Abstract:
A method and apparatus to treat a dried unfired article comprising a ceramic precursor composition substantially held together by a binder, to be resistant to binder soluble solvent based processing. The method includes depositing a fluid on the article surface, and polymerizing the deposited fluid to form a polymer thin layer on the surface. The fluid may be an aerosol, a vapor, a fog, a mist, a smoke, or combinations thereof. An apparatus to perform the method and an article resistant to binder soluble solvent based processing are also provided. The article can be an unfired honeycomb body that includes a dried composition of ceramic precursor substantially held together by a binder and a layer disposed on a surface of the unfired honeycomb body. The surface to be exposed in the green state to a binder soluble solvent and the layer protects the binder from solubilization by the solvent.
Abstract:
Systems and methods for rapid drying of ceramic greenwares having a high graphite content are disclosed. The methods include employing microwave drying to bring the dryness of the ceramic greenware to a first select dryness and then employing close-coupled hot-air drying to bring the dryness to the final target dryness. The judicious use of close-coupled hot-air drying reduces end defects due to unevenness in the microwave drying process while also substantially speeding up the drying process. Various configurations for and combinations of microwave drying and close-coupled hot-air drying are disclosed.
Abstract:
Disclosed is a honeycomb support structure comprising a honeycomb body and an outer layer or skin formed of a cement that includes an inorganic filler material having a first coefficient of thermal expansion from 25 C to 600 C and a crystalline inorganic fibrous material having a second coefficient of thermal expansion from 25 C to 600 C. Skin cement composition controls level of cement liquid/colloid components, for example water, colloidal silica, and methylcellulose migration into the substrate during the skin application process to form barrier to skin wetting and staining during the washcoating process.