Ceramic cellular structure having high cell density and catalyst

Details Ceramic cellular structure having high cell density and catalyst Ceramic cellular structure having high cell density and catalyst

1975-10-31

1977-05-24

Lesmes, George F.

Compositions

X-ray or neutron shield

23288F, 165166, 264 56, 264 59, 264 63, 428182, 428184, 428186, F28D 1700, B32B 328

Patent

active

040254623

ABSTRACT:
A ceramic cellular structure having a cell density of up to 1600 cells per square inch and wall thicknesses down to 2 mils is produced by a process which comprises: (1) forming a slurry consisting essentially of finely divided sinterable solid particles of ceramic raw materials and a controlled amount of a plastic supporting matrix containing thermoplastic resin, a thermosetting resin, a plasticizer, an organic solvent and a small amount of a deflocculant; (2) ball milling the slurry; (3) casting the slurry in the form of a film; (4) removing the solvent to produce a self-supporting green ceramic tape; (6) molding a portion of the tape to form a corrugated first member; (7) providing another portion of the tape to form a substantially flat second member; (8) forming a first bilayer by bonding the second member to the nodes of the first member; (9) mutually bonding a predetermined number of bilayers substantially identical to the first bilayer to form a cellular green structure of a desired shape; and (10) firing the green structure at a temperature sufficient to form a sinter-welded polycrystalline ceramic structure. The fired structures, after being subjected to various finishing operations, are useful as rotary heat regenerators, stationary heat recuperators and catalyst supports.

REFERENCES:
patent: 3112184 (1963-11-01), Hollenbach
patent: 3320044 (1967-05-01), Cole et al.
patent: 3444925 (1969-05-01), Johnson
patent: 3502596 (1970-03-01), Sowards
patent: 3717487 (1973-02-01), Hurley et al.
patent: 3794707 (1974-02-01), O'Neill et al.

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