Corning Incorporated

Mark Allen Spetseris

Thomas William Brew

Tudor Constantin Gheorghiu

Eric L Thompson

Christopher Steven Witte

Douglas Munroe Beall

Sriram Rangarajan Iyer

Elizabeth Marie Vileno

Christopher John Malarkey

Conor James Walsh

Martin Joseph Murtagh

David Robertson Treacy, Jr

Min Shen

John Harold Brennan

Gary Graham Squier

Jon Anthony Passmore

David Scott Franzen

Alan T Dull

Thomas S Hinkle

Tushar Gulati

Yuk Fung Chan

Darin Wayne Felty

Gregory N Yourkievitz

Slater Kent Atkins

Balaji Venkatesan Swarnamani

Cecilia S Magee

Jonathan Mark Stalker

Robert Joseph Castilone

David L Oliver

Thomas E Landon

Eric Lee Thompson

Robert J Castilone

David R Treacy

A skin-forming die includes an inlet face; an outlet face; one or more slots, each of the one or more slots comprising one or more slot inlets extending between the one or more slot inlets and the outlet face; a plurality of feedholes extending between the inlet face and the one or more slot inlets; and a central opening configured to receive a matrix die. Extrusion die apparatus and methods of manufacturing honeycomb bodies are also disclosed.

Skin-forming die and honeycomb extrusion die

A honeycomb extrusion die assembly () comprising a honeycomb extrusion die () and a forming plate () to block batch flow to at least a portion of a skin forming region. The honeycomb extrusion die () comprising a step cut discharge surface () in the skin forming region and at least some slots () each with a divot () spaced toward a discharge surface () from a feedhole-slot intersection and a wide portion at the discharge surface () extending into the die body to the divot () to strengthen a peripheral region of a honeycomb extrudate in a reinforcement region, and a bulk nominal section corresponding to a bulk region of the honeycomb body.

Extrusion components for honeycomb bodies

Methods of firing a cordierite green body to form a fired cordierite body. The green body comprises cordierite-forming raw materials and organic material, the body having a core portion and a skin portion. The green body is pre-heated to a pre-heat temperature that is less than a thermal decomposition temperature of the organic material. The green body is maintained at the pre-heat temperature for a period of time sufficient to minimize a temperature differential between the core portion and the skin portion. The green body is heated to a low firing temperature in a firing atmosphere sufficient to reduce a content of the organic material and to substantially remove chemically bound water from hydrous alumina. The green body is heated to a high firing temperature in a firing atmosphere sufficient to reduce the content of the organic material prior to a substantial removal of chemically bound water from clay.

Method of firing cordierite bodies

The invention is directed to a method for managing pore size distribution in honeycomb substrates by using two or more pore forming agents in the batch ingredients. In particular, the invention is particularly useful in managing pore size distribution in cordierite and aluminum titanate honeycomb substrates in the face of particle size variations in the pore forming agents and other materials used to make such substrates.

Managed pore size distribution in honeycomb substrates

An improvement in a process of forming ceramic articles comprising oil-based components or extrusion aids, the improvement including removing the oil-based components after drying and prior to firing by flowing a heated gas through the green ceramic honeycomb articles to evaporate and condense the oil-based components, with or without microwave radiation.

Process for removing oil-based components and forming ceramic bodies

A process for automatically controlling combustible vapors during debinding and firing of ceramic products which includes establishing a maximum percentage of lower flammability limit (LFL) setpoint no greater than 50%; measuring continuously the percentage of LFL in the kiln atmosphere; and, maintaining the measured percentage of LFL to be less than or equal to the maximum percentage of LFL setpoint by an action selected from the group consisting of increasing gas volume delivered to the kiln, decreasing O concentration in the kiln, decreasing heating rate in the firing cycle, and combinations thereof.

Control of combustibles during firing

A method of firing ceramic bodies and includes placing the ceramic material in a heating apparatus and subjecting the ceramic material to an amount of heat energy that results in the ceramic article exhibiting a ceramic body core temperature, T , a ceramic body surface temperature T , and surface-core temperature differential that is less than or equal to a predetermined maximum temperature differential setpoint.

Method for controlling the firing of ceramics

Fine circumferential skin cracking in extruded thin-walled cordierite honeycombs having channel wall thicknesses not exceeding about 0.004 inches (100 &mgr;m) but skin layers of substantially higher thickness is prevented by extruding the honeycombs under conditions that enhance cordierite crystal alignment in the skin; thin-walled honeycomb products having skins free of fine cracks that are well-matched in thermal expansion to the honeycomb cores are provided.

Method for extruding ceramic honeycombs

A method of firing a green cordierite-ceramic honeycomb structural body containing a carbonaceous material, for example, an organic binder, comprising a two phase process. The first phase comprises firing the green honeycomb structural body in a firing atmosphere to a temperature and for a time sufficient to initiate and sufficiently achieve release of the carbonaceous material while introducing into the firing atmosphere a fluorine-free low-oxygen gas comprising less than about 20% O.sub.2, by volume. Once the carbonaceous material is sufficiently released, the second phase involves conventionally firing the green body for a time and a temperature sufficient to initiate and sufficiently achieve the conversion of the green ceramic honeycomb structural body into a fired honeycomb body.

Method for firing ceramic honeycomb bodies

The present invention is directed toward the improvement of the properties of cordierite sintered structures. The improvement consists essentially of heat treating the calcined kaolin component which when added to the batch of ray materials increases the thermal shock resistance and decreases the coefficient of thermal expansion.

Material and process to produce low thermal expansion cordierite

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Pine City, NY, United States of America

Mark Allen Spetseris