NARROW PORE SIZE DISTRIBUTION CORDIERITE CERAMIC HONEYCOMB ARTICLES AND METHODS FOR MANUFACTURING SAME

摘要

Disclosed are ceramic honeycomb articles, which are composed predominately of a crystalline phase cordierite composition. The ceramic honeycomb articles possess a microstructure characterized by a unique combination of relatively high porosity between 42% and 56%, and relatively narrow pore size distribution wherein less than 15% of the total porosity has a pore diameter less than 10 µm, less than 20% of the total porosity has a pore diameter greater than 30 µm, and dl_breadth = 1 -50 wherein d_breadth = (d90-d10) / d5o. The articles exhibits high thermal durability and high filtration efficiency coupled with low pressure drop across the filter. Such ceramic articles are particularly well suited for filtration applications, such as diesel exhaust filters or DPFs. Also disclosed is a method for manufacturing the ceramic article wherein the pore former is preferably potato starch having a median particle diameter greater than 40 µm.