Patents by Inventor Daniel Edward McCauley

Daniel Edward McCauley 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).

  • Publication number: 20190169072
    Abstract: According to embodiments, a batch mixture includes inorganic components, a non-polar carbon chain lubricant, and an organic surfactant having a polar head. The non-polar carbon chain lubricant and the organic surfactant are present in concentrations satisfying the relationship: B(C1(d+d0)+C2(f+f0))=SC, where: d0+d is an amount of non-polar carbon chain lubricant in percent by weight of the inorganic components, by super addition; f0+f is an amount of organic surfactant in percent by weight of the inorganic components, by super addition; B is a scaling factor; C1 is a scaling factor of the concentration of the non-polar carbon chain lubricant; and C2 is a scaling factor of the concentration of the organic surfactant. Embodiments provide that 3.6?SC?14.
    Type: Application
    Filed: February 6, 2019
    Publication date: June 6, 2019
    Inventors: Daniel Edward McCauley, Maxime Moreno, Conor James Walsh, Stephanie Stoughton Wu
  • Patent number: 9751811
    Abstract: A method for green-to-fired shrinkage control in honeycomb ceramic article manufacture, including: measuring, prior to mixing, the particle size distribution properties of at least one fine particle size graphite pore former ingredient of a provided ceramic source batch mixture; calculating the expected shrinkage of the green body to the fired ceramic article based on the measured particle size distribution properties of the at least one fine particle graphite pore former; making the honeycomb ceramic article; measuring the shrinkage of the resulting fired honeycomb ceramic article; and adjusting the ceramic source batch mixture in a subsequent batch material schedule, as defined herein, wherein the adjusted ceramic source batch mixture provides finished honeycomb ceramic articles having controlled green-to-fired shrinkage.
    Type: Grant
    Filed: January 7, 2016
    Date of Patent: September 5, 2017
    Assignee: Corning Incorporated
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodbourn, Patrick David Tepesch
  • Patent number: 9475734
    Abstract: A method for reducing shrinkage variability of aluminum titanate honeycombs includes preparing an aluminum titanate-forming batch material that includes least one alkaline earth carbonate having a particle size distribution. The particle size distribution of the at least one alkaline earth carbonate is selected based on the predicted shrinkage during sintering of the aluminum titanate honeycombs.
    Type: Grant
    Filed: May 31, 2012
    Date of Patent: October 25, 2016
    Assignee: Corning Incorporated
    Inventors: Daniel Edward McCauley, Patrick David Tepesch, Christopher John Warren, Jeffrey S White
  • Patent number: 9464004
    Abstract: A method of manufacturing porous ceramic articles is provided that includes forming a plurality of extruded green bodies from a ceramic precursor batch composition. The method also includes firing the extruded green bodies in a tunnel kiln to produce porous ceramic articles, periodically determining a shrinkage characteristic of at least one sample passing through the tunnel kiln, and adjusting a top soak temperature in the kiln if the shrinkage characteristic is outside of a predetermined range.
    Type: Grant
    Filed: February 28, 2011
    Date of Patent: October 11, 2016
    Assignee: Corning Incorporated
    Inventors: Jean E Balster, Michael P Brown, Thomas James Deneka, Joshua L Howell, Daniel Edward McCauley
  • Publication number: 20160289123
    Abstract: According to embodiments, a batch mixture includes inorganic components, a non-polar carbon chain lubricant, and an organic surfactant having a polar head. The non-polar carbon chain lubricant and the organic surfactant are present in concentrations satisfying the relationship: B(C1(d+d0)+C2(f+f0))=SC, where: d0+d is an amount of non-polar carbon chain lubricant in percent by weight of the inorganic components, by super addition; f0+f is an amount of organic surfactant in percent by weight of the inorganic components, by super addition; B is a scaling factor; C1 is a scaling factor of the concentration of the non-polar carbon chain lubricant; and C2 is a scaling factor of the concentration of the organic surfactant. Embodiments provide that 3.6?SC?14.
    Type: Application
    Filed: March 30, 2015
    Publication date: October 6, 2016
    Applicant: CORNING INCORPORATED
    Inventors: Daniel Edward McCauley, Maxime Moreno, Conor James Walsh, Stephanie Stoughton Wu
  • Patent number: 9233881
    Abstract: The disclosure relates to ceramic-body-forming batch materials comprising at least one pore former and inorganic batch components comprising at least one silica source having a specified particle size distribution, methods of making ceramic bodies using the same, and ceramic bodies made in accordance with said methods. The disclosure additionally relates to methods for reducing pore size variability in ceramic bodies and/or reducing process variability in making ceramic bodies.
    Type: Grant
    Filed: May 13, 2014
    Date of Patent: January 12, 2016
    Assignee: Corning Incorporated
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodbourn, Patrick David Tepesch, Christopher John Warren
  • Patent number: 9126871
    Abstract: The disclosure relates to aluminum titanate-forming batch materials comprising inorganic batch components comprising at least one alkaline earth carbonate having a specified particle size distribution, methods of making ceramic bodies using the same, and ceramic bodies made in accordance with said methods.
    Type: Grant
    Filed: May 31, 2012
    Date of Patent: September 8, 2015
    Assignee: Corning Incorporated
    Inventors: Daniel Edward McCauley, Patrick David Tepesch, Christopher John Warren
  • Publication number: 20150175489
    Abstract: A method of making ceramic bodies includes systematically orienting the bodies during firing relative to a temperature gradient in a kiln. The systematic orientation of the bodies relative to the temperature gradient can allow for an average deviation of a measured shape of the ceramic bodies from a predetermined target contour shape to be less than what they would be if the bodies were oriented randomly relative to the temperature gradient.
    Type: Application
    Filed: January 28, 2015
    Publication date: June 25, 2015
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodbourn, David Robertson Treacy, JR., Casey Allen Volino
  • Patent number: 8979993
    Abstract: A precursor batch composition that can be used to make porous ceramic articles is provided. The batch composition includes a cellulose-based polymer and, in particular, a methylcellulose showing a specified micro-calorimetry thermal response fingerprint. The methylcellulose can also have a cloud point above a specified temperature.
    Type: Grant
    Filed: May 22, 2012
    Date of Patent: March 17, 2015
    Assignee: Corning Incorporated
    Inventors: Gregg William Crume, Rebecca L. DeRosa, Daniel Edward McCauley, Misty Riesbeck
  • Patent number: 8974721
    Abstract: A method of making ceramic bodies includes systematically orienting the bodies during firing relative to a temperature gradient in a kiln. The systematic orientation of the bodies relative to the temperature gradient can allow for an average deviation of a measured shape of the ceramic bodies from a predetermined target contour shape to be less than what they would be if the bodies were oriented randomly relative to the temperature gradient.
    Type: Grant
    Filed: August 1, 2012
    Date of Patent: March 10, 2015
    Assignee: Corning Incorporated
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodbourn, David Robertson Treacy, Jr., Casey Allen Volino
  • Publication number: 20140249020
    Abstract: The disclosure relates to ceramic-body-forming batch materials comprising at least one pore former and inorganic batch components comprising at least one silica source having a specified particle size distribution, methods of making ceramic bodies using the same, and ceramic bodies made in accordance with said methods. The disclosure additionally relates to methods for reducing pore size variability in ceramic bodies and/or reducing process variability in making ceramic bodies.
    Type: Application
    Filed: May 13, 2014
    Publication date: September 4, 2014
    Applicant: CORNING INCORPORATED
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodbourn, Patrick David Tepesch, Christopher John Warren
  • Patent number: 8759240
    Abstract: The disclosure relates to ceramic-body-forming batch materials comprising at least one pore former and inorganic batch components comprising at least one silica source having a specified particle size distribution, methods of making ceramic bodies using the same, and ceramic bodies made in accordance with said methods. The disclosure additionally relates to methods for reducing pore size variability in ceramic bodies and/or reducing process variability in making ceramic bodies.
    Type: Grant
    Filed: April 30, 2013
    Date of Patent: June 24, 2014
    Assignee: Corning Incorporated
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodbourn, Patrick David Tepesch, Christopher John Warren
  • Publication number: 20140145360
    Abstract: A method for green-to-fired shrinkage control in honeycomb ceramic article manufacture, including: measuring, prior to mixing, the particle size distribution properties of at least one fine particle size graphite pore former ingredient of a provided ceramic source batch mixture; calculating the expected shrinkage of the green body to the fired ceramic article based on the measured particle size distribution properties of the at least one fine particle graphite pore former; making the honeycomb ceramic article; measuring the shrinkage of the resulting fired honeycomb ceramic article; and adjusting the ceramic source batch mixture in a subsequent batch material schedule, as defined herein, wherein the adjusted ceramic source batch mixture provides finished honeycomb ceramic articles having controlled green-to-fired shrinkage.
    Type: Application
    Filed: November 28, 2012
    Publication date: May 29, 2014
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodbourn, Patrick David Tepesch
  • Publication number: 20130320600
    Abstract: A method for reducing shrinkage variability of aluminum titanate honeycombs includes preparing an aluminum titanate-forming batch material that includes least one alkaline earth carbonate having a particle size distribution. The particle size distribution of the at least one alkaline earth carbonate is selected based on the predicted shrinkage during sintering of the aluminum titanate honeycombs.
    Type: Application
    Filed: May 31, 2012
    Publication date: December 5, 2013
    Inventors: Daniel Edward McCauley, Patrick David Tepesch, Christopher John Warren, Jeffrey S. White
  • Publication number: 20130323160
    Abstract: The disclosure relates to aluminum titanate-forming batch materials comprising inorganic batch components comprising at least one alkaline earth carbonate having a specified particle size distribution, methods of making ceramic bodies using the same, and ceramic bodies made in accordance with said methods.
    Type: Application
    Filed: May 31, 2012
    Publication date: December 5, 2013
    Inventors: Daniel Edward McCauley, Patrick David Tepesch, Christopher John Warren
  • Publication number: 20130244860
    Abstract: The disclosure relates to ceramic-body-forming batch materials comprising at least one pore former and inorganic batch components comprising at least one silica source having a specified particle size distribution, methods of making ceramic bodies using the same, and ceramic bodies made in accordance with said methods. The disclosure additionally relates to methods for reducing pore size variability in ceramic bodies and/or reducing process variability in making ceramic bodies.
    Type: Application
    Filed: April 30, 2013
    Publication date: September 19, 2013
    Applicant: CORNING INCORPORATED
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodboum, Patrick David Tepesch, Christopher John Warren
  • Patent number: 8503816
    Abstract: The disclosure relates to methods for determining mixedness of batch material for making ceramic ware, and methods for obtaining substantially consistent mixedness of batch material for making ceramic ware.
    Type: Grant
    Filed: April 15, 2011
    Date of Patent: August 6, 2013
    Assignee: Corning Incorporated
    Inventors: Kevin Michael Erskine, Jacob George, Amit Halder, Daniel Edward McCauley, Andrew Paul Schermerhorn, Adama Tandia
  • Patent number: 8450227
    Abstract: The disclosure relates to ceramic-body-forming batch materials comprising at least one pore former and inorganic batch components comprising at least one silica source having a specified particle size distribution, methods of making ceramic bodies using the same, and ceramic bodies made in accordance with said methods. The disclosure additionally relates to methods for reducing pore size variability in ceramic bodies and/or reducing process variability in making ceramic bodies.
    Type: Grant
    Filed: February 28, 2011
    Date of Patent: May 28, 2013
    Assignee: Corning Incorporated
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodbourn, Patrick David Tepesch, Christopher John Warren
  • Publication number: 20130049243
    Abstract: A method of making ceramic bodies includes systematically orienting the bodies during firing relative to a temperature gradient in a kiln. The systematic orientation of the bodies relative to the temperature gradient can allow for an average deviation of a measured shape of the ceramic bodies from a predetermined target contour shape to be less than what they would be if the bodies were oriented randomly relative to the temperature gradient.
    Type: Application
    Filed: August 1, 2012
    Publication date: February 28, 2013
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodbourn, David Robertson Treacy, JR., Casey Allen Volino
  • Publication number: 20120302421
    Abstract: A precursor batch composition that can be used to make porous ceramic articles is provided. The batch composition includes a cellulose-based polymer and, in particular, a methylcellulose showing a specified micro-calorimetry thermal response fingerprint. The methylcellulose can also have a cloud point above a specified temperature.
    Type: Application
    Filed: May 22, 2012
    Publication date: November 29, 2012
    Inventors: Gregg William Crume, Rebecca L. DeRosa, Daniel Edward McCauley, Misty Riesbeck