Corning Incorporated

Ryan Joseph Grohsmeyer

Kenneth Richard Miller

Mark Lee Humphrey

Zakariya Radwan Khayat

Samir Biswas

John Charles Rector

Memduh Volkan Demirbas

Dana Craig Bookbinder

Thomas William Brew

Christopher John Malarkey

Richard Curwood Peterson

Keith Norman Bubb

Timothy Eugene Antesberger

Min Shen

Michael James Lehman

Kenneth Charles Sariego

Dominick John Forenz

Dana Eugene Coots

Seyed Amir Farzadfar

Shyam Lekhraj Chatlani

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

Methods for extruding a ceramic-forming mixture through a honeycomb extrusion die (), methods for forming a green honeycomb extrudate from a ceramic-forming mixture, methods of preparation of a honeycomb extrusion die () that extrudes a ceramic-forming mixture, and systems including a honeycomb extrusion die (), ceramic-forming mixture, and abrasive flow media. The method of extruding a ceramic-forming mixture through a honeycomb extrusion die () includes conditioning the honeycomb extrusion die () by extruding an abrasive flow media through the slots () of the die () prior to extruding the ceramic-forming mixture through the slots () of the die (). The abrasive flow media includes abrasive inorganic particles dispersed in a flowable carrier. The ceramic-forming mixture includes one or more types of inorganic ceramic-forming particles. The abrasive inorganic particles in the flowable carrier have a particle size distribution that corresponds to that of at least one type of the ceramic-forming particles in the ceramic-forming mixture.

Extrusion die preparation methods

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 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

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Addison, NY, United States of America

Ryan Joseph Grohsmeyer