Corning Incorporated

Min Shen

Thomas William Brew

Kenneth Charles Sariego

Yuehao Li

Tushar Gulati

Achim Karl-Erich Heibel

Suhao He

Michael James Lehman

Douglas Munroe Beall

Jacob George

Todd Parrish St Clair

Kenneth Richard Miller

Eric L Thompson

Thorsten Rolf Boger

Keith Norman Bubb

Mark Allen Spetseris

Parasuram Padmanabhan Harihara

Kunal Upendra Sakekar

Ryan Joseph Grohsmeyer

Sam George

Konstantin Vladimirovich Khodosevich

Darin Wayne Felty

Slater Kent Atkins

Helmut Roland Letzel

John Wilbur Allard

Lee James Parks

Hrushikesh Govindrao Pimpalgaonkar

Thomas Mark Dubots

Eric Lee Thompson

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 honeycomb extrusion die () with improved wear properties. Extrusion die has a die body () with inlet () and exit () faces, feedholes () with feedhole entrances (A) and outlets (B), and a plurality of die pins () having side surfaces () configured to define a matrix of intersecting slots (). At least some of the intersecting slots and die pins define a slot structure with divots () formed in the side surfaces of the die pins between the feedholes and the exit face, entrance slot portions between the feedhole outlets and the divots, the entrance slot portions having an entrance slot width W, and exit slot portions between the divots and the exit face, the exit slot portions having an exit slot width W, wherein W>Wover an entire slot length. Methods of manufacturing honeycomb structures using the honeycomb extrusion dies and of fabricating the extrusion dies are provided as are other aspects.

Honeycomb extrusion dies and methods of using and making same

A honeycomb extrusion die () includes a die body () including an inlet face () and an outlet face (). A plurality of pins () extend from the die body (), wherein the pins () are arranged to define primary (P) and secondary slots (S). Primary slots (P) include primary slot inlets (P) and primary slot outlets () and the secondary slots (S) include secondary slot inlets (SI) and secondary slot outlets (SO). Feedholes () extend within the die body (), the feedholes () including feedhole outlets (), wherein the feedhole outlets () intersect only with the primary slot inlets (P). First surface indentation features () extend into side surfaces () of the plurality of pins () defining the primary slots (P). The first surface indentation features () are spaced from the primary slot outlets (). The secondary slots (S) are devoid of surface indentation features. Other die bodies, extruders, and methods are disclosed.

Honeycomb extrusion dies and forming methods

A honeycomb extrusion die () includes a die body () including an inlet face () and an exit face. The die body () has slot inlets () and a plurality of pins () disposed between the slot inlets () and the exit face. The plurality of pins () include side surfaces (B) configured to define a matrix of intersecting slots (), wherein the matrix of intersecting slots () has slot exit () widths at the exit face. Divots () extend into a plurality of the side surfaces (B) between the slot inlets () and the exit face. Each individual divot () has a divot depth (D) extending into a side surface (A,B,A,B) of the side surfaces (B). A ratio between a slot exit width (W) Wof an individual slot () and the divot depth (D) of an individual divot () extending into a side surface (A,B,A,B) of the individual slot () is greater than 1.2. Methods of forming honeycomb bodies with honeycomb structures are provided, as are other aspects.

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

Methods of depositing an inorganic material on an extrusion die including positioning an extrusion die within a vapor deposition chamber, positioning an impedance disk over a face of the extrusion die, the impedance disk having a plurality of through holes and the face of the extrusion die having a plurality of slots defined by a plurality of extrusion die pins, and flowing one or more deposition gases through the plurality of through holes and into the plurality of slots to deposit inorganic particles on side walls of the plurality of pins. The total impedance to the flow of the deposition gases across the impedance disk and the extrusion die may be equal to a disk impedance of the impedance disk plus a die impedance of the extrusion die, and the disk impedance may be at least 40% of the total impedance to the flow of the deposition gases.

System and method for vapor deposition coating of extrusion dies using impedance disks

A honeycomb extrusion die body () including inlet () and exit () faces, and a plurality of pins () on the exit face () defining a matrix of intersecting wide slots () and narrow slots (). The wide slots () have an exit width (W) greater than an exit width (W) of the narrow slots (). The die body () further includes feedholes () at the inlet face () and intersecting with inlet portions () to the wide slots () and/or the narrow slots (). Some of the pins () defining the wide slots () include a first surface indentation feature () that is (i) located between the inlet portion () and the wide slot exit and (ii) spaced away from the wide slot exit. Some of the pins () defining the narrow slots () include a second surface indentation feature () that is (i) located between the inlet portion and the narrow slot exit and (ii) spaced away from the narrow slot exit.

Extrusion dies

An extrusion die () for a honeycomb body, the die () including: an input surface (); an opposing output surface (); feed holes () extending from the input surface () toward the output surface (); discharge slots () having a slot width (SW) and a slot length (SL), and extending from the output surface () toward the input surface (); and a plenum () fluidly connecting the feed holes () and the discharge slots (). The plenum () may include chambers () connected to the feed holes () and including tapered outlets () connected to the discharge slots (). The plenum () may include first chambers (A) connected to the feed holes () and including first tapered outlets (A), and second chambers (B) connected to the first outlets and including second tapered outlets (B) connected to the discharge slots ().

Extrusion dies for honeycomb body

A honeycomb extrusion die comprising 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

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.

Particulate filters for reducing NOand particulate matter in diesel exhaust and methods for forming the same are disclosed. In one embodiment, a particulate filter may include a honeycomb body with a plurality of channel walls extending from an inlet end to an outlet end. At least a first set of the channels are plugged proximate at least one of the inlet end or the outlet end. A filter zone may extend from the inlet end in an axial direction of the particulate filter. A DeNOzone may be located downstream of the filter zone. The channel walls of the particulate filter may include a DeNOfunctional catalyst in the DeNOzone and a ratio of the permeability &#x3ba;of the channel walls in the filter zone to the permeability &#x3ba;of the channel walls in the DeNOzone (&#x3ba;:&#x3ba;) is at least 2.

[object Object]

Mass based methods and systems for estimating soot load in a filter of an after-treatment system for exhaust stream are provided. The after-treatment system can comprise a sensor, a filter, and a processor configured to estimate soot load in the filter based on a mass based multi-layer model. An example system includes a virtual sensor comprising an estimator for providing information corresponding to a filter outlet NOconcentration. An example method includes the steps of providing the mass based multi-layer model, passing the exhaust stream through the filter, and using the sensor to monitor a condition of the exhaust stream. The example method further includes the steps of calculating a total regeneration rate based on the multi-layer model by solving a second-order ordinary differential equation with a plurality of parameters using an analytical approach, and estimating the soot load based on the calculated total regeneration rate.

Mass based methods and systems for estimating soot load

Methods and apparatus for drying ceramic green bodies include providing one or more ceramic green bodies in a microwave heating chamber operatively connected to a microwave source and a PLC. The total mass of the ceramic green bodies present in the microwave heating chamber is determined. Microwave energy is generated with the microwave source and transmitted from the microwave source to the microwave heating chamber. A transmitted power of the microwave energy transmitted from the microwave source to the microwave heating chamber is measured with power sensors. The reflected power of reflected microwave energy reflected back from the microwave heating chamber is also measured. The power of the microwave energy transmitted from the microwave source to the microwave heating chamber is adjusted based on the total mass of ceramic green bodies present in the microwave heating chamber, the measured transmitted power and the measured reflected power.

Growing community of inventors

Horseheads, NY, United States of America

Min Shen