Patents by Inventor Christopher John Malarkey
Christopher John Malarkey has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11345059Abstract: A method of manufacturing a honeycomb body, comprising extruding honeycomb extrudate (200) in an axial direction (A), the honeycomb extrudate (200) having an outer periphery (206); and laser machining in situ the honeycomb extrudate (200) to form a laser cut in the honeycomb extrudate. A system for in situ cutting a wet green ceramic extrudate, comprising a laser (500, 732, 826) configured to irradiate laser energy to an outer periphery of a wet green ceramic article, the laser energy adapted to cut through at least a portion of the outer periphery (206).Type: GrantFiled: June 7, 2017Date of Patent: May 31, 2022Assignee: Corning IncorporatedInventors: Ravindra Kumar Akarapu, Priyank Paras Jain, Christopher John Malarkey, Barada Kanta Nayak
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Publication number: 20220088823Abstract: Methods for extruding a ceramic-forming mixture through a honeycomb extrusion die (10), methods for forming a green honeycomb extrudate from a ceramic-forming mixture, methods of preparation of a honeycomb extrusion die (10) that extrudes a ceramic-forming mixture, and systems including a honeycomb extrusion die (10), ceramic-forming mixture, and abrasive flow media. The method of extruding a ceramic-forming mixture through a honeycomb extrusion die (10) includes conditioning the honeycomb extrusion die (10) by extruding an abrasive flow media through the slots (20) of the die (10) prior to extruding the ceramic-forming mixture through the slots (20) of the die (10). 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.Type: ApplicationFiled: January 9, 2020Publication date: March 24, 2022Inventors: Shyam Lekhraj Chatlani, Ryan Joseph Grohsmeyer, Christopher John Malarkey, John Charles Rector
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Patent number: 11220021Abstract: A system (100) and method to control rheology of ceramic pre-cursor batch during extrusion is described herein. An extrusion system (100) comprises an extruder (122) with an input port (144) configured to feed ceramic pre-cursor batch into a first section (120) of an extruder barrel and a discharge port configured to extrude a ceramic pre-cursor extrudate (172) out of the extruder barrel downstream of the input port (144). A liquid injector (210) is configured to inject liquid into the ceramic pre-cursor batch. A sensor (106) is configured to detect a rheology characteristic of the ceramic pre-cursor batch. A controller (108) is configured (i) to receive the rheology characteristic from the sensor (106), (ii) compare the rheology characteristic to a predetermined rheology value of the ceramic pre-cursor batch, and (iii) generate a command based on the comparison. A liquid regulator (110) is configured to receive the command and adjust liquid flow to the liquid injector (210) based on the command.Type: GrantFiled: August 3, 2017Date of Patent: January 11, 2022Assignee: Corning IncorporatedInventors: Christopher John Malarkey, Conor James Walsh
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Publication number: 20190255735Abstract: A method of manufacturing a honeycomb body, comprising extruding honeycomb extrudate (200) in an axial direction (A), the honeycomb extrudate (200) having an outer periphery (206); and laser machining in situ the honeycomb extrudate (200) to form a laser cut in the honeycomb extrudate. A system for in situ cutting a wet green ceramic extrudate, comprising a laser (500, 732, 826) configured to irradiate laser energy to an outer periphery of a wet green ceramic article, the laser energy adapted to cut through at least a portion of the outer periphery (206).Type: ApplicationFiled: June 7, 2017Publication date: August 22, 2019Inventors: Ravindra Kumar Akarapu, Priyank Paras Jain, Christopher John Malarkey, Barada Kanta Nayak
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Publication number: 20190176362Abstract: A system (100) and method to control rheology of ceramic pre-cursor batch during extrusion is described herein. An extrusion system (100) comprises an extruder (122) with an input port (144) configured to feed ceramic pre-cursor batch into a first section (120) of an extruder barrel and a discharge port configured to extrude a ceramic pre-cursor extrudate (172) out of the extruder barrel downstream of the input port (144). A liquid injector (210) is configured to inject liquid into the ceramic pre-cursor batch. A sensor (106) is configured to detect a rheology characteristic of the ceramic pre-cursor batch. A controller (108) is configured (i) to receive the rheology characteristic from the sensor (106), (ii) compare the rheology characteristic to a predetermined rheology value of the ceramic pre-cursor batch, and (iii) generate a command based on the comparison. A liquid regulator (110) is configured to receive the command and adjust liquid flow to the liquid injector (210) based on the command.Type: ApplicationFiled: August 3, 2017Publication date: June 13, 2019Inventors: Christopher John Malarkey, Conor James Walsh
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Patent number: 9957200Abstract: A ceramic precursor batch composition, green ware formed thereof, porous ceramic honeycomb article formed thereof, and methods of making same.Type: GrantFiled: November 26, 2014Date of Patent: May 1, 2018Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Gregg William Crume, James Anthony Feldman, Christopher John Malarkey, Elizabeth Marie Vileno
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Patent number: 9889592Abstract: 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.Type: GrantFiled: May 29, 2012Date of Patent: February 13, 2018Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Thomas William Brew, Christopher John Malarkey, Seth Thomas Nickerson, David John Thompson
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Publication number: 20170120498Abstract: A method of making a die body configured to extrude a honeycomb body, the method comprising the step (I) of manufacturing a die body and the step (II) of predetermining an upstream slot width W1 of the die body such that the upstream slot width W1 is optimized while a root of each die pin includes a section modulus within a predetermined section modulus range. The method still further comprises the step (III) of predetermining a slot length L such that a pin stress is within a predetermined pin stress range.Type: ApplicationFiled: October 28, 2015Publication date: May 4, 2017Inventors: Thomas William Brew, Steven John Kremer, Christopher John Malarkey, Bryan Michael Miller
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Patent number: 9586187Abstract: A mixing segment for an extrusion apparatus comprises a shaft and a plurality of plow elements aligned along a helical path extending about a rotation axis of the shaft. Each plow element includes an outer peripheral arcuate ramp extending radially outwardly along the helical path from a root to an outer tip of the plow element. Methods of manufacturing a mixing segment and methods of manufacturing a honeycomb structure with an extrusion apparatus are also provided.Type: GrantFiled: April 12, 2013Date of Patent: March 7, 2017Assignee: CORNING INCORPORATEDInventors: Matthew Joseph Dispenza, Christopher John Malarkey, Kenneth Charles Sariego, Chauncey James Watches
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Publication number: 20160376200Abstract: A ceramic precursor batch composition, green ware formed thereof, porous ceramic honeycomb article formed thereof, and methods of making same.Type: ApplicationFiled: November 26, 2014Publication date: December 29, 2016Inventors: Douglas Munroe Beall, Gregg William Crume, James Anthony Feldman, Christopher John Malarkey, Elizabeth Marie Vileno
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Patent number: 8864486Abstract: A twin screw extruder includes a barrel having a chamber, a discharge port, an extrusion molding die coupled to the discharge port of the barrel, axially extending first and second screw shafts, and a screw shaft support. The screw shaft support includes first and second spacer bearings disposed on the first and second screw shafts, and a first cross member including first and second loops slidably coupled to the first and second spacer bearings. A second cross member is spaced apart from the first cross member by a connection member, and also includes first and second loops slidably coupled to the first and second spacer bearings. The connection member is situated between the first spacer bearing and the second spacer bearing, and connected to the first cross member and the second cross member.Type: GrantFiled: March 15, 2013Date of Patent: October 21, 2014Assignee: Corning IncorporatedInventors: Matthew Joseph Dispenza, Christopher John Malarkey, Kenneth Charles Sariego
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Publication number: 20140306370Abstract: A mixing segment for an extrusion apparatus comprises a shaft and a plurality of plow elements aligned along a helical path extending about a rotation axis of the shaft. Each plow element includes an outer peripheral arcuate ramp extending radially outwardly along the helical path from a root to an outer tip of the plow element. Methods of manufacturing a mixing segment and methods of manufacturing a honeycomb structure with an extrusion apparatus are also provided.Type: ApplicationFiled: April 12, 2013Publication date: October 16, 2014Applicant: CORNING INCORPORATEDInventors: Matthew Joseph Dispenza, Christopher John Malarkey, Kenneth Charles Sariego, Chauncey James Watches
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Publication number: 20140271969Abstract: A twin screw extruder includes a barrel having a chamber, a discharge port, an extrusion molding die coupled to the discharge port of the barrel, axially extending first and second screw shafts, and a screw shaft support. The screw shaft support includes first and second spacer bearings disposed on the first and second screw shafts, and a first cross member including first and second loops slidably coupled to the first and second spacer bearings. A second cross member is spaced apart from the first cross member by a connection member, and also includes first and second loops slidably coupled to the first and second spacer bearings. The connection member is situated between the first spacer bearing and the second spacer bearing, and connected to the first cross member and the second cross member.Type: ApplicationFiled: March 15, 2013Publication date: September 18, 2014Inventors: Matthew Joseph Dispenza, Christopher John Malarkey, Kenneth Charles Sariego
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Patent number: 8673206Abstract: 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: GrantFiled: November 24, 2010Date of Patent: March 18, 2014Assignee: Corning IncorporatedInventors: James Frederick Avery, Ronald Alan Boyko, Daniel Wayne Corbett, Christopher John Malarkey, Kenneth Charles Sariego, David Robertson Treacy, Jr.
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Publication number: 20140060253Abstract: A method of making a die body configured to extrude a honeycomb body, the method comprising the step (I) of manufacturing a die body and the step (II) of predetermining an upstream slot width W1 of the die body such that the upstream slot width W1 is optimized while a root of each die pin includes a section modulus within a predetermined section modulus range. The method still further comprises the step (III) of predetermining a slot length L such that a pin stress is within a predetermined pin stress range.Type: ApplicationFiled: August 28, 2012Publication date: March 6, 2014Inventors: Thomas William Brew, Steven John Kremer, Christopher John Malarkey, Bryan Michael Miller
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Publication number: 20130320586Abstract: 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.Type: ApplicationFiled: May 29, 2012Publication date: December 5, 2013Inventors: Douglas Munroe Beall, Thomas William Brew, Christopher John Malarkey, Seth Thomas Nickerson, David John Thompson
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Patent number: 8236084Abstract: The present disclosure relates to radial wall flow particulate filters comprised of ceramic material. The filters include a filter body that has a plurality of adjacent troughs circumferentially arranged around a longitudinal axis.Type: GrantFiled: August 16, 2010Date of Patent: August 7, 2012Assignee: Corning IncorporatedInventors: Michael Fischer, Michael Thomas Gallagher, Keith Leonard House, Thomas Dale Ketcham, Christopher John Malarkey, John Stephen Rosettie
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Publication number: 20110291319Abstract: 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: ApplicationFiled: November 24, 2010Publication date: December 1, 2011Inventors: James Frederick Avery, Ronald Alan Boyko, Daniel Wayne Corbett, Christopher John Malarkey, Kenneth Charles Sariego, David Robertson Treacy, JR.
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Patent number: 7976769Abstract: A method of manufacturing a honeycomb structure is disclosed wherein a green honeycomb body having a first contour is differentially altered such that the green honeycomb body has a second contour which is wider at a first end than at a second end. In one aspect, the altering is accomplished by removing a part of the green honeycomb body, such as with a removal tool. In another aspect, the altering is accomplished by exposing different regions of the honeycomb body to different drying environments.Type: GrantFiled: November 21, 2008Date of Patent: July 12, 2011Assignee: Corning IncorporatedInventors: Tonia Havewala Fletcher, Thomas George Havens, Christopher John Malarkey
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Publication number: 20110041469Abstract: The present disclosure relates to radial wall flow particulate filters comprised of ceramic material. The filters include a filter body that has a plurality of adjacent troughs circumferentially arranged around a longitudinal axis.Type: ApplicationFiled: August 16, 2010Publication date: February 24, 2011Inventors: Michael Fischer, Michael Thomas Gallagher, Keith Leonard House, Thomas Dale Ketcham, Christopher John Malarkey, John Stephen Rosettie