A batch mixture comprising pre-reacted pseudobrookite particles consisting essentially of aluminum titanate and magnesium dititanate, a reactive alumina source, a reactive titania source, and a reactive silica source. Other batch mixtures and methods of manufacturing honeycomb extrudates and porous honeycomb bodies using the batch mixture are disclosed.

A batch mixture comprising pre-reacted pseudobrookite particles consisting essentially of aluminum titanate and magnesium dititanate, a reactive alumina source, a reactive titania source, and a reactive silica source. Other batch mixtures and methods of manufacturing honeycomb extrudates and porous honeycomb bodies using the batch mixture are disclosed.

A batch mixture comprising pre-reacted pseudobrookite particles consisting essentially of aluminum titanate and magnesium dititanate, a reactive alumina source, a reactive titania source, and a reactive silica source. Other batch mixtures and methods of manufacturing honeycomb extrudates and porous honeycomb bodies using the batch mixture are disclosed.

The present disclosure relates to porous ceramic articles and a method of making the same. The porous ceramic articles have a porosity (P) as a fraction in a range of about 0.3 to about 0.7; a permeability factor PQ>0.025, wherein PQ is (K.sub.bulk)/(P.Math.d.sub.50.sup.2), K.sub.bulk being bulk permeability in Darcy, and d.sub.50 being the mean pore size in micrometers (μm); a tortuosity in a range of about 1.8 to 3; and a median pore size diameter d.sub.50 in a range of about 10 μm to about 35 μm. The porous ceramic articles can have an interconnected bead microstructure comprising beads and bead connections, PQ is directly proportional to bead size, and wherein in a random cross section through the body, the beads appear as globular portions.

The present disclosure relates to porous ceramic articles and a method of making the same. The porous ceramic articles have a porosity (P) as a fraction in a range of about 0.3 to about 0.7; a permeability factor PQ>0.025, wherein PQ is (K.sub.bulk)/(P.Math.d.sub.50.sup.2), K.sub.bulk being bulk permeability in Darcy, and d.sub.50 being the mean pore size in micrometers (μm); a tortuosity in a range of about 1.8 to 3; and a median pore size diameter d.sub.50 in a range of about 10 μm to about 35 μm. The porous ceramic articles can have an interconnected bead microstructure comprising beads and bead connections, PQ is directly proportional to bead size, and wherein in a random cross section through the body, the beads appear as globular portions.

Batch compositions containing pre-reacted inorganic spheroidal particles, small amount of fine inorganic particles (“fines”), and an extremely large amount of liquid vehicle. The batch compositions contain pre-reacted inorganic particles having a particle size distribution with 20 μm≤D50≤100 μm, D90≤100 μm, and D5≥10 μm; less than 20 wt % of fine inorganic particles (fines) whose particle distribution(s) have a median diameter of less than 5 μm; and a liquid vehicle in a weight percent (LV %≥28%) by super-addition to all inorganic particles in the batch composition. Fast extruding batch compositions having extremely high Tau Y/Beta ratios are provided. Green bodies, such as green honeycomb bodies and methods of manufacturing green honeycomb bodies are provided, as are other aspects.

Batch compositions containing pre-reacted inorganic spheroidal particles, small amount of fine inorganic particles (“fines”), and an extremely large amount of liquid vehicle. The batch compositions contain pre-reacted inorganic particles having a particle size distribution with 20 μm≤D50≤100 μm, D90≤100 μm, and D5≥10 μm; less than 20 wt % of fine inorganic particles (fines) whose particle distribution(s) have a median diameter of less than 5 μm; and a liquid vehicle in a weight percent (LV %≥28%) by super-addition to all inorganic particles in the batch composition. Fast extruding batch compositions having extremely high Tau Y/Beta ratios are provided. Green bodies, such as green honeycomb bodies and methods of manufacturing green honeycomb bodies are provided, as are other aspects.

Batch compositions containing pre-reacted inorganic spheroidal particles, small amount of fine inorganic particles (“fines”), and an extremely large amount of liquid vehicle. The batch compositions contain pre-reacted inorganic particles having a particle size distribution with 20 μm≤D50≤100 μm, D90≤100 μm, and D5≥10 μm; less than 20 wt % of fine inorganic particles (fines) whose particle distribution(s) have a median diameter of less than 5 μm; and a liquid vehicle in a weight percent (LV %≥28%) by super-addition to all inorganic particles in the batch composition. Fast extruding batch compositions having extremely high Tau Y/Beta ratios are provided. Green bodies, such as green honeycomb bodies and methods of manufacturing green honeycomb bodies are provided, as are other aspects.

Methods of manufacturing a ceramic honeycomb body having a honeycomb structure with a matrix of intersecting walls, and a skin disposed on an outer peripheral portion of the matrix where the skin has a first average porosity and the interior portion of the matrix has a second average porosity that is greater than the first average porosity. The methods include coating at least the skin with a fluid formulation containing a sintering aid and subsequently firing the honeycomb structure. In certain embodiments, a glass layer is formed in the skin or in regions of the walls directly adjacent to the skin. In certain embodiments, the coating is applied to a green honeycomb structure, and in other embodiments the coating is applied to a ceramic honeycomb structure. Other honeycomb bodies and methods are described.

Methods of manufacturing a ceramic honeycomb body having a honeycomb structure with a matrix of intersecting walls, and a skin disposed on an outer peripheral portion of the matrix where the skin has a first average porosity and the interior portion of the matrix has a second average porosity that is greater than the first average porosity. The methods include coating at least the skin with a fluid formulation containing a sintering aid and subsequently firing the honeycomb structure. In certain embodiments, a glass layer is formed in the skin or in regions of the walls directly adjacent to the skin. In certain embodiments, the coating is applied to a green honeycomb structure, and in other embodiments the coating is applied to a ceramic honeycomb structure. Other honeycomb bodies and methods are described.