Corning Incorporated

Christopher John Malarkey

Douglas Munroe Beall

Devi Chalasani

Kenneth Charles Sariego

Michael Fischer

Gregory A Merkel

Thomas William Brew

Kevin Robert McCarthy

Michael E Zak

David Robertson Treacy, Jr

Brian E Stutts

Nancy A Golomb

Matthew Joseph Dispenza

Thomas Dale Ketcham

Ronald E Johnson

Michael Thomas Gallagher

Jonathan David Pesansky

Elizabeth Marie Vileno

Barada Kanta Nayak

Keith Leonard House

Jeffrey John Domey

Conor James Walsh

Kevin Robert Brundage

Lin He

Thomas G Havens

David John Thompson

James Anthony Feldman

Mark Allen Spetseris

Tudor Constantin Gheorghiu

Ravindra Kumar Akarapu

Priyank Paras Jain

Seth Thomas Nickerson

Tonia Havewala Fletcher

Victor F Janas

Ryan Joseph Grohsmeyer

Gregg William Crume

John Charles Rector

John Stephen Rosettie

Ronald Alan Boyko

Chauncey James Watches

James Frederick Avery

Dale Russell Hess

John Edmond Graham

Daniel Wayne Corbett

Vincent Kwapong

Shyam Lekhraj Chatlani

Steven John Kremer

Bryan Michael Miller

John E Graham

Dale R Hess

David R Treacy

Methods for extruding a ceramic-forming mixture through a honeycomb extrusion die (), methods for forming a green honeycomb extrudate from a ceramic-forming mixture, methods of preparation of a honeycomb extrusion die () that extrudes a ceramic-forming mixture, and systems including a honeycomb extrusion die (), ceramic-forming mixture, and abrasive flow media. The method of extruding a ceramic-forming mixture through a honeycomb extrusion die () includes conditioning the honeycomb extrusion die () by extruding an abrasive flow media through the slots () of the die () prior to extruding the ceramic-forming mixture through the slots () of the die (). The abrasive flow media includes abrasive inorganic particles dispersed in a flowable carrier. The ceramic-forming mixture includes one or more types of inorganic ceramic-forming particles. The abrasive inorganic particles in the flowable carrier have a particle size distribution that corresponds to that of at least one type of the ceramic-forming particles in the ceramic-forming mixture.

Extrusion die preparation methods

A method of manufacturing a honeycomb body, comprising extruding honeycomb extrudate () in an axial direction (A), the honeycomb extrudate () having an outer periphery (); and laser machining in situ the honeycomb extrudate () to form a laser cut in the honeycomb extrudate. A system for in situ cutting a wet green ceramic extrudate, comprising a laser () configured to irradiate laser energy to an outer periphery of a wet green ceramic article, the laser energy adapted to cut through at least a portion of the outer periphery ().

Methods of laser machining wet cellular ceramic extrudate for honeycomb body manufacture

A system () and method to control rheology of ceramic pre-cursor batch during extrusion is described herein. An extrusion system () comprises an extruder () with an input port () configured to feed ceramic pre-cursor batch into a first section () of an extruder barrel and a discharge port configured to extrude a ceramic pre-cursor extrudate () out of the extruder barrel downstream of the input port (). A liquid injector () is configured to inject liquid into the ceramic pre-cursor batch. A sensor () is configured to detect a rheology characteristic of the ceramic pre-cursor batch. A controller () is configured (i) to receive the rheology characteristic from the sensor (), (ii) compare the rheology characteristic to a predetermined rheology value of the ceramic pre-cursor batch, and (iii) generate a command based on the comparison. A liquid regulator () is configured to receive the command and adjust liquid flow to the liquid injector () based on the command.

Apparatus and methods of ceramic pre-cursor batch rheology control

A ceramic precursor batch composition, green ware formed thereof, porous ceramic honeycomb article formed thereof, and methods of making same.

Composition for improved manufacture of substrates

The present disclosure provides a flow device including a body disposed in an extrusion apparatus. The body is defined along a plane and has a first side and a second side. The second side is disposed opposite the first side. The flow device also includes a first face formed at the first side and a second face formed at the second side. The body has a thickness defined between the first face and second face. A plurality of feedholes is defined in the body between the first side and the second side. In addition, at least a portion of the first face or second face forms a curvature that extends outwardly from the plane.

Extrusion die with curved face

A mixing segment for an extrusion apparatus comprises a shaft and a plurality of plow elements aligned along a helical path extending about a rotation axis of the shaft. Each plow element includes an outer peripheral arcuate ramp extending radially outwardly along the helical path from a root to an outer tip of the plow element. Methods of manufacturing a mixing segment and methods of manufacturing a honeycomb structure with an extrusion apparatus are also provided.

Mixing segments for an extrusion apparatus and methods of manufacturing a honeycomb structure

Methods of manufacturing a honeycomb structure comprise the step of providing a honeycomb body having a multiplicity of cells extending therethrough between opposing end faces. The cells are defined by intersecting porous walls. The methods further include the steps of applying an after-applied skin layer on the honeycomb body and chamfering an edge of the after-applied skin. The chamfering step is performed on a wet after-applied skin layer.

Methods and apparatus for making honeycomb structures with chamfered after-applied akin and honeycomb structures produced thereby

A twin screw extruder includes a barrel having a chamber, a discharge port, an extrusion molding die coupled to the discharge port of the barrel, axially extending first and second screw shafts, and a screw shaft support. The screw shaft support includes first and second spacer bearings disposed on the first and second screw shafts, and a first cross member including first and second loops slidably coupled to the first and second spacer bearings. A second cross member is spaced apart from the first cross member by a connection member, and also includes first and second loops slidably coupled to the first and second spacer bearings. The connection member is situated between the first spacer bearing and the second spacer bearing, and connected to the first cross member and the second cross member.

Twin screw shaft spacer bearing

Methods of extruding a honeycomb body with an extruder comprise the step of feeding batch material to the extruder, wherein the batch material comprises a ceramic or ceramic-forming material. The methods further include the step of rotating at least one mixing screw to cause the batch material to travel along a flow path defined by a barrel of the extruder. The methods further include the step of indexing a carriage to remove a first device from the flow path and introduce a second device into the flow path of the batch material. In one example, the pressure of the batch material changes less than about 25% as a result of indexing the carriage. In addition or alternatively, further methods include the step of reducing a decrease in temperature of the batch material resulting from the step of indexing. In further examples, the method includes the step of pre-filling a second honeycomb extrusion die held by the carriage with a plugging material.

Methods of extruding a honeycomb body

The present disclosure relates to radial wall flow particulate filters comprised of ceramic material. The filters include a filter body that has a plurality of adjacent troughs circumferentially arranged around a longitudinal axis.

Ceramic radial wall flow particulate filter

A method of manufacturing a honeycomb structure is disclosed wherein a green honeycomb body having a first contour is differentially altered such that the green honeycomb body has a second contour which is wider at a first end than at a second end. In one aspect, the altering is accomplished by removing a part of the green honeycomb body, such as with a removal tool. In another aspect, the altering is accomplished by exposing different regions of the honeycomb body to different drying environments.

Method of manufacturing a ceramic honeycomb structure

The present invention provides honeycomb ceramic articles and methods of manufacturing such articles having few or no defects in the outer skin. Methods for minimizing and/or eliminating cracks in thin-wall and ultra-thin-wall cordierite honeycomb articles are disclosed. Advantageously, the present invention prevents skin cracks from forming during the production of thin-wall and ultra-thin-wall cordierite honeycomb articles by optimizing skin properties such as porosity, thickness and pore size distribution.

Crack-resistant ceramic honeycomb articles and methods of manufacturing same

An improvement in a process of making honeycomb articles, which process utilizes a co-rotating, intermeshing twin screw extrusion apparatus to mix, screen, and extrude a batch of ceramic materials through a die, the improvement which comprises the steps of separating the mixing and screening phase from the extrusion phase, by passing the batch through a first co-rotating, intermeshing twin screw extruder or a mixer extruder to mix and screen the batch, and then directly passing the mixed and screened batch through a second co-rotating, intermeshing twin screw extruder or a pumping extruder to extrude said batch through a die assembly to produce a honeycomb article.

Extrusion method for ceramic honeycomb articles

A sintered ceramic that exhibits an average linear coefficient of thermal expansion (25-800&deg; C.) below about 5.0&times;10 &deg; C. , a total porosity between the range of 20% to about 30%. Furthermore, the sintered ceramic article exhibits a pore size distribution such that at least about 86% of pores are of a pore size of less than about 2 &mgr;m. Lastly, the ceramic article exhibits an interconnected pore structure with the pores exhibiting a generally elongated shape, i.e., the pores are predominately oriented with their long axis in the plane of the webs. This invention also relates to a method for producing a sintered cordierite ceramic article involving first compounding and plasticizing a cordierite-forming inorganic powder batch comprising a platy talc having median particle of size less than about 2 &mgr;m, and preferably a talc morphology index greater than about 0.75. The batch further comprises at least 4% by weight of the inorganic powder batch mixture of a dispersible Al O -forming source having a specific surface area in excess of 50 m /g and one or more of the components of kaolin, calcined kaolin, silica, and corundum, each having a median particle sizes less than 5 &mgr;m. The plasticized powder batch thus provided is next formed into a green honeycomb by extrusion through a honeycomb extrusion die and the green honeycomb is fired to a temperature and for a time sufficient to convert the green honeycomb into a crystallized cordierite ceramic article having the aforementioned properties.

Method for making cordierite honeycomb

Fine circumferential skin cracking in extruded thin-walled cordierite honeycombs having channel wall thicknesses not exceeding about 0.004 inches (100 &mgr;m) but skin layers of substantially higher thickness is prevented by extruding the honeycombs under conditions that enhance cordierite crystal alignment in the skin; thin-walled honeycomb products having skins free of fine cracks that are well-matched in thermal expansion to the honeycomb cores are provided.

Method for extruding ceramic honeycombs

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Corning, NY, United States of America

Christopher John Malarkey