Corning Incorporated

Kenneth Richard Miller

Douglas Munroe Beall

Mark Lee Humphrey

Achim Karl-Erich Heibel

David John Thompson

Dana Craig Bookbinder

Pushkar Tandon

Thomas William Brew

Suhao He

Ryan Joseph Grohsmeyer

Zakariya Radwan Khayat

Dominick John Forenz

Priyank Paras Jain

Seth Thomas Nickerson

Samir Biswas

John Charles Rector

Memduh Volkan Demirbas

Thomas Dale Ketcham

Thierry Luc Alain Dannoux

Yawei Sun

John Forrest Wight, Jr

Weiguo Miao

Todd Parrish St Clair

Rodney I Frost

Richard Curwood Peterson

Sujanto Widjaja

Lin He

Thorsten Rolf Boger

Alan Thomas Stephens, Ii

David Robertson Treacy, Jr

Timothy Eugene Antesberger

Robert John Paisley

Min Shen

John Steele Abbott, Iii

Charles Mitchel Sorensen, Jr

Michael Fischer

Pronob Bardhan

Samir Khanna

James Joseph Bernas

Kunal Upendra Sakekar

Kenneth William Aniolek

Mircea Despa

Konstantin Vladimirovich Khodosevich

Dana Eugene Coots

Danhong Zhong

Dale Russell Hess

Gregg Lee Shugars

Seyed Amir Farzadfar

Christine Marie Share

Hrushikesh Govindrao Pimpalgaonkar

Artemii Alexandrovitch Shamkin

Alan T Ii Stephens

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

Extrusion dies and methods of manufacturing extrusions dies, the extrusion die including a first plate and a second plate. The first plate has first upstream and downstream surfaces. A first material of the first plate has a first elastic modulus. The first plate includes pins formed between a plurality of slots. The pins and slots define a discharge face for the extrusion die at the first downstream surface of the first plate. The second plate has second upstream and downstream surfaces. The second plate is joined at the second downstream surface to the first upstream surface of the first plate. A second material of the second plate has a second elastic modulus. The second elastic modulus is greater than the first elastic modulus. A plurality of feed holes extend from the second upstream surface of the second plate through the extrusion die into communication with the slots.

Multi-piece layered honeycomb extrusion dies and methods of making same

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 honeycomb body having a honeycomb structure and a peripheral skin, the honeycomb structure having walls defining a plurality of cells including peripheral cells disposed directly adjacent to the peripheral skin. One or more of the peripheral cells is at least partially defined by a first wall surface, a second wall surface, and a skin surface portion extending between the first wall surface and the second wall surface. A continuously-varying radius extends from a first tangent to the first wall surface along the skin surface portion and to a second tangent to the second wall surface. Other honeycomb bodies, structures, and extrusion dies for forming honeycomb structures are disclosed.

Honeycomb bodies with honeycomb structure strengthening features and extrusion dies therefor

Methods for forming an electrode for use in forming a honeycomb extrusion die. The method includes forming, by means of an additive manufacturing process, an electrode includes a base having a web extending from the base. The web defines a matrix of cellular openings. The method further includes forming a secondary electrode having a plurality of pins. The plurality of pins are shaped and arranged so as to mate with the matrix of cellular openings defined by the web of the electrode. The method further includes machining the electrode using the secondary electrode to smooth surfaces of the electrode formed by the additive manufacturing process.

Method of preparing an electrode for use in forming a honeycomb extrusion die

A honeycomb body () including a plurality of radially-extending walls () intersecting with a plurality of circumferentially-extending walls (), the plurality of radially-extending walls () and the plurality of circumferentially-extending walls () form a plurality of circumferential zones (A,B,C) of cells (). The plurality of circumferential zones (A,B,C) of cells () includes a first zone of cells (A) including two or more first rings of cells () and having a first cell density, and a second zone of cells (B) including two or more rings of cells () having varying cell densities across the two or more rings of cells. Other structures and extrusion dies are disclosed.

Honeycomb bodies with varying cell densities and extrusion dies for the manufacture thereof

A coated ceramic honeycomb body comprising a honeycomb structure comprising a matrix of intersecting porous walls forming a plurality of axially-extending channels, at least some of the plurality of axially-extending channels being plugged to form inlet channels and outlet channels, wherein a total surface area of the outlet channels is greater than a total surface area of the inlet channels, and wherein a catalyst is preferentially located within the outlet channels, and preferentially disposed on non-filtration walls of the outlet channels. Methods and apparatus configured to preferentially apply a catalyst-containing slurry to the outlet channels and non-filtration walls are provided, as are other aspects.

Outlet-coated ceramic honeycomb bodies and methods of manufacturing same

Ceramic honeycomb bodies and methods for canning the bodies are disclosed herein. The honeycomb bodies comprise a porous ceramic honeycomb structure. The honeycomb structure comprises a network of cells defined by walls that extend in an axial direction about a longitudinal axis from an inlet end to an outlet end of the honeycomb structure. The honeycomb structure also comprises a portion of cells with protrusions. The portion of cells with protrusions supports a greater concentration of catalyst, as compared to a portion of cells without protrusions. The portion of cells with protrusions is disposed off-center with respect to the longitudinal axis of the honeycomb structure such that the portion of cells with protrusions (and greater concentration of catalyst) corresponds to areas of high exhaust flow through the structure.

Ceramic honeycomb bodies and method for canning thereof

A method and extrusion die to form a laminar integral skin of a honeycomb structure is provided. The method includes extruding a ceramic precursor batch through a die with feedholes in entry side and slots in exit face of the die to form the honeycomb structure. In a region on the periphery of the die configured to form the cell matrix, a series of concentric slots around the matrix in the exit face of the die are configured to feed skin onto the matrix. Ring sections between concentric slots are angled away from the center and a mask is disposed on top of the periphery producing a channel for extruded skin to meet and bond to extruded matrix. Optionally, slots in the skin-forming ring sections enhance knitting between laminar skin layers.

Ceramic honeycomb bodies, honeycomb extrusion dies, and methods of making ceramic honeycomb bodies

A method to form a laminar integral skin of a honeycomb structure is provided. The method includes extruding a ceramic precursor batch through a die with feedholes in entry side and slots in exit face of the die to form the honeycomb structure. In a region on the periphery of the die configured to form the cell matrix, a series of concentric slots around the matrix in the exit face of the die are configured to feed skin onto the matrix. Ring sections between concentric slots are angled away from the center and a mask is disposed on top of the periphery producing a channel for extruded skin to meet and bond to extruded matrix. Optionally, slots in the skin-forming ring sections enhance knitting between laminar skin layers. The die and honeycomb body having uniform integral skin are also provided.

An apparatus and method to machine cavities in die blanks having little to no taper. The apparatus includes an electrode tool () including intersecting walls coated with electrically insulating coating (), an erosion face () comprising a cross section of the walls exposed through the electrically insulating coating, and a channel formed by the walls to supply electrolyte to the erosion face, the channels defined by interior surfaces of the walls and having an opening formed by edges of the erosion face. The method includes pulsed electrochemical machining a work piece with the electrode tool.

Apparatus and method for making extrusion dies

Methods for making extrusion dies using a LIGA process, a German acronym for lithography (Lithographie), electroplating (Galvanoformung), and molding (Abformung), are described. The resulting extrusion dies can be used, for example, for extrusion of cellular ceramic substrates, precision extrusion of optical fiber or optical fiber precursors, or other applications where profile extrusion requires high dimensional precision and/or has otherwise intricate patterns.

Methods of making extrusion dies

Growing community of inventors

Addison, NY, United States of America

Kenneth Richard Miller