Corning Incorporated

Corning Glass Works

Corning Inorporated

Lawrence S Rajnik

George M Cunningham

David F Thompson

Gregory A Merkel

Ronald E Johnson

Dell Joseph St Julien

Yuming Xie

Lung-Ming Wu

David L Hickman

G Daniel Lipp

Kevin Robert Brundage

David S Weiss

Paul S Schmitt

J Paul Day

A method for making a composite extrusion die for making a cellular honeycomb structure with thin cell walls. The method includes the steps of drilling a grid of separate feed holes/channels into an inlet face of an extrusion die base element, and cutting a grid of intersecting primary outlet slots into an outlet face of the base element, where every alternate one of the primary outlet slots is in direct communication with a plurality of the feed channels. Further, the method includes cutting a grid of intersecting secondary outlet slots into the outlet face, where each one of the secondary outlet slots bisects each one of the primary outlet slots. The method further includes scoring a plurality of indentations into that region of the outlet face that does not contain any of the primary and secondary outlet slots, and filling each of the feed channels and each of the primary and secondary outlet slots with a filler material. Further, the method includes placing a bonding material onto the outlet face and into each of the plurality of indentations, and permanently attaching to the outlet face, a first side of a capping plate having a plate thickness not greater than 0.060 inches. Finally, the method includes cutting through the capping plate a grid of cap slots having a slot width not greater than 0.007 inches. The method further comprises eliminating the filler material from each of the feed channels and each of the primary and secondary outlet slots.

Extrusion die and method

An extrusion die for forming a cellular honeycomb structure having a finned protrusion extending from at least one cell wall of the honeycomb structure. The extrusion die is a composite extrusion die that comprises a primary extrusion die body having an inlet face and an outlet face, and at least a first insert member that is secured into a first intersection formed by a pair of intersecting slots at the outlet face of the primary extrusion die body. More preferably, a plurality of insert members are secured into a plurality of intersections, each intersection being formed by a pair of intersecting slots and each of the intersections being defined by four pegs/pins at the outlet face of the primary extrusion die body. Each of the insert members is adapted to fit into one of the intersections of the die body, where the size and shape of the insert members and the positioning of the insert members into a plurality of the intersections cuts off the flow path of an extrudable material through the plurality of the intersections. Thereby, when a cellular honeycomb structure is extruded through the composite extrusion die, the honeycomb structure comprises a plurality of finned protrusions extending from a plurality of the cell walls of the honeycomb structure corresponding to the plurality of the intersections of the die body into which the insert members are secured.

Cellular extrusion die

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

A device for altering a feed stock is made of a structure for passage of a feed stock. The structure can be either an extruded unibody structure, or a nested structure. The structure has an interior and an exterior section, and a longitudinal axis, and walls defining two sets of open-ended passages which extend along the longitudinal axis. The two sets of passages have different cross sectional shapes or dimensions with respect to each other. When the structure is nested, at least one set of channels have a cross section in the shape of truncated arcs. A method for making the unibody structure involves extruding a plasticized raw material mixture through a die, followed by heat-treating. A method of altering a feed stock which involves passing a feed stock into the device through one set of passages to cause an altering of the feed stock, and thereafter passing the output stream into and through the other set of channels to the exterior of the device.

Device for altering a feed stock and method for using same

Assembly and method of installing an electrode of a predetermined size and configuration in an electric heater envelope having an electrode opening at a preselected position. The assembly and associated method consist of affixing a hollow compression fitting about or within the electrode opening and providing a sleeve of a refractory deformable dielectric material within the fitting through which the electrode passes into the envelope. Dielectric spacing means are positioned between the electrode and electrically conductive portions of the fitting or envelope to prevent electrical conduction therebetween. Compression fastening means are then provided, securable to the fitting, to impart sufficient compressive force to the assembly to deform the sleeve about the electrode, thereby effectively sealing and securing the electrode within the fitting without the electrode grounding against the fitting or the envelope.

Electrode assembly and method

A metal honeycomb heater is protectively mounted in an axially assembled enclosure comprising opposing tubular enclosure sections incorporating internal bore stops and a resilient mounting material to support the heater. An axial force of predetermined magnitude is applied to the sections during assembly, preloading the resilient mounting material and generating a selected spring tension and preloading force on the honeycomb. The sections are fastened together under this force so that the preloading force and spring tension are retained during subsequent use of the assembly.

Axially assembled enclosure for electrical fluid heater and method

Thick-skinned extruded metal honeycomb structures, and a method and apparatus for making them, are disclosed wherein a plasticized powder metal extrusion batch is extruded though a die assembly comprising a die and annular mask, the mask having a central outlet for extrusion of the skin and honeycomb core and an extrudate reservoir adjacent the central outlet, the die and mask cooperating to form a skinforming gap fed by the die and by the extrudate reservoir, such that batch material supplied from the reservoir and directly from the die combines to form a thickened outer skin which is integral with, and resistant to separation from, the honeycomb core.

Extrusion of metal honeycombs

A multi-part extrusion die is disclosed which not only permits the formation of thin discharge slots down to about 0.003 or 0.002 inches, but also provides the ability to produce a die for forming a honeycomb article with different cell densities and web thicknesses in various sections. A plurality of individual die parts are each provided with discharge slots in a discharge face thereof of desired width and spacing, and then a plurality of such individual die parts are secured together in a desired alignment such that the discharge face of each of the plurality of die parts forms a continuous discharge face for the multi-part extrusion die.

Multi-part extrusion die

Novel method and structure is disclosed for strengthening and mounting sloted metallic honeycomb structures by positioning rod members within the slots to prevent the slots from closing or deforming, and by utilizing the rod members to precisely engage positionable restraining inserts of an enclosing housing, so as to accurately mount the honeycomb structure within the housing.

Strengthening and mounting slotted metal honeycomb structures

A method is disclosed for trimming a newly formed article from sheet glass while it is still in a semi-molten condition, by maintaining a peripheral portion of the sheet glass about the newly formed article out of contact with the mold so as to maintain its temperature, and then reducing the thickness of such peripheral portion without severing the same, and then cooling the thinned section to thermally crack-off and separate the newly formed article from the sheet glass.

Trimming products from sheet glass

In a printing apparatus using a collector membrane, certain formulations of room temperature vulcanizing silicone materials form membranes with superior performance. The preferred release characteristic of the material is set forth in terms of the time it takes a test element to roll along an inclined plane having an adhesive material thereon.

Collector membrane

A flexible membrane pickup surface for receiving thereon one or more color portions of a design. A backing member is provided in opposition to a design receiving side of the membrane to rigidly locate it in a plane while receiving the color. The backing member has pore openings therein coupled to a source of reduced atmosphere for drawing the membrane thereagainst. In a printing mode the membrane is pressed against a ware surface by means of a pressing head having a shape causing a selected contact angle across the ware surface.

Growing community of inventors

Corning, NY, United States of America

Lawrence S Rajnik