Corning Incorporated

David John Thompson

Douglas Munroe Beall

Achim Karl-Erich Heibel

Pushkar Tandon

Kenneth Richard Miller

Gregory A Merkel

Suhao He

Tinghong Tao

Isabelle Marie Melscoet-Chauvel

Dana Craig Bookbinder

Jianguo Wang

Thomas William Brew

Christopher John Malarkey

Seth Thomas Nickerson

Peter Gottfried Hebgen

Isabelle M Melscoet-Chauvel

A method of manufacturing a ceramic honeycomb structure by mixing a ceramic precursor batch composition having a median particle diameter less than or equal to about 10 μm and at least one starch-based pore former having a median particle diameter greater than or equal to about 10 μm. The method also includes forming a mixture of ceramic precursor batch composition and a starch-based pore former into a green ceramic structure having a web structure, and firing the green ceramic structure to yield a ceramic honeycomb structure.

High porosity ceramic honeycomb structure and method of manufacturing

A particulate filter having a honeycomb structure of a matrix of interconnected porous walls including inlet cells and outlet cells defining a plurality of inlet channels and outlet channels, respectively, wherein at least a portion of the outlet cells are larger than any of the inlet cells, and a cross-sectional shape of at least some of the outlet channels is rectangular. Honeycomb extrusion dies, honeycomb bodies, honeycomb structures, and methods of manufacture are described, as are other aspects.

Rectangular outlet honeycomb structures, particulate filters, extrusion dies, and method of manufacture thereof

Methods of manufacturing honeycomb-structure-forming extrusion dies having a number of slots for use in producing extruded articles having complex honeycomb patterns and extrusion dies for use in the manufacture of extruded honeycomb bodies. The method includes inserting a die insert having a runner and a number of teeth into a slot of an extrusion die such that each of the teeth blocks at least a portion of the slot of the extrusion die. The method further includes separating the runner from the teeth so that the teeth remain within the slot of the extrusion die.

Method of modifying a honeycomb-structure-forming extrusion die and modified extrusion dies

A ceramic honeycomb structure having a web structure including a plurality of intersecting channel walls forming channels. The ceramic honeycomb structure has a total porosity greater than or equal to about 55%, an average channel wall thickness less than or equal to about 150 &#x3bc;m, a median pore diameter greater than or equal to about 10 &#x3bc;m, a dless than or equal to about 0.45, where d=(d&#x2212;d)/d, and a strength (MOR/CFA) greater than or equal to about 900 psi. A method of manufacturing a ceramic honeycomb structure by mixing a ceramic precursor batch composition having a median particle diameter less than or equal to about 10 &#x3bc;m and at least one starch-based pore former having a median particle diameter greater than or equal to about 10 &#x3bc;m. The method also includes forming a mixture of ceramic precursor batch composition and a starch-based pore former into a green ceramic structure having a web structure, and firing the green ceramic structure to yield a ceramic honeycomb structure.

A honeycomb body with a honeycomb structure having an inner zone of a first plurality of walls and an outer zone of a second plurality of walls at least partially surrounding the inner zone. The honeycomb structure has Pi that is greater than Po and MPSi that is greater than MPSo, wherein Pi is an average bulk porosity of the first plurality of walls, Po is an average bulk porosity of the second plurality of walls, MPSi is a median pore size of pores in the first plurality of walls, and MPSo is a median pore size of pores in the second plurality of walls. Various honeycomb structures, honeycomb extrusion apparatus, and co-extrusion methods are disclosed.

Honeycomb bodies with multi-zoned honeycomb structures and co-extrusion manufacturing methods

An apparatus and method for debindering a cellular ceramic green body. The apparatus includes a flow modulation member to selectively restrict circulation of a heated oxygen-containing atmosphere through a top of a cellular core section of the green body. The method includes heating the green body in a circulating oxygen-containing atmosphere while selectively restricting circulation of the atmosphere through the top of the cellular core section of the green body.

Method and apparatus for thermally debindering a cellular ceramic green body

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 method of manufacturing a honeycomb body is disclosed having the steps of mixing inorganic source materials, a nut shell pore former, and forming aids to form a plasticized batch, wherein the nut shell pore former has a particle size distribution with 20 &#x3bc;m&#x2266;d&#x2266;70 &#x3bc;m, and forming the plasticized batch into the honeycomb body having a plurality of channels formed by intersecting walls. Green honeycombs and porous ceramic honeycombs produced by the method are also disclosed.

Honeycomb manufacturing method using ground nut shells and honeycomb body produced thereby

Disclosed are ceramic honeycomb articles which possess a unique microstructure characterized by porosity between 40% and 70%, and the presence of coarse pores exhibiting a depth equivalent to the thickness of the cell wall and a dimensional width, in the plane of the cell wall, exhibiting a diameter that is at least as large as the thickness of the cell wall. The articles exhibits reduced filtration efficiency coupled with low pressure drop across the filter, and a reduced regeneration need. Such ceramic articles are particularly well suited for filtration applications, such as off-road and retro-fit diesel exhaust filters or DPFs. Also disclosed is a method for manufacturing the ceramic article wherein the pore former is capable of forming coarse pores.

Low back pressure porous honeycomb and method

Substantially non-microcracked, porous, cordierite ceramic honeycomb bodies are provided. Although exhibiting moderately high thermal expansion (CTE) between 7&#xd7;10to 16&#xd7;10/&#xb0; C. (25-800&#xb0; C.), the honeycomb bodies exhibit relatively high thermal shock parameter (TSP), such as TSR&#x2267;525&#xb0; C. by virtue of a high MOR/E ratio, and/or low E=E/E. and well interconnected porosity, as witnessed by a relatively high pore connectivity factor (PCF). A method of manufacturing the honeycomb ceramic structure is also provided.

Low-microcracked, porous ceramic honeycombs and methods of manufacturing same

Substantially non-microcracked, porous, cordierite ceramic honeycomb bodies are provided. Although exhibiting moderately high thermal expansion (CTE) between 7&#xd7;10to 16&#xd7;10/&#xb0; C. (25-800&#xb0; C.), the honeycomb bodies exhibit relatively high thermal shock parameter (TSP), such as TSR&#x2267;525&#xb0; C. by virtue of a high MOR/E ratio, and/or low E=E/Eand well interconnected porosity, as witnessed by a relatively high pore connectivity factor (PCF). A method of manufacturing the honeycomb ceramic structure is also provided.

A porous cordierite ceramic honeycomb article with increased mechanical strength and thermal shock resistance. The porous cordierite ceramic honeycomb article has M&#x3c;2220, or M&#x3e;2660 wherein()&#x2212;106()+19()+17(% porosity),()+116()&#x2212;26()&#x2212;28(% porosity),and a CTE&#x2266;9&#xd7;10/&#xb0; C. in at least one direction. A method of manufacturing is also disclosed wherein the inorganic raw material mixture contains talc, an alumina-forming source, a silica-forming source, and 0-18 wt. % of a kaolin or calcined kaolin containing not more than 8 wt. % of a fine kaolin source having a median particle diameter of less than 7 &#x3bc;m, wherein the fired porous ceramic cordierite honeycomb article has a porosity&#x3c;54% . Alternatively, if greater than 8 wt. % of the fine kaolin source is used, then a slow ramp rate is utilized from 1200&#xb0; C. to 1300&#xb0; C. of not more than 20&#xb0; C./hr.

Porous cordierite ceramic honeycomb article with improved strength and method of manufacturing same

The present invention relates to a dispersion compensating optical fiber (&ldquo;DC fiber&rdquo;) having a segmented core and having a negative total dispersion and negative dispersion slope in the C-band. The index profile of the fiber is selected to provide an optical properties suitable for a high performance communication system operating in the C-band wavelength band, i.e., between about 1525 nm to 1565 nm. The DC fiber according to the invention exhibits dispersion slope at 1549 nm more negative than &minus;3.4 ps/nM -km and has a negative &Dgr; % that is more negative than &minus;0.4%. Preferably, the DC fiber has a total dispersion more negative than &minus;125 ps/nm -km. The DC fiber may be optically connected to a Non-Zero Dispersion Shifted Fiber (NZDSF) in the system to compensate for dispersion thereof. Optionally, the transmission system may include a positive dispersion, positive slope trim fiber.

Growing community of inventors

Savona, NY, United States of America

David John Thompson