% and 70%, and the presence of coarse pores exhibiting a depth equivalent to the thickness of the cell wall and a dimensional width, in the plane of the cell wall, exhibiting a diameter that is at least as large as the thickness of the cell wall. The articles exhibits reduced filtration efficiency coupled with low pressure drop across the filter, and a reduced regeneration need. Such ceramic articles are particularly well suited for filtration applications, such as off-road and retro-fit diesel exhaust filters or DPFs. Also disclosed is a method for manufacturing the ceramic article wherein the pore former is capable of forming coarse pores.