KR20000007527A - Coated catalyst converter substrate and supporting stand - Google Patents

Abstract

PURPOSE: A coated catalyst converter substrate is provided to a converter system having an excellent resistance for the damage of vibration and shock and high temperature, and also having low expenses and reduced evaporation complexity. CONSTITUTION: A catalyst converter substrate has:a low-expansion ceramic honeycomb supporting body(10) including plural penetrating channels surrounded with the outer surface; a heat interrupting coating film(12) having insulating, porous, heat-proof properties, deposited and connected at least one part of the outer surface; the coating film has porousness, and the enough thickness for providing the surface temperature of at least 50°C of the outer interrupting coating film.

Description

Coated Catalytic Converter Substrates and Supports

The present invention relates to a catalytic converter useful for the treatment of combustion exhaust gases from internal combustion engines. More particularly, the present invention relates to an improved honeycomb catalyst support and a support system for mounting them, wherein the high temperature thermal damage, shock, and with reduced cost and reduced deposition complexity and Provided is a deposited converter system having excellent resistance to vibration damage.

The current problem facing the development of deposition systems for catalytic converters relates to the temperature stability of deposition. This problem is particularly acute in so-called "close-coupled" catalytic converters which are typically located very close to the engine in the engine exhaust system. This proximity to the engine exposes the catalyst, ceramic honeycomb substrate, and converter deposition system to much higher exhaust temperatures and vibration loads than those encountered with converters in more conventional automotive underbody locations.

Conventionally, expandable mats have been used as an essential deposition material for supporting ceramic substrate catalytic converters in metal enclosures or “cans”. Since the mat increases in mat temperature during first use, the mat expands and thereby consists of mineral components selected to protect the substrate in the converter can. Intumescent mat deposition materials alone and in combination with other fiber mat materials that limit ceramic honeycomb in metal converter enclosures are described, for example, in US Pat. No. 4,863,700 to Ten Eyck and 5,376,341 to Gulati.

Unfortunately, conventional expandable mat materials tend to decompose at temperatures above about 700 ° C. With this decomposition, the retention pressure exerted by the mat on the substrate decreases, increasing the ability to move the substrate on the axis under the exhaust backpressure and the resulting defects of the deposition system. In the severe heat and vibration environment of automobile exhaust pre-converters, the thermal decomposition of the mat is gradually becoming a serious problem.

Discussion of the deposition problem is presented in SAE Paper 952414 and SAE Paper 960563. In general, the experiments detailed in the above papers show that the residual shear strength of a conventional mat deposition system is drastically reduced at environmental temperatures in the range of 950 ° C to 1050 ° C. Between 1000 ° C. and 1050 ° C., the residual share strength can fall below the minimum strength level accommodated, the level being calculated to require on-axis substrate exchange in a hot (950 ° C.) high-acceleration (75 g) vibration environment. A stability factor of 3-4 times the pressure (15 kPa) should be provided. In addition to thermal problems, mechanical degradation of the mat deposition material under the vibration conditions can also be expected.

It is an object of the present invention to improve converter deposition durability at high temperatures through the use of a thermal barrier coating on the ceramic substrate. This approach can reduce the mat temperature by applying an insulating coating covering the substrate outer surface to reduce heat flow to the mat. Heat reduction can occur by keeping the mat away from the hot substrate outer surface and reducing the light rays and conductive thermal transitions from the surface due to the insulating properties of the coating film.

In addition to the observed reduction in mat temperature, the coating can also correct the problem of out-of round dimensions in the cylindrical substrate, in particular higher cell counts. And honeycomb designs that provide thinner cell separation walls can increase substrate breaking strength as industrially applied.

In a first object, as a result, the present invention comprises an integral block-coated ceramic honeycomb body comprising a honeycomb support essentially comprising a heat shield coating on its outer cylindrical surface. The support is a low-expansion ceramic honeycomb support and is typically a kind useful for supporting catalysts in harsh chemical environments, such as automotive exhaust environments.

The thermal barrier coating film deposited on the outer cylindrical surface of the support comprises an adherent porous heat resistant ceramic layer, wherein the term "ceramic" herein refers to conventionally free of semicrystalline ceramics such as glass, glass-ceramic and essentially glassy phases. It is used in a broad sense, including crystalline ceramics. Typically the porous glass, glass-ceramic or ceramic layer, having a lower thermal conductivity than the honeycomb support, of the barrier-coated body below the surface temperature of the honeycomb support without the coating, when maintained at the equivalent honeycomb temperature It has sufficient thickness and porosity to significantly reduce surface temperature.

A surface temperature reduction of at least about 50 ° C. at a honeycomb temperature of about 950 ° C. means a significant decrease in surface temperature. This reduction makes it easy to use porous ceramic barrier coatings having a bulk density of no greater than about 2.0 g / cm 3 and a thickness of at least about 1 mm.

In a second object, the present invention comprises a deposited catalyst support assembly, which is integrated with a ceramic honeycomb body and body comprising a plurality of through-channels surrounded by an outer surface. And an insulating porous heat resistant ceramic coating film bonded to all or part of the outer surface. The assembly further comprises a sealing container comprising a metal wall for the support of the coated honeycomb body in the sealing container, and at least one layer of an inorganic expandable material deposited between the porous heat resistant ceramic coating film and the metal wall. The assembly provides a good physical barrier to the ceramic substrate, while at the same time protecting the expandable material from thermal damage and loss of retention strength, which is described in more detail below.

1 is a cross-sectional end view of a barrier-coated honeycomb body provided in accordance with the present invention.

2 is a side cross-sectional view of a mount diagram according to the present invention.

FIG. 3 is a graph showing converter mount sheer strengths before and after thermal aging, both for designs provided in accordance with the present invention and for honeycomb substrate deposition designs used in the prior art.

Many different coating compositions can be applied to the ceramic support substrate to provide the insulating coating layer. The particular choice of coating will depend in principle on the thermal and mechanical environment of the intended use of the coating and on the composition of the support structure. Limitations in coating composition and properties typically arise due to the nature of the intended application, with more severe circumstances requiring careful selection of the ceramic support and its associated coating film to achieve the desired service length. .

For applications such as automotive preconverters, which are catalytic exhaust gas converters deposited in the exhaust system in close proximity to the engine, particularly severe conditions of temperature and vibration are required. Prior attempts to provide a durable deposition system for the converter include the use of intumescent deposition mats that directly contact both the substrate and the preconverter seals, but they have not been completely successful. When the expandable mat is in direct contact with the substrate, mat decomposition begins in the form of envelope formation or “glazing” at a substrate temperature of about 950 ° C. or higher.

Better results have been obtained with a “hybridization” deposition system, which is a system that includes an outer layer of an expandable mat and an inner layer of a non-expandable mat deposited between the substrate. It is known that non-expandable mat materials with minimal degradation at 1050 ° C. can insulate the expandable mat from the hot substrate. However, a multi-matte deposition system is undesirably complex and results in other problems such as lower resistance to "push-out" of the substrate from the hybrid deposition structure and instability of the non-expandable mat. do.

The adhesive insulation barrier coating film of the present invention is at least as effective as the prior art heat resistant fiber mat coating film in reducing heat transfer from the substrate to the substrate sealing container or to the expandable mat material lining the sealing container. They are also much more durable and provide firmness rather than elastic bases where the outer expandable mat layer can apply holding pressure more effectively. As a result, the coating film can avoid the problem of fiber mat decomposition and reduce the possibility of substrate loss during use.

A schematic example of a barrier-coated ceramic honeycomb body provided according to the invention is provided in FIG. 1. In this embodiment of the terminal front view of the body, the honeycomb substrate comprises a core portion 10 consisting of a plurality of through channels across the core, the portion typically consisting of a core-like material. It is surrounded by the substrate surface 12. Porous ceramic barrier coating 14 is deposited on surface 12 and is fully bonded to the surface.

Other advantages of the insulating barrier coating include: the ability to "cut" the diameter and / or external shape of the substrate, the ability to recover a damaged external substrate surface that otherwise requires part rejection, the breaking strength of the substrate. Capacity for improving the performance of the converter, and / or for other purposes related to the performance of the converter. For example, the profile of the barrier coating can be tailored to provide a coated substrate profile having a protruding end portion and a recessed central portion. This forms a central depression in the coating that the expandable mat layer can be recessed to block hot exhaust gases that affect the converter end face. In this way, the coating provides a partially integrated corrosion seal against expandable mat wear.

FIG. 2 schematically illustrates a design for a barrier-coated substrate inserted with such a corrosion seal, consisting of a cross-sectional front view of the side cross-section of the substrate 10 deposited in a steel can or sealed container 16. In the deposition, the barrier coating film 12 includes a protruding end portion 12a that forms a central depression in which the expandable mat 14 is recessed. The protruding end portion 12a consequently forms a partial seal to protect the mat 14 from corrosion by the hot exhaust gas inlet can 16 and the substrate 10.

Materials useful for forming the insulation barrier coating of the present invention typically belong to the group comprising heat resistant ceramics such as, for example, glass, semi-crystallized glass and crystalline ceramics. For the best thermal insulation properties, the ceramic chosen will be relatively low density. In addition, in order to impart good thermal shock resistance to the coated composite, it will be relatively low in thermal expansion, as a rapid and substantial change in substrate temperature is often caused by the composite in use. Thermal cycling is due to the various thermal expansions of the coating film, which can quickly degrade the higher expansion material.

Specific examples of heat resistant ceramic compositions for substrate barrier coatings include powdered heat resistant glass, typically a silicate base, a mineral mixture convertible to a low-expansion crystalline ceramic layer upon heat treatment, and a sintering heat treatment. And compositions based on crystalline ceramic powders that can be converted to integrated coatings. For some applications, foam glass compositions, such as known aluminum- and boron-based phosphate foam glass, are suitable, although higher expansion and lower strength of the foams define their attachment. And durability issues in severe environments, such as automotive catalytic preconverters.

In order to increase the porosity of some of the higher densities, a lower expansion coating material is used and graphite or other carbon is added to the coating composition in order to be removed later by sintering to leave the desired open or closed residual pore structure. Additives containing may be included. For still higher porosities or lower densities, blowing agents can be used that can produce gases in the coating composition during sintering, and can also be hollow, including, for example, glass or other ceramic cores. Fillers may also be added to the composition prior to drying or sintering. The latter can reduce the density without increasing the open porosity, and can also act to increase the strength of the coating film.

Depending on the intended application for the coated honeycomb, various other additives for insertion into the barrier coating can be considered. The addition of fibrous materials, such as heat resistant glass, ceramic or metal fibers, to a portion of the coating composition can help to improve coating film strength. The fibers will be selected for compatibility with the coating composition selected in terms of thermal expansion, reactivity and / or wetness; Examples of specific fibers that can be used are spun glass fibers or polycrystalline ceramic oxide fibers produced by, for example, sol-gel processes and continuous sintering methods.

The thickness of the barrier coating film required will depend on a number of factors including the thermal environment of the intended use, the durability of the expandable or other mat material used with the coating film for deposition of the substrate, and the density and composition of the coating material selected. In general, coating film thicknesses in the range of about 1-4 mm will be appropriate for all cases except the most stringent applications.

Application of the particulate ceramic material to the coating film on the heat resistant ceramic substrate typically involves combining them with a suitable temporary organic or permanent inorganic binder / carrier component, applying them as a coating on the outer surface of the substrate, and Sintering the substrate and the coating film together to produce a composite. In some cases, surface preparation of the substrate can be useful to ensure durable bonding; In other cases, proper bonding and composite durability can be achieved without the sintering step.

The substrate to which the coating film is applied may be pre-sintered or microcrystalline (“green”), depending on the composition of the substrate and the coating film. Co-injection of the substrate and coating film may be a useful method consisting of a compatible composition and substrate that allows the injected substrate and coating film to be coated film application in the green state.

Although the present invention will be described in more detail with reference to the following examples, the scope of the present invention is not limited thereto.

Example

Example 1 Application of Barrier Coating Films

In order to provide composite substrates for automotive applications that include exposure to relatively high temperatures and significant mechanical vibrations, multiple injection molded ceramic substrates of cordierite compositions are selected for coating. The chosen substrate is a Celcor ^R XT cordierite honeycomb substrate with a circular cross section, each with a honeycomb cell density of about 350 cells / inch ² of open front area, a length of 89 mm (parallel to the channel or cell direction) and 76.2 mm Has a diameter.

Four coating compositions are selected for application to the substrate, which are capable of reacting upon sintering to form a highly crystalline ceramic (cordierite) material and two compositions consisting primarily of sinterable ceramic (cordierite) powders. Two compositions comprising a reactive mixture of clay, talc, alumina and silica. The particular coating composition selected has a composition as shown in Table 1 below.

Coating composition Coating components Example One 2 3 4 Cordierite Powder (㎛) 34.2 29.1 Cordierite Powder (㎛) 34.2 29.1 Silicon carbide 15.6 talc 33.9 33.9 Alumina 18.4 18.4 Silica 12.9 12.9 clay 9.4 9.4 Sodium stearate 2.5 2.5 Methyl cellulose 0.5 0.4 1.0 1.0 Sodium silicate solution (40%) 20.6 3.7 Graphite powder 16.5 32 Hydrated Alumina 7.7 7.7 water 10.5 22.1 33.0

Suitable ingredients for the batch materials used in the coatings described in Table 1 include Carborundum silicon carbide powder, Pfizer 96/68 talc, Alcan C-701 alumina, Ashbury 4740 graphite, Sil-Co-Sil Prepared by grinding and powdering silica powder, K-10 (kaolin) clay, Aluchem AC714K hydrated alumina, A4M methyl cellulose, and injection molded, sintered commercial cordierite honeycomb substrates as described herein. Included cordierite powder.

At the thickness of each coating composition shown in Table 1, a 4mm coating film is applied to the ceramic substrate. For application of coating compositions 2-4, the substrates are sandblasted, washed with deionized water, and oven-dried before application of the coating film to enhance adhesion of the coating film to the substrate. For the application of coating compositions 3 and 4, overlapping application of the coating liquid is used to dry each layer before application of the next layer to achieve the desired 4 mm thickness.

Coating compositions 1 and 2 obtained from Table 1 comprising pre-crystallized cordierite and an inorganic sodium silicate binder do not require any heat treatment to protect the applied coating. Compositions 3 and 4 comprising reactive mineral powders that are not silicate inorganic binders and graphite combustion adducts for enhanced porosity are protected by an additional sintering step after drying for best results.

The sintering process used to protect the reactive coating compositions 3 and 4 obtained from Table 1 is shown in Table 2 below.

Coating film sintering Soak / Ramp Temperature (℃) Duration (hours) Sock Room temperature 0 lamp 200 One lamp 410 7 lamp 600 6 lamp 900 5 lamp 1100 4 lamp 1350 11 lamp 1400 6 Sock 1400 7 lamp 1375 One lamp Room temperature 13.5

The sintering treatment is effective in converting the dried clay / talc / alumina / silica coating films of the compositions 3 and 4 into an adhesive coating film which constitutes the crystal phase in which the cordierite crystals are dominant.

The coatings applied as described above span a relatively wide range of thermal expansion and density variations and are consequently useful in a variety of environments, including but not limited to automotive engine exhaust systems. Table 3 below shows the density and thermal expansion results for each specific coating film. The thermal expansion values shown in Table 3 are values representing average thermal expansion over a temperature range from room temperature to 1000 ° C., including both heating and cooling expansion data.

Coating film characteristics Coated Example # One 2 3 4 Bulk Density (g / cm 3) 1.42 1.28 0.8 0.6 Thermal expansion (× 10 ^-7 / ℃) 24 20 11 11

The predominant sintering method up to 1080 ° C. prior to testing is as long as the coating film having the same composition as Compositions 1 and 2 from Table 1 is subjected to a temperature high enough to remove any residual moisture and organics from the dried coating film in an automotive exhaust system environment It can be used to remove the materials and adjust the coating film properties to values that more closely approximate them in use. The heating step also removes volatiles that are harmful to the measuring device.

The average thermal expansion of each of these representative coating compositions is somewhat higher than the average thermal expansion of the ceramic honeycomb substrates to which they are applied (about 5 × 10 ⁻⁷ / ° C. or more over the same temperature range). Nevertheless, adhesion of the coating film to the substrate appeared to be very appropriate.

Example 2 Deposition of Coated Substrates

Deposition of coated substrates prepared as described above is carried out using canning methods customary in the art. In general, the methods include lapping a expandable mat around a cylindrical outer surface of the substrate, a loose tubular metal seal consisting of a cylindrically-shaped steel sheet substantially surrounding the mat and the substrate. Inserting each mat-wrapped substrate into a container, applying a tourniquet pressure to an assembly that pre-compresses the wrapped sheet between the steel sheet and the substrate, while simultaneously Closing and overlapping the edges, and finally securing the overlapping edges of the steel sheet to maintain the desired level of mat compression between the substrate and the sealed cylindrical steel shell.

In the case of a coated substrate as prepared according to Example 1, any coating non-uniformity can be eliminated, and the final diameter of the coated substrate is pre-selected by the machining of the protected coating. It can be adjusted in dimensions. Mechanization is performed by any suitable means, including wet wheel grinding or dry sanding, while rotating the coated substrate in a lathe. Using the latter method, the mechanization of the substrate prepared according to Example 1 until the final coating thickness is about 1.92-3.36 mm provides the desired coating completion without disturbing the thermal performance of the coating.

Mat wrapping of the substrate is performed using a conventional expandable mat, ie a series 100 expandable mat having a mat weight of 3100 g / m ² and commercially available from 3M Company, Minneapolis, MN. Only a single lapping layer of the mat is used.

The mat-wrapped substrate is placed in a cylindrically curved sheet steel hermetically sealed container, the hermetically sealed pressurized pressure to achieve a compressed mat density ("gap bulk density") of about 1.1 g / cm3 in the expandable mat. It is sealed by. These pressure levels are chosen to have good resistance to substrate "push-out" from the sealed container under the exhaust gas pressures typically found in automotive exhaust environments.

For comparison purposes, some ceramic honeycomb substrates not provided with the barrier coating film are canned using the same canning process as used above for the coated substrate sample. One military group A of uncoated honeycomb substrates is provided with a double layer of canning series 100 expandable mat, providing a combined mat weight of 6200 g / m ² between each substrate and each steel hermetically sealed container. Torque compression is used for this sample group to provide a compressed mat density of about 1.1 g / cm 3.

The second soldier of the substrate, group B, is first provided with an insulating layer of non-expandable mat and then with a single layer of series 100 expandable mat. In this group, the non-expandable mat selected is a Fibermax ^™ heat resistant fiber mat, commercially available from Unifrax Company, Niagara Falls, NY, and has a mat mass of 800 g / m ² . Torque shells close to a mat compression level of 1700 psi were used to cancanize the sample because the gap bulk density could not be readily determined for the provided composite mat structure.

As mentioned above, the composite or “hybrid” lapping method used to canalize Group B substrates is designed to reduce expandable mat damage from high substrate surface temperatures. Such mat damage can result in expandable-mat-wrapped substrates, such as group A substrates, which experience a reduction in mat compression, which increases the risk of substrate “push-out” after thermal aging in an automotive exhaust system environment.

Example 3-Deposited Substrate Performance

The coated substrates provided according to Example 1 were deposited in a sealed container according to Example 2 and then tested to determine the deposition properties that are important for the performance of the automotive exhaust mechanism. One such characteristic is the mat temperature at the mat / converter interface where the mat temperature, most importantly the mat temperature, is the best during operation of the converter. A second property is the resistance to converter “push-out” after aging of the deposited sample in a stimulated use environment.

In order to measure the mat / substrate interface temperature in the deposited converter, a thermocouple is placed at the interface in a representative sample from each group of canned substrates described in Example 2 during the converter assembly. During later testing, each deposited substrate is heated to a normal operating temperature by a wound electrical resistance heating element disposed within the honeycomb cell structure, and the temperature at the mat / substrate interface is increased. Is recorded.

For the coated substrates, the interface temperature is determined both at the "thick" position where the coating thickness is typically 3 mm, as well as at the positions of the relatively thin barrier coating which the coating is only 2 mm thick. In the case of coated substrate samples, the change in interface temperature is usually due to uneven substrate heating, rather than due to the mat insulation effect on temperature measurement.

Table 4 below describes the results of the interface temperature measurements collected from several heated converter samples prepared as described above. All temperatures listed in Table 4 are average temperatures, in each case three or more different locations and some typical measurements of each sample array are determined.

Mat interface temperature Comparative example Coated Substrate Example Sample confirmation T (℃) Sample I.D. Thin coating T (℃) Thick Coating T (℃) Group A, # 1 1005 One 930 895 Group A, # 2 1007 2 935 876 Group B, # 1 892 3 913 914 Group B, # 2 873 4 902 911

As can be seen from the data recorded in Table 4, the interface temperature for the barrier-coated substrate is much lower than that for the Group A substrate even within the area of the relatively thin barrier coating film. In some cases, the barrier coating is nearly as effective at reducing interface temperature as the Group B composite mat design, except that there is no structure complexity and no extra manufacturing costs.

In particular, the ability of a substrate deposition system to interfere with substrate "push-out" under high exhaust back pressure, after significant intervals of use in harsh exhaust environments, is particularly important. In the laboratory, relative evaluation of these properties can be made based on the performance of the deposited substrate prior to accelerated thermal aging. The deposited converters are first subjected to extended thermal cycling using the substrate heating arrangements described above to measure the mat interface temperature, and then axially (exhaust) the substrate to overcome the on-axis retention of the mat deposition at normal converter operating temperatures. The force required to move in the direction of the gas flow is measured.

Many converter assemblies manufactured according to embodiments 1 and 2 above are processed above. Using the electrically resistive heating wire arrangement described above, each converter assembly is heated to 1050 ° C. and cooled to 100 ° C. through five thermal cycles, each cycle heating 1.5-2 hours, maintaining a temperature of 10 hours. And 1.5-2 hours of cooling. The thermally aged assemblies are then subjected to a hot push-out share test to determine the ability of each deposition system to counteract the opposite effect of thermal aging on deposition properties, depending on a number of similar unaging samples. -out shear test).

To specify the resistance of the converters to back pressure push-out, each sample was placed in an oven maintained at 550 ° C. and allowed to reach thermal equilibrium. Then, while the temperature is maintained, a load is applied to the substrate in the axial or exhaust gas flow direction, and the load is increased until damage of the substrate to the mat is detected. The load when the substrate is damaged is recorded and converted to share strength in pounds-force, psi, required to move the substrate per square inch of substrate / matt interface area. Lower share intensities typically show higher strength, and more serious mat degradation.

Table 5 below shows the push-out share strengths reported in psi for the deposited converter samples provided in accordance with the above embodiments, both before and after thermal aging. The values reported in Table 5 for each prior art group A and group B sample are five sample measurement averages, while the data for the converters of the embodiments are independent measurements. The data points for the sample results reported in Table 5 are shown in FIG. 3, which is a computerized share for each of the various sample types as calculated from the forces required to cause axial movement of each deposited substrate within its deposition. The intensity value is shown.

Deposition Share Strength (psi) Group A Group B Example 1 Example 2 Example 3 Example 4 Deaging 114 53 98 94 105 80 Aging 18 35 33 43 63 64

As demonstrated from the studies in Figures 3 and 5, prior art A deposition exhibits the greatest loss in share strength during aging, while exhibiting the best share strength in non-aging conditions due to the use of a dual expandable mat layer. Indicated. The deposition design also has the lowest level of share strength of any deposition design tested, and the ability affects relatively fast mat deterioration during thermal aging due to the high substrate / matt interface temperatures encountered.

Prior art group B samples showed significantly improved aging share strength levels when compared to the group A samples. This result is due to the thermal barrier affected inflatable mat by the heat resistant fiber substrate wrapping around the substrate.

Finally, the data suggests a significant additional improvement in residual aging share strength for the coated embodiment of the present invention. The above examples show a substantially higher aging share strength than the average group A deposition, with three of these cases significantly exceeding the average. This performance, combined with the simplification in the deposition complexity described above, provides substantial improvements in the field of durable substrate deposition and other high temperature process stream applications for automobiles.

The coated catalytic converter substrates and depositions provided in accordance with the present invention provide excellent resistance to high temperature thermal damage and shock and vibration damage, providing substantial improvements in the field of durable substrate deposition for automobiles and other high temperature process stream applications. do.

Claims (10)

A low expansion ceramic honeycomb support comprising a plurality of through-channels surrounded by an outer surface; And An insulating porous heat resistant thermal barrier coating deposited and bonded to at least a portion of the outer surface, the coating having a porosity and having a thickness sufficient to provide an outer barrier coating surface temperature of at least 50 ° C. or less. , Heat-blocking-coated ceramic honeycomb body. The honeycomb body according to claim 1, wherein the barrier coating film is made of a heat resistant ceramic selected from the group consisting of glass, semicrystalline glass and crystalline ceramic. 3. The honeycomb body according to claim 2, wherein the heat resistant ceramic is made from a material selected from the group consisting of powdered heat resistant glass, mineral mixture, crystalline ceramic powder and foam glass. 4. The honeycomb body according to claim 3, wherein the material used to make the heat resistant ceramic comprises a pore-forming agent selected from the group consisting of oxidizable particle fillers, ceramic ejectors and glass or ceramic cores. 3. A honeycomb body according to claim 2, wherein said barrier coating comprises a fiber reinforced phase. 3. The honeycomb body according to claim 2, wherein said heat resistant ceramic is provided from a composition selected from the group consisting of a sinterable cordierite powder and an interactable reactive mixture which forms cordierite upon sintering. The honeycomb body according to claim 1, wherein the coating film has a thickness in the range of 1-4 mm and a density in the range of 0.5-1.5 g / cm 3. A ceramic honeycomb body comprising a plurality of through-channels surrounded by an outer surface; An insulating porous heat resistant thermal barrier coating deposited and bonded to at least a portion of the outer surface; A sealing vessel including a metal wall factor for holding and supporting the ceramic honeycomb body in a sealing vessel; And And a layer of fiber support material deposited between at least a portion of the insulating porous heat resistant coating film and the metal wall factor. 9. The assembly of claim 8, wherein said layer of fiber support material is a layer of expandable fiber mat. 10. The assembly of claim 9, wherein the thermal barrier coating includes a recessed portion, and wherein the expandable fiber mat layer is at least partially deposited within the recessed portion.