Corning Incorporated

Robert John Locker

Constance B Sawyer

John P Day

Keith Norman Bubb

Thomas Adam Collins

Joseph Henry Citriniti

Huthavahana Kuchibhotla Sarma

Paul S Schmitt

Gregory Eisenstock

Joel Andrew Schultes

Robert A Morse

Theresa Chang

Patrick David Tepesch

Kevin Lee Wasson

Achim Karl-Erich Heibel

Monika Backhaus-Ricoult

Mark Alan Lewis

Todd Parrish St Clair

Thomas Richard Chapman

G Daniel Lipp

David Lambie Tennent

Conor James Walsh

Christopher John Warren

Xinyuan Liu

Martin Joseph Murtagh

Devi Chalasani

Kenneth Charles Sariego

Kevin Eugene Elliott

Leslie E Hampton

Kenneth Joseph Drury

Christopher Lane Kerr

David Dasher

Robert Arthur McIntosh

Gregg William Crume

Wenbin Qiu

Robert Bernard Lubberts

Dennis M Brown

Prashanth Abraham Vanniamparambil

Shu Yuan

James Monroe Marlowe

Casey Allen Volino

Martin J Schad

Maryam Khanbaghi

Robert Arthur Mcintosh

Achim K Heibel

David Robert Potts

Angus G Craig

James F Unruh

Douglas J Fox

Kyle Owen Beebe

Earl James Sanford

Stephen John Caffrey

Daniel Edward Mccauley

Jr David Robertson Treacy

A method for plugging a subset of cells of a honeycomb structure that includes: covering a first end face of the honeycomb structure with a mask that comprises a body and a plurality of openings, wherein the plurality of openings of the mask is coincident with a plurality of cells of the honeycomb structure; providing a plenum, a movable plunger and a flow plate; positioning a cylinder between the honeycomb structure and the plenum; dispensing a plugging material into the plenum; moving the plunger toward the flow plate with a force to push the plugging material through the flow plate into the cylinder, the moving generating a pressure in the plenum and the cylinder that forces the plugging material through the mask into the plurality of cells of the honeycomb structure to a predetermined depth; and determining the pressure within the cylinder during the moving of the plunger.

Methods and apparatus for plugging cells of ceramic structures and honeycomb filters

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 method for plugging a subset of cells of a honeycomb structure that includes: covering a first end face of the honeycomb structure with a mask that comprises a body and a plurality of openings, wherein the plurality of openings of the mask is coincident with a plurality of cells of the honeycomb structure; providing a plug of material upon a film material; applying a force to the film material with a piston to push the plug of material through the plurality of openings of the mask and into the plurality of cells of the honeycomb structure; and measuring a plurality of pressures within the plurality of cells of the honeycomb structure during the applying step.

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

Disclosed herein are methods for preparing a titanate compound powder comprising titanate compound particles having a controlled particle size and/or particle size distribution. The methods include mixing at least one first inorganic compound chosen from sources of a first metal or metal oxide, at least one second inorganic compound chosen from sources of titania, and at least one binder to form a mixture; calcining the mixture to form a polycrystalline material comprising a plurality of titanate compound grains and a plurality of microcracks; and breaking the polycrystalline material along at least a portion of the microcracks. Also disclosed are titanate compound powders having a controlled particle size distribution, ceramic batch compositions comprising the powders, and ceramic articles prepared from the batch compositions.

Ceramic powders with controlled size distribution

A control strategy for producing high quality extrudates, including the steps of monitoring the temperature of a ceramic precursor batch by measuring the temperature of the batch material either directly or indirectly by measuring the temperature of a component of the extruder proximate to the die and transmitting the temperature data to an extrusion control system which comprises a master controller (), at least one slave controller () and an optional supervisory controller. The supervisory controller determines batch temperature setpoint () in order to achieve the desired temperatures for extruding a certain type of batch material based on real time temperature inputs and stored parameters such as batch composition, process throughput, extruder cooling capacity, and the like. The master controller () receives batch temperature setpoint from the supervisory controller, and monitors batch temperature and in turn regulates at least one slave controller () which controls the flow of coolant () to portions of an extruder () in contact with the batch material.

Dual loop control of ceramic precursor extrusion batch

A method for making a ceramic body, the method including: mixing inorganic ceramic-forming ingredients to form a batch; adding a rapidly hydratable cellulosic binder and a liquid vehicle to the batch and further mixing to form a plasticized mixture; extruding the plasticized mixture to form a green body. The green body can then be heated sufficiently to produce a predominant ceramic phase, thereby transforming the green body into the ceramic body.

Ceramics manufacture using rapidly dissolvable cellulosic binder

Aluminum titanate precursor batch compositions comprising a recycled aluminum titanate component, at least a portion of the recycled aluminum titanate component being comprised of a recycled pre-reacted aluminum titanate composition or alternatively of an un-reacted green aluminum titanate precursor composition, and methods for producing aluminum titanate ceramic articles utilizing the inventive batch compositions.

Aluminum titanate batch compositions and method

A plate suitable for positioning with an extruder apparatus is provided in which the plate includes at least one temperature sensor. The plate is upstream of the die located at or near the end of the extruder apparatus. The sensor(s) allow for the simultaneous measurement of batch material temperatures at multiple spatial locations across the face of the plate. The temperature sensors associated with the plate can be used to identify spatial and temporal temperature patterns within the batch flow.

Devices and methods for regulating extruder ceramic batch material

In-line systems for and methods of measuring the moisture content of ceramic material within an extrusion system used to form ceramic articles are disclosed. One method includes arranging, relative to the extrusion system, at least one radio-frequency (RF) sensor system having an RF antenna, and generating through the RF antenna an RF field that resides substantially entirely within the ceramic material. The method also includes, in response to the RF field interacting with the ceramic material, generating in the RF sensor system a signal representative of a raw moisture-content measurement of the ceramic material. The method also includes generating calibration data by performing RF moisture-content measurements on samples of the ceramic material having different known moisture contents, and establishing a calibrated moisture-content measurement using the raw moisture-content signal and the calibration data. Both contact and non-contact systems and measurement methods are described.

In-line moisture-content measurement of ceramic materials in ceramic article manufacturing

Porous ceramic diesel particulate filters are regenerated to combust accumulated carbon particulates trapped therein through a controlled regeneration process wherein heat is input to the filter at a ramped or staged heating rate below that rate at which the particulate combustion process would proceed so rapidly and extensively that filter temperatures would be raised to filter-damaging levels.

Regeneration of diesel particulate filters

The regeneration responses of diesel engine exhaust filters are mapped by conducting multiple regeneration runs under controlled conditions of soot loading, exhaust temperature, exhaust flow rate, exhaust oxygen content and/or other regeneration condition variables to generate a multivariate response surface or filter map that can be used to predict regeneration response under other conditions and aid in the design and active management of the filters to improve filter efficiency and extend filter service life.

Filters for engine exhaust particulates

A catalytic converter for purifying exhaust gases from an internal combustion engine includes a monolithic ceramic substrate having a peripheral surface encircled by a non-intumescent supporting mat material. A metal shell comprising a wider portion which is adjacent to and encloses the mat material and the substrate. The metal shell further comprises a narrower portion which overlaps and is attached to the outer surface of the wider metal shell portion. The wider and narrower metal shell portions combine to exert a compressive force on the wrapped substrate.

Catalytic converter for use in an internal combustion engine

A method of assembling a catalytic converter comprising the steps of: (1) providing a metal shell exhibiting a predetermined shape that substantially matches the shape of the ceramic substrate; (2) inserting into the metal shell a sufficient amount of a resilient supporting mat material to form a encircling mat layer; (3) compressing the encircling mat layer to an initial gap bulk density, the initial gap bulk density being higher than the final gap bulk density; (4) releasing the compression on the mat layer and prior to the mat layer reaching its final gap bulk density, inserting at least a portion of the substrate into the encircling mat layered metal shell and then allowing the mat layer to further release until the mat layer is compressed against the ceramic substrate at the final predetermined gap bulk density.

Method of assembling a catalytic converter for use in an internal combustion engine

A catalytic converter for purifying exhaust gases from an internal combustion engine includes a monolithic ceramic substrate having a peripheral surface encircled by a non-intumescent supporting mat material. A metal shell comprising a wider portion which is adjacent to and encloses the mat material and the substrate. The metal shell further comprises a narrower portion, preferably triangularly shaped, that overlaps and is attached to the outer surface of the wider metal shell portion. The wider and narrower metal shell portions combine to exert a compressive force on the wrapped substrate.

Catalytic converter for use in an internal combustion engine and a method of making

Growing community of inventors

Corning, NY, United States of America

Robert John Locker