Honeycomb Patents (Class 264/177.12)
  • Patent number: 8282385
    Abstract: A die comprising molding grooves arranged in a lattice pattern and moldable-material-supplying holes communicating with the molding grooves for molding a ceramic honeycomb structure, the molding grooves having width of 0.05-0.5 mm, the moldable-material-supplying holes being arranged in every intersecting portions of the molding grooves, or in every other intersecting portions of the molding grooves in a checkerboard pattern, and an average distance between the centers of the intersecting portions of the molding grooves, at which the moldable-material-supplying holes are arranged, and the center axes of the moldable-material-supplying holes being 10-100 ?m.
    Type: Grant
    Filed: March 18, 2009
    Date of Patent: October 9, 2012
    Assignee: Hitachi Metals, Ltd.
    Inventor: Tomohisa Ogata
  • Patent number: 8257623
    Abstract: An extrusion die is processed to alter the flow of extrudable material through the die by collecting data reflecting flow variations across the face of the die, constructing a graded resistance flow restrictor utilizing the data, and forcing an abrasive machining medium through the flow restrictor and die with the flow restrictor being arranged to deliver higher abrasive flow through die portions initially exhibiting low extrusion rates, the resulting die being useful for the manufacture of ceramic honeycomb bodies exhibiting a reduced incidence of shape defects attributable to die flow variations.
    Type: Grant
    Filed: August 27, 2009
    Date of Patent: September 4, 2012
    Assignee: Corning Incorporated
    Inventors: John Charles Rector, David Robertson Treacy, Jr., Kevin Lee Wasson
  • Patent number: 8257629
    Abstract: A manufacturing method of a honeycomb structure that can improve a manufacturing efficiency and a raw material yield is provided. There is provided a manufacturing method of a honeycomb structure comprising: subjecting a raw material to extrusion forming to form a honeycomb formed body 100 having a partition wall that partitions a plurality of cells that serve as flow paths for a fluid and are extended from one end surface to the other end surface; forming a plurality of notches extended in a direction along which the cells are extended in the honeycomb formed body 100 to form a partial segment aggregate 120 in such a manner that a plurality of partial segments 3 are partitioned; and forming a buffer portion 5 between respective partial segments 3 adjacent to each other in the partial segment aggregate 120 to fill an entire space between the respective partial segments adjacent to each other, thereby obtaining a honeycomb structure 130.
    Type: Grant
    Filed: February 26, 2009
    Date of Patent: September 4, 2012
    Assignee: NGK Insulators, Ltd.
    Inventors: Yutaka Ogura, Satoshi Yamada, Hiroshi Kurachi
  • Patent number: 8226400
    Abstract: A die for extrusion-forming a honeycomb structure which includes: a die base provided with ceramic puddle introducing holes and slits in communication with the ceramic puddle introducing holes; and a substrate layer, which roughly defines the final width of the slits, and a surface layer, which precisely defines the final width of the slits, formed on the die base in this order so that the final width of the slits becomes 15 to 200 ?m, wherein the surface layer is made up of tungsten carbide particles which are 5 ?m or less in average particle diameter and contain W3C as a main ingredient. According to this invention, there is provided a die for extrusion-forming a honeycomb structure which can restrain fluctuation in extrusion-forming speed among its parts and resistance to pushing force, both caused at the time of extrusion-forming, to be very small and is superior in productivity and durability.
    Type: Grant
    Filed: January 14, 2010
    Date of Patent: July 24, 2012
    Assignee: NGK Insulators, Ltd.
    Inventors: Susumu Matsuoka, Seiichi Inoue, Haremi Ito, Keiji Matsumoto
  • Patent number: 8216499
    Abstract: A structural filler is installed in a gap between at least first and second composite members by extruding a flowable filler material, placing the extruded filler on one of the composite structural members, and assembling the composite members.
    Type: Grant
    Filed: December 9, 2008
    Date of Patent: July 10, 2012
    Assignee: The Boeing Company
    Inventors: Travis J. Sherwood, Brian G. Robins, Darrell D. Jones, Joseph D. Brennan, Michael R. Anderson
  • Patent number: 8133422
    Abstract: A batch mixture including ceramic-forming ingredients, a pore former, a binder comprising an ammonium salt of an alkylated cellulose binder, and a liquid vehicle, as defined herein. Also disclosed is a method for producing a ceramic precursor article as defined herein having excellent extrusion properties.
    Type: Grant
    Filed: October 30, 2008
    Date of Patent: March 13, 2012
    Assignee: Corning Incorporated
    Inventors: Patricia Ann Beauseigneur, Kevin Ying Chou
  • Patent number: 8128395
    Abstract: A honeycomb segment-forming die includes: an introducing portion provided on an introduction face side and having a plurality of back holes, and a forming portion provided on an formation face side and having slits communicating with the back holes. The forming portion has a polygonal outer peripheral shape and forms a prismatic honeycomb segment by passing kneaded clay for forming which is introduced from the back holes of the introducing portion through the slits of the forming portion, and a gap between slits formed in each of corner portions including a vertex of the polygonal forming portion is larger than a gap of slits formed in the central portion of the forming portion. This enables to form a honeycomb segment having high compressive strength.
    Type: Grant
    Filed: November 12, 2009
    Date of Patent: March 6, 2012
    Assignee: NGK Insulators, Ltd.
    Inventors: Hiroyuki Shindo, Tomoki Nagae
  • Patent number: 8110139
    Abstract: A honeycomb structure is manufactured by molding a pillar-shaped honeycomb molded body having a large number of cells disposed in parallel with one another in a longitudinal direction with a cell wall therebetween by extrusion-molding a raw material composition including a ceramic powder and a binder, and carrying out a firing treatment on the honeycomb molded body to manufacture a honeycomb fired body. A plurality of the honeycomb fired bodies are provided, and both end faces of each of the plurality of the honeycomb fired bodies are hold with a holding member after positioning the plurality of the honeycomb fired bodies on a predetermined position. An adhesive paste is injected into a gap between the plurality of honeycomb fired bodies held on the predetermined position. The adhesive paste is dried and solidified to form an adhesive layer.
    Type: Grant
    Filed: March 7, 2008
    Date of Patent: February 7, 2012
    Assignee: Ibiden Co., Ltd.
    Inventors: Kazushige Ohno, Masafumi Kunieda, Masatoshi Okuda
  • Publication number: 20110314821
    Abstract: A flow-through substrate comprising a sulfur-containing compound distributed throughout the flow-through substrate structure. The flow-through substrate may be used, for example, in the removal of a heavy metal from a fluid such as a gas stream.
    Type: Application
    Filed: December 18, 2009
    Publication date: December 29, 2011
    Inventors: Dana Craig Bookbinder, Kishor Purushottam Gadlkaree, Paul John Shustack, Shaole Wu
  • Patent number: 8075829
    Abstract: There is provided a method for drying a honeycomb formed article 1. The method has the first step, where an unfired honeycomb formed article 1 having a plurality of cells separated by partition walls made from raw material composition containing a ceramic raw material, water, and a binder is heated and dried by microwave drying or dielectric drying, and a second step, where the honeycomb formed article 1 is dried by hot air drying, where hot air whose humidity was adjusted to have a wet-bulb temperature of 50 to 100° C. using a hot air drying apparatus 11 after the first step is passed through the cells. The method can dry a honeycomb formed article in a shorter period of time with inhibiting generation of a defect such as a deformation or breakage.
    Type: Grant
    Filed: August 7, 2009
    Date of Patent: December 13, 2011
    Assignee: NGK Insulators, Ltd.
    Inventors: Shuichi Takagi, Yasuhiro Horiba
  • Publication number: 20110291319
    Abstract: Methods of extruding a honeycomb body with an extruder comprise the step of feeding batch material to the extruder, wherein the batch material comprises a ceramic or ceramic-forming material. The methods further include the step of rotating at least one mixing screw to cause the batch material to travel along a flow path defined by a barrel of the extruder. The methods further include the step of indexing a carriage to remove a first device from the flow path and introduce a second device into the flow path of the batch material. In one example, the pressure of the batch material changes less than about 25% as a result of indexing the carriage. In addition or alternatively, further methods include the step of reducing a decrease in temperature of the batch material resulting from the step of indexing. In further examples, the method includes the step of pre-filling a second honeycomb extrusion die held by the carriage with a plugging material.
    Type: Application
    Filed: November 24, 2010
    Publication date: December 1, 2011
    Inventors: James Frederick Avery, Ronald Alan Boyko, Daniel Wayne Corbett, Christopher John Malarkey, Kenneth Charles Sariego, David Robertson Treacy, JR.
  • Patent number: 8057889
    Abstract: A method is disclosed for manufacturing an anisotropic material comprising providing a viscoplastic material having a yield stress, and a plurality of magnetic particles disposed therein, and then subjecting the viscoplastic material to a magnetic field for a time sufficient to at least partially align at least a portion of the magnetic particles to at least one of a predetermined position or orientation. Also disclosed is an article having anisotropic properties comprising a viscoplastic material, and a plurality of magnetic particles distributed therein and at least partially aligned to a predetermined orientation. An article having anisotropic properties, comprising a fixed viscoplastic material, and a plurality of magnetic particles distributed and at least partially anisotropically aligned in the fixed viscoplastic material is disclosed.
    Type: Grant
    Filed: May 21, 2007
    Date of Patent: November 15, 2011
    Assignee: Corning Incorporated
    Inventors: Andrey V Filippov, Charlotte Diane Milia
  • Patent number: 8052411
    Abstract: A plate-like shape die 1 for forming a honeycomb structure provided with an introduction portion 3 having plural back holes on one side face (an introduction side) thereof and a formation portion provided with silts 6 communicating with plural back holes 7 on other side face thereof; using for forming a honeycomb shape with passing raw materials being introduced from back holes 7 of an introduction portion 3 through silts 6 being provided on the forming portion 2, wherein the introduction portion 3 is composed of two layers of a plate-like abrasion portion 5 constituting an introduction face 8, and an introduction portion main body 4 located between the abrasion portion 5 and the forming portion 2, and the abrasion portion 5 is detachably disposed on the introduction portion main body 4.
    Type: Grant
    Filed: October 31, 2008
    Date of Patent: November 8, 2011
    Assignee: NGK Insulators, Ltd.
    Inventors: Seiichiro Hayashi, Masanari Iwade, Hirofumi Hosokawa, Hironori Takahashi
  • Publication number: 20110204544
    Abstract: A honeycomb extrusion apparatus comprises a die body and a flow control device. The die body comprises an inlet end, an outlet end, a central axis, a first set of feedholes, a second set of feedholes, a set of central slots, and a set of outermost peripheral slots. The first set of feedholes extends from the inlet end to an interior interface portion of the die body. The second set of feedholes extends through the die body from the inlet end to the outlet end. The set of central slots extends from the outlet end to the interior interface portion of the die body. The set of outermost peripheral slots is disposed radially outwardly of the central slots. The interior interface portion of the die body is configured to allow flow of the batch material from the first set of feedholes to the central slots and to the outermost peripheral slots.
    Type: Application
    Filed: February 25, 2010
    Publication date: August 25, 2011
    Inventors: Jeffrey O. Foster, Robert Bernard Lubberts, Kenneth Charles Sariego, David Robertson Treacy, JR.
  • Patent number: 7997888
    Abstract: A die for forming a honeycomb structure is provided with back pores through which a forming material is introduced and slits through which the forming material is extruded into a lattice-like shape, and the die comprises a first plate-like member made of a super hard alloy containing tungsten carbide and a bonding agent and provided with the back pores extending in a thickness direction; and a second plate-like member bonded to the first plate-like member, made of the super hard alloy containing tungsten carbide and the bonding agent, and provided with the slits connected to the back pores, wherein the bonding agent is dispersed in a lesser amount in a bonded part between the first plate-like member and the second plate-like member than in the other part.
    Type: Grant
    Filed: November 24, 2009
    Date of Patent: August 16, 2011
    Assignee: NGK Insulators, Ltd.
    Inventors: Kazumasa Kitamura, Tomoki Nagae
  • Patent number: 7993561
    Abstract: A method for producing a ceramic honeycomb filter by blending a starting material mixture comprising a ceramic material, a molding aid and a pore-forming material under a pressure of 0.12-0.5 MPa in a pressure kneader to form a moldable material for a honeycomb extrudate.
    Type: Grant
    Filed: September 27, 2007
    Date of Patent: August 9, 2011
    Assignee: Hitachi Metals, Ltd.
    Inventor: Junji Komatsu
  • Patent number: 7922951
    Abstract: Methods and apparatus for plugging cells of honeycomb structures are disclosed. A first method covers the honeycomb structure's end face with a mask having a body and plurality of sized openings positioned to oppose certain cell channels, wherein the outer edge of the body extends radially outwardly from the end face. A film also extends outwardly of the end face, and a plug of material is provided upon the film. The mask and film material are sealed to one another, and a force is applied to the film forcing the material through the mask and into the cells. Also disclosed is adhering a mask to a first end face of the honeycomb structure such that the mask has an outer portion that extends radially beyond an outer edge of the honeycomb; providing a volume of plugging material; clamping the outer portion between a first clamping portion and a second clamping portion; and transferring the plugging material into the honeycomb.
    Type: Grant
    Filed: November 22, 2005
    Date of Patent: April 12, 2011
    Assignee: Corning Incorporated
    Inventors: James Raymond Mudd, Robert Alan Powell, William Paul Ryszytiwskyj, Jason Edward Schoonmaker, Richard Henry Weachock
  • Patent number: 7914724
    Abstract: Disclosed is a method and apparatus for forming a circumferential skin surrounding a central cellular structure of an extruded honeycomb article. The method and apparatus may be used to produce defect-free skins and/or skins having large thickness and a high degree of particle alignment thereby preferably exhibiting CTE comparable to the extruded webs. These benefits are achieved by providing a die and method wherein a flow, Q, exiting any two active ones of a plurality of peripheral slots forming the skin is substantially equal. Also disclosed is a thick-skinned ceramic article having a thick extruded skin (ts?>5 tw?) with an I-value comparable to the webs.
    Type: Grant
    Filed: July 28, 2006
    Date of Patent: March 29, 2011
    Assignee: Corning Incorporated
    Inventors: Dana Craig Bookbinder, Thomas William Brew, Frank Fabian, Darin Wayne Felty, Robert Bernard Lubberts, David Lewin Poff, Kenneth Charles Sariego, Andrew Joseph Sullivan, David Robertson Treacy, Jr.
  • Patent number: 7914728
    Abstract: A method for manufacturing a porous honeycomb structure, which comprises a mixing and kneading step, a forming and then drying step, and a firing and then cooling step of firing a dried honeycomb article to form a fired honeycomb article and then cooling the fired honeycomb article to prepare a porous honeycomb structure, wherein the fired honeycomb article is cooled from the firing temperature under a cooling condition of a temperature falling speed of 100° C./hr or less at least in a temperature region of 800° C. or lower.
    Type: Grant
    Filed: July 14, 2005
    Date of Patent: March 29, 2011
    Assignee: NGK Insulators, Ltd.
    Inventor: Tomoo Nakamura
  • Patent number: 7871958
    Abstract: A catalyst carrier includes a honeycomb structure where cells extending in a longitudinal direction are divided by cell walls; and a coating layer provided at a peripheral part of the honeycomb structure. The honeycomb structure and the coating layer contain at least one of inorganic fibers and whiskers. At least one of the inorganic fiber and whisker contained in the honeycomb structure is oriented mainly in a first direction. At least one of the inorganic fiber and whisker contained in the coating layer is oriented mainly in a second direction. The first direction and the second direction cross at substantially right angles to each other.
    Type: Grant
    Filed: September 11, 2007
    Date of Patent: January 18, 2011
    Assignee: Ibiden Co., Ltd.
    Inventor: Takahiko Ido
  • Patent number: 7858007
    Abstract: A die was provided for forming a honeycomb body having a structure provided with groovy slits on a front face thereof, the slits being formed by cell blocks and back holes on a back surface thereof, each hole being communicatively connected with the slit. The die is made of cemented carbide having wear resistance. The cemented carbide is formed by compacting, followed by sintering at high temperature, metal carbide powder of transition metal element series with an iron group metal binder having toughness. A connection area ratio of the back hole and the cell block is 35 to 65%.
    Type: Grant
    Filed: December 17, 2007
    Date of Patent: December 28, 2010
    Assignee: NGK Insulators, Ltd.
    Inventors: Takahisa Kaneko, Masayuki Nate, Masayuki Hironaga, Yuji Deguchi
  • Publication number: 20100301515
    Abstract: A die apparatus and methods of making a die body can provide a skin slot extending through a honeycomb network and an end portion of a plurality of pins, wherein the skin slot includes opposed sides that are each in fluid communication with the honeycomb network. In further embodiments, methods are provided for co-extruding a honeycomb body and an integral skin with a die body including a skin slot.
    Type: Application
    Filed: May 29, 2009
    Publication date: December 2, 2010
    Inventors: Thomas William Brew, Keith Norman Bubb, Michael James Lehman
  • Patent number: 7842213
    Abstract: A die for extrusion-molding in accordance with the present invention comprises: a molding groove part, a material supplying part, and an outer frame for fixing a die main body comprising the molding groove part and the material supplying part to the front end of an extrusion-molding apparatus, wherein the die main body has a form in which the plate-shaped molding groove part smaller than the material supplying part is provided at almost the middle of the plate-shaped material supplying part such that it protrudes from the material supplying part, the outer frame comprises: a die holding part which is provided such that it covers the material supplying part around the molding groove part; and a peripheral part which is provided near the die holding part, and supposing that the thickness of the molding groove part is X, the thickness of the material supplying part is Y, and the thickness of the die holding part of the outer frame is Z, these X, Y and Z are allowed to satisfy the inequalities (1) about 3?X?ab
    Type: Grant
    Filed: October 3, 2006
    Date of Patent: November 30, 2010
    Assignee: Ibiden Co., Ltd.
    Inventor: Takehisa Yamada
  • Publication number: 20100244309
    Abstract: A die for forming a honeycomb structure, comprising a platy die base member having a clay supply face on back surface thereof and including a plurality of introduction holes for introducing a mixed raw material for forming; and a clay forming face on upper surface including a plurality of slits for extrusion of the material being connected to the introduction holes and formed lattice-like partition regions; at least a part of lattice-like partition regions being provided in such a position that the extended line of at least part of a plurality of lattice-like regions overlap with the slits at edges thereof as top view, slits including inner peripheral slits formed in the inner peripheral region, and outer peripheral slits formed in the outer peripheral region surrounding the inner peripheral region and having a width-enlarged portion having a width larger than that of the inner peripheral slit, and production method thereof.
    Type: Application
    Filed: March 25, 2010
    Publication date: September 30, 2010
    Applicant: NGK Insulators, Ltd.
    Inventors: Seiichiro HAYASHI, Tomoki NAGAE, Masanari IWADE
  • Publication number: 20100244308
    Abstract: An extrusion-forming device 100 includes an extruding portion 21 having a drum 7 including a supply port 19 through which a clay flows into the inside, a screw 4 having a rotary shaft 6 and a rotary blade 5 and configured to convey the clay, and an extrusion port 20 through which the clay is discharged; and a forming portion 22 having a die provided with forming grooves. The device includes, as the screw 4 on the side of the supply port 19, supply port side screws 10 having two rotary blades 5 and, as the screw 4 on the side of the extrusion port 20, a extrusion port side screw 12 having one rotary blade 5, and a ratio P/D is in a range of 0.5 to 0.9.
    Type: Application
    Filed: February 19, 2010
    Publication date: September 30, 2010
    Applicant: NGK Insulators, Ltd.
    Inventor: Yasunori YAMAZAKI
  • Patent number: 7803303
    Abstract: A plugging apparatus for plugging channels in a honeycomb structure used to form a particulate filter. The apparatus includes an extrusion apparatus that holds plugging material and that has an opening through which the plugging material is extruded. An extrusion plate having first through holes that correspond in location to a subset of honeycomb channels is arranged adjacent the opening. An annular flow plate is operatively arranged face-to-face with the extrusion plate. The annular flow plate has second through holes corresponding in location to the first through holes but that are smaller to compensate for a radial variation in the extrusion rate when plugging the channels in the honeycomb structure. The plugging apparatus is thus able to fill select channel ends with same-size plugs, which leads to a better-performing filter.
    Type: Grant
    Filed: November 29, 2007
    Date of Patent: September 28, 2010
    Assignee: Corning Incorporated
    Inventor: Ralph Henry Hagg
  • Publication number: 20100219556
    Abstract: Honeycomb extrudate is made by extruding a plasticized ceramic-forming batch material to form a length of wet honeycomb extrudate, transferring the extrudate to a support tray, and transferring the tray and extrudate to a dryer, the tray being capable of contactingly supporting greater than one-third of the circumferential surface of the wet extrudate. The extrudate is subject to reduced handling damage, e.g. from forces of gravitational and/or lateral acceleration arising during transfer.
    Type: Application
    Filed: February 27, 2009
    Publication date: September 2, 2010
    Inventors: Douglas M. Noni, Wei Xu
  • Patent number: 7718113
    Abstract: A gas delivery substrate and method of manufacture is disclosed. A thermoplastic extrusion compound is created comprising a ceramic material and a thermoplastic resin, a green body is formed by thermoplastic extrusion of the compound, and the green body is sintered to form the gas delivery substrate. Such gas delivery substrates may be thin walled, highly porous and have secondary operations such as crimping and machining done prior to sintering.
    Type: Grant
    Filed: August 1, 2008
    Date of Patent: May 18, 2010
    Assignee: Rolls-Royce North American Technologies, Inc.
    Inventors: Aaron T. Crumm, Christopher J. Reilly
  • Patent number: 7713050
    Abstract: A die for forming a honeycomb structure includes a die base having a first plate-like member and a second plate-like member, the first plate-like member is provided with groove portions on the side of a bonding surface between the first plate-like member and the second plate-like member, and a depth y (mm) of the groove portions satisfies: y?a·(t1×E1+t2×E2)/(t1×t2×E1×E2) where t1 is a thickness (mm) obtained by subtracting the depth (mm) of the groove portions from a thickness (mm) of the first plate-like member, E1 is an apparent volume elasticity (GPa) of the first plate-like member at 25° C. in consideration of a state in which back holes are formed, t2 is a thickness (mm) of the second plate-like member, E2 is a volume elasticity (GPa) of the second plate-like member at 25° C., and a is a coefficient determined based on conditions during manufacturing.
    Type: Grant
    Filed: November 1, 2007
    Date of Patent: May 11, 2010
    Assignee: NGK Insulators, Ltd.
    Inventors: Hironori Takahashi, Masayuki Hironaga
  • Publication number: 20100052205
    Abstract: Methods and apparatus for manufacturing strengthened ceramic honeycomb articles having thickened peripheral web segments by extruding, drying and firing honeycomb shapes formed by the extrusion of plasticized ceramic powder batches through honeycomb extrusion dies having peripheral slots incorporating outer widened slot portions of controlled depths, the controlled depths being selected to increase ceramic powder batch flow through the peripheral slots to a degree sufficient to form the thickened web segments but insufficient to cause geometric distortion of the thickened web segments.
    Type: Application
    Filed: March 26, 2009
    Publication date: March 4, 2010
    Inventors: Thomas William Brew, Rudy Paul Ellis, Susan Clair Lauderdale, Michael James Lehman
  • Publication number: 20100044910
    Abstract: A method for producing a die for molding a ceramic honeycomb structure, which has molding grooves arranged in a lattice pattern and apertures communicating with the molding grooves for supplying a moldable material, wherein the formation of the lattice-patterned grooves by machining is conducted by a first machining operation for forming pluralities of first parallel grooves, and a second machining operation for forming second grooves crossing the first grooves; wherein the first and second machining operations are conducted by at least 2 passes of grinding or cutting using a rotating tool; and wherein the second machining operation is conducted by up-cutting in the second pass or later, and a method for producing a ceramic honeycomb structure using such a die.
    Type: Application
    Filed: October 29, 2007
    Publication date: February 25, 2010
    Applicant: HITACHI METALS, LTD.
    Inventors: Kazuyuki Kurakake, Tomohisa Ogata, Hiroshi Inoue
  • Publication number: 20100025884
    Abstract: A method for producing a ceramic honeycomb structure comprising the steps of mixing and blending starting materials comprising ceramic materials, a molding aid and a pore-forming material to obtain a moldable material, adjusting the properties of the moldable material, and extruding the moldable material in a honeycomb shape, the type C durometer hardness (according to JIS K 7312) of the moldable material being adjusted to 16-23 in the step of adjusting the properties of the moldable material.
    Type: Application
    Filed: January 30, 2008
    Publication date: February 4, 2010
    Applicant: HITACHI METALS, LTD.
    Inventor: Shunji Okazaki
  • Patent number: 7637731
    Abstract: A honeycomb structure body molding die is disclosed including a die main body, having a feed bore section and a slit recess section, and a guide ring having an upright support section and a guide section carried on the upright section, which includes a stepped section and has a central slit recess forming section, provided on the stepped section, and an outer circumferential slit recess forming surface. The die main body has a non-opposing region, formed on an area outside the stepped section, in which the outer circumferential slit recess forming surface does not axially face the guide section, while having a feed bore closing region closing the feed bores. The die main body has outer circumferential-skin forming material feed passages formed in an area outside the feed bore closing region for feeding the molding material to a squeezing outlet for forming an outer circumferential skin.
    Type: Grant
    Filed: July 15, 2008
    Date of Patent: December 29, 2009
    Assignee: Denso Corporation
    Inventor: Tadanobu Asaoka
  • Publication number: 20090311471
    Abstract: A heat shield having a honeycomb core. The honeycomb core has a plurality of intersecting wall portions forming a plurality of cells. A strain compliant material is applied to the wall portions of the honeycomb core prior to filling of the cells with an ablative material. An ablative material at least substantially fills the cells of the honeycomb core.
    Type: Application
    Filed: June 13, 2008
    Publication date: December 17, 2009
    Applicant: The Boeing Company
    Inventors: James V. Tompkins, Chad M. Franks
  • Publication number: 20090295018
    Abstract: There is provided an oil-removing jig for removing oil applied on an outer peripheral face of kneaded clay extruded from a kneader to have a cylindrical shape for the purpose of inhibiting drying prior to feeding the kneaded clay into an extrusion-forming apparatus. The jig includes a tabular rubber plate having a through-hole having a diameter 5 to 30 mm smaller than that of the kneaded clay, and two support plate each having a through-hole having a diameter 25 to 95 larger than that of the kneaded clay and 40 to 100 mm larger than that of the through-hole of the aforementioned rubber plate; and the rubber plate is held between the two support plates and fixed in a state that centers of the through-holes coincide with one another.
    Type: Application
    Filed: August 14, 2009
    Publication date: December 3, 2009
    Applicant: NGK INSULATORS, LTD.
    Inventor: Makoto MURAI
  • Publication number: 20090246107
    Abstract: Dry-scrubbing media compositions, methods of preparation and methods of use are provided. The compositions contain activated alumina and magnesium oxide. Optionally, activated carbon and other impregnates, such as hydroxides of group 1A metals, are included. The compositions exhibit improved efficiency and capacity for the removal of compounds, such as hydrogen sulfide, from an air-stream. The compositions are particularly useful for reducing or preventing the release of toxic gaseous compounds from the areas such as landfills, petroleum storage areas, refineries, drinking water systems, sewage treatment facilities, swimming pools, hospital morgues, animal rooms, and pulp and paper production sites.
    Type: Application
    Filed: March 25, 2009
    Publication date: October 1, 2009
    Inventor: William G. England
  • Publication number: 20090246452
    Abstract: A manufacturing method of a honeycomb structure that can improve a manufacturing efficiency and a raw material yield is provided. There is provided a manufacturing method of a honeycomb structure comprising: subjecting a raw material to extrusion forming to form a honeycomb formed body 100 having a partition wall that partitions a plurality of cells that serve as flow paths for a fluid and are extended from one end surface to the other end surface; forming a plurality of notches extended in a direction along which the cells are extended in the honeycomb formed body 100 to form a partial segment aggregate 120 in such a manner that a plurality of partial segments 3 are partitioned; and forming a buffer portion 5 between respective partial segments 3 adjacent to each other in the partial segment aggregate 120 to fill an entire space between the respective partial segments adjacent to each other, thereby obtaining a honeycomb structure 130.
    Type: Application
    Filed: February 26, 2009
    Publication date: October 1, 2009
    Applicant: NGK INSULATORS, LTD.
    Inventors: Yutaka OGURA, Satoshi YAMADA, Hiroshi KURACHI
  • Patent number: 7576035
    Abstract: A pillar-shaped honeycomb structure has a plurality of cells longitudinally placed in parallel with one another with a wall portion therebetween, wherein the honeycomb structure mainly includes inorganic fibers which form the honeycomb structure without lamination interfaces.
    Type: Grant
    Filed: April 7, 2008
    Date of Patent: August 18, 2009
    Assignee: Ibiden Co., Ltd.
    Inventors: Kazushige Ohno, Tomokazu Oya
  • Patent number: 7575793
    Abstract: A radial cell ceramic honeycomb structure is provided that is particularly adapted for use as a catalytic carrier or a particulate filter in an automotive or diesel exhaust system. The honeycomb structure includes a network of interconnected webs having a central axis. The network of webs includes radial webs of varying lengths, only some of which substantially extend the entire radial length of the network, and tangential webs that intersect to define rings of gas-conducting radial cells, and a rounded outer skin that surrounds the cells formed by the interconnected webs. The radial webs extending to the periphery of the network join an inner edge of the outer skin in a substantially orthogonal orientation to reduce thermally generated stresses and to increase strength of the resulting structure. The number of radial webs in the network changes along the radial length at transition zones that are defined by one of the tangential webs such that a desired cell density is achieved across the network.
    Type: Grant
    Filed: March 31, 2006
    Date of Patent: August 18, 2009
    Assignee: Corning Incorporated
    Inventors: Kenneth William Aniolek, Douglas Munroe Beall, Priyank Paras Jain, Kenneth Richard Miller, Seth Thomas Nickerson, Alan Thomas Stephens, II
  • Publication number: 20090140453
    Abstract: A plugging apparatus for plugging channels in a honeycomb structure used to form a particulate filter. The apparatus includes an extrusion apparatus that holds plugging material and that has an opening through which the plugging material is extruded. An extrusion plate having first through holes that correspond in location to a subset of honeycomb channels is arranged adjacent the opening. An annular flow plate is operatively arranged face-to-face with the extrusion plate. The annular flow plate has second through holes corresponding in location to the first through holes but that are smaller to compensate for a radial variation in the extrusion rate when plugging the channels in the honeycomb structure. The plugging apparatus is thus able to fill select channel ends with same-size plugs, which leads to a better-performing filter.
    Type: Application
    Filed: November 29, 2007
    Publication date: June 4, 2009
    Inventor: Ralph Henry Hagg
  • Patent number: 7524448
    Abstract: The invention discloses method and apparatus for providing a desired batch flow through desired regions of an extrusion die for forming honeycomb structures, and more particularly to the enhancement of batch flow in the skin-forming region of the die so as to provide a bounding wall of desired thickness and strength about a honeycomb core. Unlike prior methods, a recess or trough of desired depth and width is formed in a desired region of the inlet face of the honeycomb die, which reduces the pressure required to flow batch material through the die in such region. Such reduced pressure requirement translates in an increased flow rate in such region under constant extrusion pressure. Thus by increasing the flow rate through a honeycomb extrusion die in an outer peripheral region of flow in this manner, improved skin formation around a honeycomb core is obtained during the forming process.
    Type: Grant
    Filed: May 23, 2005
    Date of Patent: April 28, 2009
    Assignee: Corning Incorporated
    Inventor: John Charles Rector
  • Publication number: 20090072431
    Abstract: A method for producing a ceramic honeycomb filter by immersing an end surface of a ceramic honeycomb structure having a lot of flow paths partitioned by cell walls in a plugging material slurry in a container to introduce the plugging material slurry into the predetermined flow paths to form plugs, and taking the ceramic honeycomb structure provided with the plugs out of the container horizontally.
    Type: Application
    Filed: September 28, 2006
    Publication date: March 19, 2009
    Applicant: HITACHI METALS, LTD
    Inventor: Shinya Tokumaru
  • Patent number: 7500847
    Abstract: A die for forming a honeycomb structure may realize a sophisticated formability and superior resistance to wear. The die may be provided with a die base including two surfaces, one being provided with slits of honeycomb shape, and the other being provided with back holes through which a forming material may be introduced. The die base may include: a die precursor obtained by stacking and bonding a first member (one surface of the die base) and of tungsten carbide-based super hard alloy and a second member (the other surface of the die base) and of a metal material that causes at least up to three phase transformation of martensite transformation, bainite transformation, and pearlite transformation by cooling of an austenite phase together. Tensile and compressive stresses in a mutually bonded surface of the two plate-like members are 1000 MPa or less.
    Type: Grant
    Filed: July 22, 2005
    Date of Patent: March 10, 2009
    Assignee: NGK Insulators, Ltd.
    Inventors: Hironori Takahashi, Hirofumi Hosokawa, Yoshimasa Kondo, Masayuki Hironaga
  • Publication number: 20080245040
    Abstract: A method for forming a diesel particulate filter is presented. The method includes provided an extruder for receiving material to be extruded such extruder being configured to converting such material into a honeycomb structure having a lower portion and an upper portion. The lower portion has a bottom surface and a pair of vertically extending sidewalls terminating along outer edges of the bottom surface. The upper portion has a pair of opposing, pitched, sidewalls having lower edges terminating along upper edges of the vertically extending sidewalls and upper edges terminating along a common edge.
    Type: Application
    Filed: April 4, 2007
    Publication date: October 9, 2008
    Inventor: James Riley
  • Patent number: 7431873
    Abstract: The present invention provides a method for manufacturing a honeycomb structure, the method including steps of: forming, by extrusion, a formed body 1 having an outer wall, partition walls provided inside the outer wall, and cells each surrounded by the partition walls as well as extending to an axial direction of the body; and drying the formed body 1.
    Type: Grant
    Filed: February 5, 2003
    Date of Patent: October 7, 2008
    Assignee: NGK Insulators, Ltd.
    Inventors: Masayuki Nate, Takahisa Kaneko, Yukihisa Wada
  • Publication number: 20080203626
    Abstract: A method is provided that includes extrusion-molding a raw material composition containing ceramic powder and a binder to manufacture a coupled honeycomb molded body having a shape in which a plurality of pillar-shaped honeycomb molded bodies, each having a number of cells disposed in parallel with one another in a longitudinal direction with a cell wall therebetween, are integrated with one another by interposing a coupling portion. The method includes firing the coupled honeycomb molded body to manufacture a coupled honeycomb fired body, cutting the coupling portion to manufacture coupling-portion-cut honeycomb fired bodies, and binding a plurality of honeycomb fired bodies by interposing an adhesive layer, where at least one of the bound honeycomb fired bodies is a coupling-portion-cut honeycomb fired body.
    Type: Application
    Filed: December 14, 2007
    Publication date: August 28, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazushige Ohno, Masafumi Kunieda, Shigeharu Ishikawa
  • Publication number: 20080179781
    Abstract: A peripheral layer forming apparatus for coating a pillar-shaped member with a peripheral layer. The apparatus includes supporting members configured to sandwich the member from both sides and support the member so that an axis of the member is maintained in a horizontal orientation. A peripheral layer forming head is provided having a squeegee with a face configured to be oriented parallel to the axis. The apparatus is configured to provide the face at a predetermined angle with respect to a virtual face, where the virtual face is defined as a plane that is parallel to the axis of the member and that is tangential to a contact point on a peripheral face of the member where the squeegee is configured to contact the member. The apparatus is configured to maintain the predetermined angle as a peripheral layer is formed on the peripheral face of the member by a movement of at least one of the squeegee and the member.
    Type: Application
    Filed: December 21, 2007
    Publication date: July 31, 2008
    Applicant: IBIDEN CO., LTD.
    Inventor: Satoshi IWATA
  • Publication number: 20080136053
    Abstract: A cooling apparatus for a fired body includes a transporting member for transporting a firing jig in which a ceramic fired body is housed; a plurality of blowers for cooling the ceramic fired body; and a suction mechanism for changing the atmosphere inside the firing jig from an inert gas atmosphere to an air atmosphere.
    Type: Application
    Filed: October 26, 2007
    Publication date: June 12, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Koji Kuribayashi, Takamitsu Saijo, Koji Higuchi
  • Publication number: 20080136062
    Abstract: A drying apparatus including a conveying member configured to convey an item to be dried, a plurality of microwave irradiation portions disposed alternately at an upper side and a lower side of the conveying member, and a plurality of hot air blowing portions. The microwave irradiation portions are configured to irradiate the item to be dried with microwaves in an alternating manner from the upper side and the lower side. The hot air blowing portions are configured to apply hot air to the item to be dried in parallel with irradiation of the microwaves by the microwave irradiation portions.
    Type: Application
    Filed: December 17, 2007
    Publication date: June 12, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kenichiro KASAI, Kazuya Naruse
  • Patent number: 7384258
    Abstract: There is disclosed a die 1 for forming a honeycomb structure comprises: a plate-like die substrate 2 having at least two surfaces 8, 9, in which back holes 3 for introducing a green material are formed in one surface 8, and slits 4 communicating with back holes 3 are formed in the other surface 9; an underlayer 5 disposed on the substrate 2 so as to coat at least a part of a portion constituting the back hole 3 and the slit 4; an intermediate layer 6 disposed so as to coat at least a part of the underlayer 5 and constituted of tungsten carbide particles whose average particle diameter is 5 ?m or less and containing W3C as a main component; and a surface layer 7 disposed so as to coat at least a part of the intermediate layer 6 and constituted of diamond and/or diamond-like carbon.
    Type: Grant
    Filed: July 6, 2005
    Date of Patent: June 10, 2008
    Assignee: NGK Insulators, Ltd.
    Inventors: Hiroshi Kuwahara, Susumu Matsuoka, Takao Saito