Corning Incorporated

Keith Norman Bubb

Anthony Joseph Cecce

Thomas Richard Chapman

Cameron Wayne Tanner

Huthavahana Kuchibhotla Sarma

Kenneth Joseph Drury

Courtney Spencer Warren

Todd Parrish St Clair

Robert John Locker

Allison Elizabeth Cronin

Theresa Chang

Patrick David Tepesch

Kevin Lee Wasson

Thomas William Brew

Mark Alan Lewis

Conor James Walsh

Xinyuan Liu

Min Shen

Michael James Lehman

Joseph Henry Citriniti

Kevin Eugene Elliott

Kenneth Charles Sariego

Christopher Lane Kerr

Ryan Joseph Grohsmeyer

Prashanth Abraham Vanniamparambil

Shu Yuan

Julie Marie Daugherty

An extrusion die () including a plurality of pins () having side surfaces defining an intersecting array of slots () extending axially into the die () from a discharge face () of the die (). A plurality of feedholes () extend axially from an inlet face () of the die () opposite to the discharge face (). The feedholes () connect with the slots () at intersections () within the die () to create a flow path from the inlet face () to the discharge face (). A first coating () is on at least a portion of the feedholes () in a first zone () extending over a first axial length of the flow path. A second coating () that is different than the first coating () is on at least a portion of the side surfaces () of the pins () in a second zone () extending over a second axial length of the flow path. Methods of fabricating an extrusion die () and manufacturing a ceramic article (), such as a honeycomb body, are also disclosed.

Extrusion dies with zoned coatings, methods of fabricating such dies, and methods of manufacturing ceramic articles

A method of plugging a honeycomb body includes mixing a plugging mixture at a mixing temperature, wherein the plugging mixture comprises a plurality of inorganic particles, inorganic binder, organic binder, and water; dispensing the plugging mixture into a patty mold at a dispensing temperature; cooling the plugging mixture within the patty mold to a cooled temperature, such that a cement patty is formed; and pressing the cement patty into a plurality of channels in a honeycomb body, wherein the mixing temperature and the dispensing temperature are above a hydration point temperature of the organic binder in the plugging mixture, and the cooled temperature is below the hydration point temperature of the organic binder in the plugging mixture.

Methods of making plugged honeycomb bodies with cement patties

A method of plugging a permeable porous cellular body () comprises: contacting the permeable porous cellular body () with a plugging mixture (), the permeable porous cellular body () defining a plurality of channels (); forcing the plugging mixture () into the plurality of channels () until a maximum, self-limiting, depth () of plugging mixture () is disposed within the plurality of channels (); and maintaining a constant flow rate of the plugging mixture () into the plurality of channels until () a pressure on the plugging mixture () elevates to a predetermined pressure. Alternatively, the method comprises forcing the plugging mixture () into the plurality of channels () utilizing the application of a constant pressure over time until a maximum, self-limiting, depth () of the plugging mixture () is disposed within the plurality of channels (); and maintaining the constant pressure applied to the plugging mixture () until flow of the plugging mixture () into the channels () decays from an initial flow rate to a predetermined flow rate.

Methods of plugging a permeable porous cellular body

A method of plugging channels of a honeycomb body and a honeycomb body including plugged channels. The method includes applying a shear force to a plugging mixture including a plurality of inorganic particles, clay, and a liquid vehicle to alter the viscosity of the plugging mixture from a first viscosity prior to the vibrating to a second viscosity which is less than the first viscosity. A honeycomb body is placed into contact with the plugging mixture such that a portion of the plugging mixture having the second viscosity flows into the plurality of channels. Application of the shear force is stopped or reduced to increase the viscosity of the portion of the plugging mixture in the plurality of channels to greater than the first viscosity.

Methods of plugging a honeycomb body

A system and method to dry plug cement in a ceramic honeycomb body during the manufacture of plugged ceramic honeycomb bodies. The system includes a heating element () configured to immediately heat without contact a face () of a ceramic honeycomb body () plugged with a wet plug cement () to rapidly dry and stiffen the plug cement () on the face () of the ceramic honeycomb body (). The method includes immediately applying heat without contact to a face () of a ceramic honeycomb body () having wet plug cement () disposed in channels () of the ceramic honeycomb body at the face, and rapidly drying and stiffening the plug cement on the face of the ceramic honeycomb body.

System and methods of plugging ceramic honeycomb bodies

A porous ceramic honeycomb body () including intersecting walls that form channels () extending axially from a first end face to a second end face and layered plugs () comprised of a first layer () disposed on channel walls and a second layer () disposed inward toward an axial center of each respective channel on the first layer. The plugs seal at least one of a first portion of the channels at the first end face and a second portion of channels at the second end face of the porous ceramic honeycomb body.

Honeycomb body having layered plugs and method of making the same

Disclosed is a honeycomb support structure comprising a honeycomb body and an outer layer or skin formed of a cement that includes an inorganic filler material having a first coefficient of thermal expansion from 25 C to 600 C and a crystalline inorganic fibrous material having a second coefficient of thermal expansion from 25 C to 600 C. Skin cement composition controls level of cement liquid/colloid components, for example water, colloidal silica, and methylcellulose migration into the substrate during the skin application process to form barrier to skin wetting and staining during the washcoating process.

Honeycomb structure comprising a cement skin composition with crystalline inorganic fibrous material

An apparatus and method of manufacturing a porous ceramic segmented honeycomb body (') comprising axial channels () extending from a first end face () to a second end face (). A plurality of porous ceramic honeycomb segments () is moved axially past respective apertures () of an adhesive applying device (). Adhesive () is applied through openings () in the adhesive applying device () onto peripheral axial surfaces of each porous ceramic honeycomb segment (). The plurality of porous ceramic honeycomb segments () enters a wide opening () of a tapered chamber () and exits a narrow opening () of the tapered chamber (); a tapered wall () from the wide opening () to the narrow opening () presses the plurality of porous ceramic honeycomb segments () together forming the porous ceramic segmented honeycomb body (&#x2032;). The adhesive () on the peripheral axial surfaces between respective porous ceramic honeycomb segments () is distributed by the pressing.

Apparatus and method of manufacturing ceramic honeycomb body

A composition for applying to a honeycomb body includes a refractory filler, an organic binder, an inorganic binder, and a liquid vehicle, wherein the refractory filler, the particle size distribution of the refractory filler, the organic binder, and the inorganic binder are selected such that, when the composition is applied to plug a plurality of channels of the honeycomb body, the plug depth variability is reduced.

Compositions and methods for plugging honeycomb bodies with reduced plug depth variability

Various embodiments are directed to ceramic articles. The ceramic articles include a fired ceramic honeycomb body having a plurality of cell channels and at least one plug disposed in at least one cell channel of the fired ceramic honeycomb body. The at least one plug includes a refractory filler, an inorganic binder, and an organic binder. The refractory filler comprises particles having a din the range from about 10 &#x3bc;m to about 40 &#x3bc;m, and a dless than about 110 &#x3bc;m.

Ceramic honeycomb bodies including cold set plugs

Various embodiments provide methods of making ceramic articles and cold-set plugs for ceramic honeycomb bodies. The methods of making ceramic articles include providing a ceramic honeycomb body and applying an aqueous composition to the ceramic honeycomb body to form a cold-set plug. The aqueous composition includes a refractory filler, an inorganic binder, and an organic binder. The refractory filler includes particles having a dranging from about 10 &#x3bc;m to about 40 &#x3bc;m, a dgreater than about 2 &#x3bc;m, and a dless than about 110 &#x3bc;m. Embodiments also provide methods of making the cold-set plug that include preparing the aqueous composition and forming the cold-set plug by applying the composition to the ceramic honeycomb body.

Method for making cold-set plug for ceramic honeycomb body

A pass-through catalytic substrate can comprise a plurality of porous ceramic substrate walls defining flow channels extending between an inlet end and an outlet end of the catalytic substrate. The pass-through catalytic substrate can include a plurality of porous ceramic beveled corner portions positioned at intersecting corners of the substrate walls within the flow channels. In one example, the porous ceramic beveled corner portions each include a heat capacity less than about 1.38 J/cm/K. In another example, a catalytic washcoat layer can be provided for coating the porous ceramic substrate walls and the porous ceramic beveled corner portions. Methods for producing a pass-through catalytic substrate also provide porous ceramic beveled corner portions.

Pass-through catalytic substrate including porous ceramic beveled corner portions and methods

A porous ceramic body including a major phase of beta-spodumene and a minor phase of mullite, the aggregate composition of a batch in weight percents of LiAlSiO, SiO, and AlSiOare as defined herein. Also disclosed is a method for making a porous ceramic article is and includes: mixing inorganic batch ingredients including sources of silica, alumina, and lithia, with a liquid and an organic binder to form a plasticized batch mixture; forming a green body; and heating to the porous ceramic article, comprised of a major phase of beta-spodumene and a minor phase of mullite.

Growing community of inventors

Beaver Dams, NY, United States of America

Keith Norman Bubb