Patents Represented by Attorney, Agent or Law Firm Matthew B. McNutt
  • Patent number: 8332124
    Abstract: 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 NO2 concentration. 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.
    Type: Grant
    Filed: November 24, 2009
    Date of Patent: December 11, 2012
    Assignee: Corning Incorporated
    Inventors: Sam George, Suhao He, Achim Karl-Erich Heibel, Min Shen
  • Patent number: 8263895
    Abstract: An electrode for machining a pattern in a workpiece has a conductive body with a lattice of closed cells and a plurality of open cells. The open cells are positioned at an edge of the lattice of closed cells. The closed cells are defined by interconnected webs, and the open cells are defined by fins extending from the interconnected webs. A thickness of the fins is less than a thickness of the webs. In use, the electrode is positioned at a plurality of locations on the workpiece, such that a position of the fins of the electrode at each location overlaps a position of the fins of the electrode at an adjacent location. The pattern is formed at each of the plurality of locations by passing electrical charges repeatedly between the electrode and the workpiece and advancing the electrode into the workpiece.
    Type: Grant
    Filed: August 28, 2009
    Date of Patent: September 11, 2012
    Assignee: Corning Incorporated
    Inventor: Mark Lee Humphrey
  • Patent number: 8245501
    Abstract: Systems and methods are provided for controlling an exhaust stream temperature at a point along an exhaust system. The exhaust system can include an oxidation catalyst, a particulate filter having an outlet, and a fuel injector for injecting fuel into an exhaust stream at a location upstream from the outlet. An adaptive control can be provided to model a portion of the exhaust system. A fuel injection flow rate at which fuel is injected into the exhaust stream by the fuel injector can be calculated based on the adaptive control model. An operation of the fuel injector can be controlled based on the calculated fuel injection flow rate, to control the exhaust stream temperature at point along the exhaust system. A condition of the exhaust stream can also monitored and an error in the adaptive control model can be determined based on the monitored condition. The adaptive control model can also be changed to reduce the error.
    Type: Grant
    Filed: August 27, 2008
    Date of Patent: August 21, 2012
    Assignee: Corning Incorporated
    Inventors: Suhao He, Achim Karl-Erich Heibel, Wenbin Qiu
  • Patent number: 8244497
    Abstract: Methods are provided for solving a process function for modification of a non-test die for use in extrusion of a honeycomb body. The process function is solved by comparing measured widths of a plurality of slots between pins of a test die in the post-removal state and measured widths of a plurality of slots between pins of the test die in the pre-removal state. Methods are also provided for modifying a non-test die for use in extrusion of a honeycomb body. Such methods remove non-test-die material from a plurality of pins of the non-test die based on application of the process function.
    Type: Grant
    Filed: May 29, 2009
    Date of Patent: August 14, 2012
    Assignee: Corning Incorporated
    Inventors: David William Folmar, Mark Lee Humphrey, Shane David Seyler
  • Patent number: 8231701
    Abstract: A particulate filter may comprise an inlet end, an outlet end, and a plurality of channels disposed and configured to flow fluid from the inlet end to the outlet end, wherein the channels are defined by porous walls configured to trap particulate matter. The porous walls may have a cell density less than about 200 cpsi, a wall thickness of less than about 14 mils, a median pore size that ranges from about 13 micrometers to about 20 micrometers, a total porosity greater than about 45%, and a pore size distribution such that pores less than 10 micrometers contribute less than about 10% porosity.
    Type: Grant
    Filed: January 21, 2009
    Date of Patent: July 31, 2012
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Achim Karl-Erich Heibel, Pushkar Tandon
  • Patent number: 8187353
    Abstract: A particulate filter may comprise an inlet end, an outlet end, and a plurality of channels disposed and configured to flow fluid from the inlet end to the outlet end, wherein the channels are defined by porous walls configured to trap particulate matter. The porous walls may have a total porosity greater than about 45%, a median pore size ranging from about 13 micrometers to about 20 micrometers, and a pore size distribution such that pores less than 10 micrometers contribute less than about 10% porosity.
    Type: Grant
    Filed: January 21, 2009
    Date of Patent: May 29, 2012
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Achim Karl-Erich Heibel, Pushkar Tandon
  • Patent number: 8161738
    Abstract: A method for regenerating a particulate filter may comprise determining a temperature, a flow rate, and a total pressure drop of an exhaust gas flowing through a particulate filter, and determining a corrected soot layer permeability. The method may further comprise calculating an estimated soot load of the particulate filter based on the total pressure drop and the corrected soot layer permeability, and causing regeneration of the particulate filter when the estimated soot load is greater than or equal to a threshold value.
    Type: Grant
    Filed: November 26, 2008
    Date of Patent: April 24, 2012
    Assignee: Corning Incorporated
    Inventors: Suhao He, Achim Karl-Erich Heibel, Pushkar Tandon
  • Patent number: 8137637
    Abstract: A particulate filter includes first and second honeycomb substrates. An outlet face of a first substrate is positioned against an inlet face of a second substrate such that channels extending longitudinally through the substrates are aligned to form continuous channels. A continuous skin is joined to each of the substrates to form a unified substrate. A portion of the continuous channels are selectively plugged to form a wall flow filter.
    Type: Grant
    Filed: November 20, 2008
    Date of Patent: March 20, 2012
    Assignee: Corning Incorporated
    Inventor: Jeffrey Todd Kohli
  • Patent number: 8138108
    Abstract: The present disclosure relates to aluminum titanate-containing ceramic-forming batch materials and methods using the same.
    Type: Grant
    Filed: February 27, 2009
    Date of Patent: March 20, 2012
    Assignee: Corning Incorporated
    Inventors: Patrick David Tepesch, Christopher John Warren
  • Patent number: 8138441
    Abstract: A method of machining a pattern at a plurality of locations in a workpiece includes positioning a shaped electrode including the pattern at the plurality of locations in a sequence. In some embodiments, the sequence is random. The method further includes forming the pattern at each of the plurality of locations by passing electrical charges repeatedly between the shaped electrode and the workpiece and advancing the shaped electrode into the workpiece for a fraction of a full depth of the pattern. The method further includes repeating the positioning and forming steps a plurality of times until the full depth of the pattern has been formed at each of the plurality of locations.
    Type: Grant
    Filed: December 21, 2007
    Date of Patent: March 20, 2012
    Assignee: Corning Incorporated
    Inventors: Dominick John Forenz, Mark Lee Humphrey, Bruce Edwin Klingensmith, Jr.
  • Patent number: 8097203
    Abstract: The invention describes a high porosity ceramic article and method of manufacturing the same and intermediate dried honeycomb green body articles. The article may have a total porosity of at least about fifty-five percent, above sixty percent, or even above sixty-five percent. The method of manufacture includes mixing a ceramic-forming powder, an organic pore former, water, and a crosslinker. Drying causes a condensation reaction between the pore former and the crosslinker thereby forming a network within the green body that strengthens the green body and reduces cracking. The pore former may include starch or an activated cellulose compounds. Secondary pore forming agents, such as graphite may also be included.
    Type: Grant
    Filed: January 29, 2007
    Date of Patent: January 17, 2012
    Assignee: Corning Incorporated
    Inventors: Weiguo Miao, Steven Bolaji Ogunwumi, Jianguo Wang
  • Patent number: 8069658
    Abstract: A method for regenerating a particulate filter may comprise calculating a first estimated soot load of a particulate filter based on a pressure drop of an exhaust gas flowing through the particulate filter, and calculating a second estimated soot load of the particulate filter based on a mass balance of soot in the particulate filter. The method may further comprise calculating a hybrid estimated soot load based on the first estimated soot load and the second estimated soot load, wherein calculating the hybrid estimated soot load comprises applying at least one gate so as to weight a relative contribution of each of the first estimated soot load and the second estimated soot load to the hybrid estimated soot load, and causing regeneration of the particulate filter when the hybrid estimated soot load is greater than or equal to a threshold value.
    Type: Grant
    Filed: November 26, 2008
    Date of Patent: December 6, 2011
    Assignee: Corning Incorporated
    Inventors: Suhao He, Achim Karl-Erich Heibel, Pushkar Tandon
  • Patent number: 7976768
    Abstract: A ceramic forming batch mixture including inorganic batch materials, such as sources of alumina, titania, and silica, a pore former combination including first and second pore formers with different compositions; an organic binder; and a solvent. Also disclosed is a method for producing a ceramic article involving mixing the inorganic batch materials with the pore former combination having first and second pore formers of different composition, adding an organic binder and a solvent, forming a green body; and firing the green body. A green body having a combination of first and second pore formers with different compositions is disclosed, as are several methods for firing to produce ceramic articles such as aluminum titanate.
    Type: Grant
    Filed: May 31, 2006
    Date of Patent: July 12, 2011
    Assignee: Corning Incorporated
    Inventors: Michael Donavon Brady, Thomas James Deneka, Steven Bolaji Ogunwumi, Paul John Shustack, David Lambie Tennent, Patrick David Tepesch, Jianguo Wang, Christopher John Warren
  • 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: 7923093
    Abstract: Cordierite ceramic articles with high volume percent porosities of at least 64% but less than 80% have controlled median pore sizes and mean coefficients of thermal expansion that impart substantially improved modulus of rupture strengths (MOR) and thermal shock resistance (TSR) to the ceramic articles.
    Type: Grant
    Filed: October 6, 2006
    Date of Patent: April 12, 2011
    Assignee: Corning Incorporated
    Inventors: Isabelle Marie Melscoet-Chauvel, Gregory Albert Merkel, Steven Bolaji Ogunwumi, Tinghong Tao, Jianguo Wang
  • Patent number: 7909904
    Abstract: A method for producing a ceramic honeycomb structure comprises providing a honeycomb body having a side surface, a first cut end surface, a second cut end surface opposite the first end surface, and a maximum width (W), and removing material from at least one of the cut end surfaces of the honeycomb body to reduce the length (L), wherein the step of removing material comprises abrasively removing material from at least one of the ends with a rotating abrasive tool, such as by grinding, and wherein L/W is greater than 0.75. The method may achieve end flatness, parallelism, surface roughness and length accuracy, or combinations thereof which heretofore, were unachievable. Face finished ceramic honeycomb structures having low surface roughness (Ra), high degree of parallelism and accurate lengths are also disclosed.
    Type: Grant
    Filed: March 19, 2007
    Date of Patent: March 22, 2011
    Assignee: Corning Incorporated
    Inventor: Bruce Patrick Allen
  • Patent number: 7842371
    Abstract: Disclosed are washcoated ceramic honeycomb filters. The ceramic filters exhibit a relatively high level of washcoat loading while exhibiting minimized levels of backpressure. Also disclosed are methods for manufacturing the washcoated ceramic honeycomb filters. The method comprises providing an cell geometry derived from a predetermined level of washcoat loading to be applied to the ceramic honeycomb article.
    Type: Grant
    Filed: November 19, 2008
    Date of Patent: November 30, 2010
    Assignee: Corning Incorporated
    Inventors: Eric Jean Paul Francois, Guillaume Guzman, Maxime Moreno, Christophe Michel Remy
  • Patent number: 7841170
    Abstract: 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.
    Type: Grant
    Filed: October 24, 2006
    Date of Patent: November 30, 2010
    Assignee: Corning Incorporated
    Inventors: Thomas Adam Collins, Achim Karl-Erich Heibel, Robert John Locker
  • Patent number: 7817681
    Abstract: An optical fiber for performing pulse stretching, and fiber laser systems and methods using the pulse-stretching fiber are disclosed. The pulse-stretching (PS) fiber has low fourth-order dispersion (dispersion curvature) and a third order dispersion (dispersion slope) with a small negative, nearly zero or small positive value. Two different types of fiber laser systems that use the PS fiber in a manner that achieves optimum performance are described. The PS fiber enables an all-fiber (up to the final pulse compressor) ultra-short pulsed laser systems reaching pulse energies exceeding 100 ?J, average powers exceeding 100 W, and output pulse widths of less than 100 fs.
    Type: Grant
    Filed: June 26, 2008
    Date of Patent: October 19, 2010
    Assignee: Corning Incorporated
    Inventors: Dmitri Vladislavovich Kuksenkov, Shenping Li, William Allen Wood
  • Patent number: 7807250
    Abstract: A wall-flow honeycomb filter has a monolith body which includes repeating hexagonal unit cells, wherein each hexagonal unit cell has inner cells and outer cells arranged in a hexagonal symmetry, and wherein the inner cells are bordered by the outer cells and the outer cells are of diamond shape.
    Type: Grant
    Filed: November 29, 2007
    Date of Patent: October 5, 2010
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Kenneth Richard Miller