Corning Incorporated

Calgon Carbon Corporation

David L Hickman

Willard A Cutler

Kishor Purushottam Gadkaree

Douglas Munroe Beall

Gregory A Merkel

Tinghong Tao

Kevin Robert Brundage

Thomas Adam Collins

J Paul Day

David F Thompson

Y Lisa Peng

Timothy V Johnson

Alfred N Mack

Thomas Dale Ketcham

Lawrence S Rajnik

David S Weiss

Merrill Lynn

Jerald L Mestemaker

Russell C Wooten

Paul E Vargas

B R Thakker

Andrew N Andrascik

Stanley D Solsky

Roderick O Koehler

Richard F Smith

Randel W Gulley

A method for detecting leaks in a plugged honeycomb structure includes directing a gas at a first end face of the honeycomb structure at a temperature that is different from a temperature of the honeycomb structure and observing a temperature distribution at a second end face of the honeycomb substrate using an infrared detector, wherein the gas directed at the first end face of the honeycomb structure emerges preferentially at the second end face of the honeycomb structure at locations where the cells in the honeycomb structure are defective and appear as thermal spots in the temperature distribution.

Method and system for detecting leaks in a plugged honeycomb structure

A ceramic comprising predominately a cordierite-type phase approximating the stoichiometry MgAlSiOand having a coefficient of thermal expansion (25-800&#xb0; C.) of greater than 4&#xd7;10/&#xb0; C. and less than 13&#xd7;10/&#xb0; C. and a permeability and a pore size distribution which satisfy the relation 2.108 (permeability)+18.511 (total pore volume)+0.1863 (percentage of total pore volume comprised of pores between 4 and 40 micrometers)&#x3e;24.6. The ceramic is suitable in the fabrication of cellular, wall-flow, diesel particulate filters having a pressure drop in kPa that at an artificial carbon soot loading of 5 grams/liter and a flow rate of 26 scfm is less than 8.9-0.035 (number of cells per square inch)+300 (cell wall thickness in inches), a bulk filter density of at least 0.60 g/cmand a volumetric heat capacity of at least 0.67 J cmKas measured at 500&#xb0; C.

Cordierite body

A ceramic comprising predominately a cordierite-type phase approximating the stoichiometry Mg Al Si O and having a coefficient of thermal expansion (25-800&deg; C.) of greater than 4&times;10 /&deg; C. and less than 13&times;10 /&deg; C. and a permeability and a pore size distribution which satisfy the relation 2.108 (permeability)&plus;18.511 (total pore volume)&plus;0.1863 (percentage of total pore volume comprised of pores between 4 and 40 micrometers)>24.6. The ceramic is suitable in the fabrication of cellular, wall-flow, diesel particulate filters having a pressure drop in kPa that at an artificial carbon soot loading of 5 grams/liter and a flow rate of 26 scfm is less than 8.9&minus;0.035 (number of cells per square inch)&plus;300 (cell wall thickness in inches), a bulk filter density of at least 0.60 g/cm and a volumetric heat capacity of at least 0.67 J cm K as measured at 500&deg; C.

A honeycomb structure for a diesel engine or an automotive engine where the wall thickness is varied in a controlled manner from the front surface to the back of the honeycomb. One example is grading the web thickness continuously from thin webs on the front of the DPF to thick webs on the back of the DPF. Another example is to make a two layer honeycomb with thinner walls and/or perhaps even lower cell density on the upstream side of the honeycomb. This provides a lower thermal mass front while retaining the thicker webs and higher thermal mass at the back of the honeycomb. The honeycomb structure has a thermal mass or heat capacity ranging from above 8.5&times;10 cal/cubic cm-K to below 0.25 cal/cubic cm-K along an axis from the inlet end to the outlet end.

Honeycomb particulate filters

A ceramic filter which includes a plurality of end-plugged honeycomb structures which in combination act to trap and combust diesel exhaust particulates. The exhaust gas flows substantially equally through the end-plugged honeycombs. Preferably the ceramic filter includes two end-plugged honeycomb structures composed of a plurality of alternatingly end-plugged cell channels extending from an inlet face to an outlet face. The end-plugged honeycomb structures are arranged either parallel or perpendicular to the flow of the exhaust gas.

Diesel particulate filters

A replaceable gravity-flow cyst-reducing water filter cartridge for placement in a water filter carafe, comprising a filter cartridge housing with a cap having a plurality of untreated water inlet ports, wherein the cap is sealingly attached to a top rim of the housing. The filter housing further comprises a gooseneck conduit that is connected to a lower region of the filter housing, with the gooseneck conduit having at one end a treated water outlet port that opens into a side surface of the filter housing. The filter housing also includes a packed bed of ion-exchange resin that is disposed in an upper region of the filter housing and a high surface area cyst-reducing filter element that is disposed in the lower region of the filter housing. The filter element provides at least 99.95% removal of 3-4 &mgr;m particles when tested in accordance with NSF standard 53, Drinking Water Treatment Units&mdash;Health Effects (September 1997). A bottom surface of the ion-exchange resin is in full contact with one side of a bottom screen, which is attached at the periphery to the side surface of the housing. The filter housing further has a first chamber separating the packed bed of ion-exchange resin from the cyst-reducing filter element and a second chamber proximate to the bottom surface of the filter housing, which is in fluid communication with the gooseneck conduit. The housing also includes an air vent conduit that is connected to the upper region of the filter housing, wherein the air vent conduit has an entry end that opens into the first chamber and an exit end that opens to the outside of the housing. The exit end is positioned above the treated water outlet port of the gooseneck conduit and the exit end is further covered with a hydrophobic membrane. The packed bed of ion-exchange resin and the cyst-reducing filter element each correspond in shape to the shape of the filter housing.

Gravity-flow water filtration device

A process for making a honeycomb article having longitudinal channels extending from one face to a second face supporting a uniform coating of activated carbon on the channel walls, the process comprising the step of providing a solid heat-activated oxidant within the channels and heating the article to release the oxidant and uniformly activate the carbon coating.

Process for manufacturing activated carbon honeycomb structures

A preform for a z-flow honeycomb filter is formed by a pressing process wherein a batch charge is shaped in a press into a preform of finished plug-and-channel configuration, the shaped preform comprising opposing overlapping arrays of closed-end inlet and outlet channels wherein the end closures consist of bridging segments of batch material connected in continuous (seamless) or uninterrupted fashion with the adjoining channel walls.

Pressed porous filter bodies

Mesoporous carbon and method of making involves forming a mixture of a high carbon-yielding carbon precursor that when carbonized yields greater than about 40% carbon on a cured basis, and an additive that can be catalyst metal and/or low carbon-yielding carbon precursor that when carbonized yields no greater than about 40% by weight carbon on a cured basis. When a catalyst metal is used, the amount of catalyst metal after the subsequent carbonization step is no greater than about 1 wt. % based on the carbon. The mixture is cured, and the carbon precursors are carbonized and activated to produce mesoporous activated carbon.

Method of making mesoporous carbon

Porous sintered ceramic materials having mullite as its primary phase and a method for producing them. The method includes preparing a plasticizable raw material mixture comprised, by weight, of 75 to 99% pre-reacted mullite powder, and 1.0 to 25% of a water-swelling clay, adding an organic binder system to the mixture and mixing the mixture to form an extrudable mixture, and extruding the mixture to form a substrate of the desired configuration. The green body is dried and fired for a time and at temperature sufficient to form a sintered mullite structure having a narrow through-pore size distribution comprised of pores exhibiting an average intrusion-pore size of between about 2-15 &mgr;m, and a total intrusion porosity, as measured by Hg intrusion method, of at least 30%.

Production of porous mullite bodies

A porous ceramic filter offering both increased thermal mass and controlled exhaust flow performance for the filtration of particulates from diesel exhaust gases includes a wall-flow honeycomb filter body incorporating a plurality of parallel end-plugged cell channels traversing the body from filter inlet to filter outlet, the wall thickness, cell density, and outer dimensions of the honeycomb being selected to provide a honeycomb bulk density of at least about 0.50 grams/cm,and an effective honeycomb length-to-diameter aspect ratio not exceeding about 0.9.

Low aspect ratio diesel exhaust filter

A gravity-flow water filter cartridge for use in a drinking water carafe or the like includes a high-surface area cyst reduction filter element disposed in a water-retaining reservoir within the cartridge; the reservoir retains sufficient water between filtering and during dispensing cycles to maintain the filter element in a fully immersed state, whereby the primed (air-free) condition of the filter necessary for fast gravity flow at high cyst reduction efficiency is maintained.

Water carafe filter cartridge

The instant invention is directed at an apparatus for removing VOC's from an exhaust gas stream comprised of the following: a heatable adsorber located in the exhaust stream capable of desorption; and, an oxidizer structure having a lightoff temperature and located in the exhaust stream downstream from the adsorber structure. One particular embodiment of the apparatus comprises the following two elements: (1) a resistively heatable adsorber possessing an activated carbon phase located in the exhaust stream and having a desorption temperature; and, (2) an electrically heatable catalyst structure having a lightoff temperature and located in the exhaust stream downstream from the adsorber structure. The method enabled as a result of the development of the aforementioned apparatus, i.e., a method for removing VOC's from an exhaust stream, involves two essential steps: (1) causing exhaust gases from an exhaust gas stream to flow through an adsorber structure and an oxidizer while adsorbing an amount of VOC's; and, (2) heating the oxidizer to its lightoff temperature and desorbing the adsorbed VOC's and thereafter flowing the desorbed compounds through the oxidizer whereupon they are oxidized. One particular embodiment involves two essential steps: (1) flowing VOC-containing exhaust gases through an adsorber structure having an activated carbon phase and an electrically heatable catalyzed structure while adsorbing an amount of VOC's; and, (2) heating the catalyzed structure to its lightoff temperature, desorbing the adsorbed VOC's and thereafter flowing the desorbed compounds through the catalyzed structure whereupon the desorbed VOC's are oxidized.

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Big Flats, NY, United States of America

David L Hickman