Corning Incorporated

Thomas William Brew

Min Shen

Douglas Munroe Beall

David Robertson Treacy, Jr

Kenneth Charles Sariego

Dana Craig Bookbinder

Kenneth Richard Miller

Mark Allen Spetseris

Yuehao Li

Tushar Gulati

Yawei Sun

Weiguo Miao

Christopher John Malarkey

Eric L Thompson

Harry A Kragle

Mark Lee Humphrey

Mark Alex Shalkey

W Neil Peters

Darin Wayne Felty

Rodney I Frost

Conor James Walsh

Sujanto Widjaja

Keith Norman Bubb

David John Thompson

Michael James Lehman

Priyank Paras Jain

Seth Thomas Nickerson

Samir Khanna

James Joseph Bernas

Timothy Michael Miller

Ryan Joseph Grohsmeyer

Jeffrey Owen Foster

Dennis M Brown

Konstantin Vladimirovich Khodosevich

Robert Bernard Lubberts

James Frederick Avery

Obiefuna Chukwuemeka Okafor

David Lewin Poff

Andrew Joseph Sullivan

John M Larson

Brian James Miller

Thomas Mark Dubots

John Wilbur Allard

David R Treacy

Slater Kent Atkins

Lee James Parks

Steven John Kremer

Frank Fabian

Bryan Michael Miller

Helmut Roland Letzel

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 () 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

Methods of applying an inorganic material to a metal substrate that includes a metallic material having an austenite transformation temperature. The method includes depositing inorganic particles onto a surface of the metal substrate. In some embodiments, methods may include depositing inorganic particles at a deposition temperature that does not cause the metallic material to exceed the austenite transformation temperature. The inorganic particles deposited onto the surface of the metal substrate may form an abrasion-resistant coating on the surface of the metal substrate. The difference between the coefficient of thermal expansion of the metallic material and the coefficient of thermal expansion of the abrasion-resistant coating may be 10×10/degrees C. or less.

Methods for sub-austenite transformation temperature deposition of inorganic particles and articles produced by the same

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 () 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.

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 method and extrusion die to form a laminar integral skin of a honeycomb structure is provided. The method includes extruding a ceramic precursor batch through a die with feedholes in entry side and slots in exit face of the die to form the honeycomb structure. In a region on the periphery of the die configured to form the cell matrix, a series of concentric slots around the matrix in the exit face of the die are configured to feed skin onto the matrix. Ring sections between concentric slots are angled away from the center and a mask is disposed on top of the periphery producing a channel for extruded skin to meet and bond to extruded matrix. Optionally, slots in the skin-forming ring sections enhance knitting between laminar skin layers.

Ceramic honeycomb bodies, honeycomb extrusion dies, and methods of making ceramic honeycomb bodies

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

A honeycomb structure () includes intersecting porous walls (). Inlet channels () and outlet channels () are formed by the intersecting porous walls (), wherein the inlet channels () comprise inlet hydraulic diameters (HDi) and the outlet channels () comprise outlet hydraulic diameters (HDo). The inlet channels () comprise inlet corners () with inlet corner radii (Ri) and the outlet channels () comprise outlet corners () with outlet corner radii (Ro). A centerpost () is defined by adjacent opposing inlet corners () of two of the inlet channels () and adjacent opposing outlet corners () of two of the outlet channels (). A first diagonal length (D1) is a shortest distance between the opposing outlet corners () of the two outlet channels () and a second diagonal length (D2) is a shortest distance between the opposing inlet corners () of the two inlet channels (). The honeycomb structure () has certain aspect ratios D1:D2 depending on hydraulic diameter ratios HDi:HDo.

High isostatic strength honeycomb structures and extrusion dies therefor

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 method to form a laminar integral skin of a honeycomb structure is provided. The method includes extruding a ceramic precursor batch through a die with feedholes in entry side and slots in exit face of the die to form the honeycomb structure. In a region on the periphery of the die configured to form the cell matrix, a series of concentric slots around the matrix in the exit face of the die are configured to feed skin onto the matrix. Ring sections between concentric slots are angled away from the center and a mask is disposed on top of the periphery producing a channel for extruded skin to meet and bond to extruded matrix. Optionally, slots in the skin-forming ring sections enhance knitting between laminar skin layers. The die and honeycomb body having uniform integral skin are also provided.

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.

The present disclosure provides a flow device including a body disposed in an extrusion apparatus. The body is defined along a plane and has a first side and a second side. The second side is disposed opposite the first side. The flow device also includes a first face formed at the first side and a second face formed at the second side. The body has a thickness defined between the first face and second face. A plurality of feedholes is defined in the body between the first side and the second side. In addition, at least a portion of the first face or second face forms a curvature that extends outwardly from the plane.

Extrusion die with curved face

A honeycomb ceramic substrate, a method of making thereof, and a honeycomb extrusion die configured to extrude a honeycomb ceramic substrate from a batch of ceramic or ceramic-forming material is provided. The substrate may include a lattice of intersecting walls defining a honeycomb network of flow channels extending between an inlet end and an outlet end of the honeycomb substrate. Each flow channel may be defined by a plurality of channel walls of the intersecting walls with at least two of the plurality of channel walls including concave inner surfaces facing a center of the corresponding flow channel from central portions of the concave inner surfaces to concave corner portions facing the center of the corresponding flow channel.

Honeycomb ceramic substrates, honeycomb extrusion dies, and methods of making honeycomb ceramic substrates

Growing community of inventors

Corning, NY, United States of America

Thomas William Brew