Abstract: Methods of making a porous cordierite ceramic honeycomb article are provided. In example methods, a batch composition includes a quantity of non-crosslinked pore former provided as a superaddition of about 20% or less of a dry weight of a quantity of inorganic components. Batch compositions are also provided that include a quantity of clay and other substantially nonfibrous inorganic components sufficient to yield an article including cordierite. Example batch compositions can include clay having a median particle size of about 7 ?m or less and/or provided in an amount that is 10% or less of the dry weight of the quantity of inorganic components.

Abstract: A method for providing a catalyst on a substrate is disclosed comprising providing a first washcoat comprising a soluble washcoat salt species, a polar organic solvent, and an insoluble particulate material, contacting the first washcoat with a substrate to form a coated substrate, and then contacting the coated substrate with a second washcoat comprising an oxide or an oxide-supported catalyst to physisorb, chemisorb, bond, or otherwise adhere the oxide or the oxide-supported catalyst to the coated substrate. Also disclosed is a catalyst on a substrate comprising: a substrate; an anchor layer comprising a soluble washcoat salt species, a polar organic solvent, and an insoluble particulate material; and a second layer comprises an oxide or an oxide-supported catalyst. The catalyst on a substrate can be in either green or fired form.

Abstract: A process for making large zircon blocks by bonding multiple zircon components, and bonding materials for use in such process. The invention enables the manufacture of large zircon blocks without the need of larger-size isopressing equipment. The invention is particularly useful in making large-size isopipes for use in a fusion down-draw process in making glass sheets for use in, e.g., LCD production.

Abstract: Washcoat compositions and methods for the preparation and use thereof. A washcoat composition comprising a soluble washcoat salt species, a polar organic solvent, and an insoluble particulate material is disclosed. Also disclosed is a substrate at least partially coated with the inventive washcoat composition. A method for making a washcoat composition comprising contacting a soluble washcoat salt species, a polar organic solvent, and an insoluble particulate material is disclosed. Also disclosed is a method for coating a substrate with a washcoat, the method comprising contacting at least a portion of a substrate with the inventive washcoat composition.

Abstract: The present invention provides materials and methods for the manufacture of high porosity ceramic exhaust filters employing relatively low amounts of pore formers, the filters combining efficient diesel particulate filtration with effective support for exhaust emissions control catalysts. Cordierite-forming ceramic batches comprising non-hydrated transition alumina powders of relatively large particle size provide high porosities with well-controlled pore sizes and with low filter thermal expansion coefficients and good mechanical strengths.

Abstract: A composition is disclosed comprising a fine zircon component having a median particle size of less than 5 ?m, a medium zircon component having a median particle size of from 5 ?m to 15 ?m, and a sintering aid, wherein the composition, after firing, has a strain rate of less than about 1×10?6/hr. A method for making a green body comprising contacting a fine zircon component having a median particle size of less than 5 ?m, a medium zircon component having a median particle size of from 5 ?m to 15 ?m, and a sintering aid, and then forming the mixture into a desired shape is disclosed.

Abstract: A zircon composition having a multi-modal particle size distribution is disclosed. The multi-modal zircon composition comprises greater than about 40 parts by weight of a coarse zircon component having a median particle size of from greater than about 3 ?m to about 25 ?m, and less than about 60 parts by weight of a fine zircon component having a median particle size of 3 ?m or less. Methods for manufacturing a green body and a fired refractory ceramic body comprising the multi-modal zircon composition are also disclosed.