Patents by Inventor Douglas Munroe Beall

Douglas Munroe Beall 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: 20240159174
    Abstract: An exhaust treatment method and apparatus for treating an exhaust stream flowing through an exhaust line housing in a downstream direction, the apparatus comprising a first particulate filter, an SCR unit, and a second particulate filter downstream of the SCR unit, all serially positioned in the exhaust line.
    Type: Application
    Filed: April 5, 2022
    Publication date: May 16, 2024
    Inventors: Douglas Munroe Beall, Sam George, Mahesh Govindareddy, Achim Karl-Erich Heibel
  • Patent number: 11932582
    Abstract: Ceramic honeycomb bodies with a matrix of intersecting walls having an interior portion with a first average bulk porosity, and a skin having a second average bulk porosity, wherein the second average bulk porosity is less than the first average bulk porosity. Methods of manufacturing a ceramic honeycomb bodies include providing a firing cycle for the ceramic honeycomb structure such that at least the skin of the honeycomb structure is subjected to a thermal spike in firing temperature while the interior portion of the matrix is subjected to a lesser spike in firing temperature.
    Type: Grant
    Filed: June 19, 2019
    Date of Patent: March 19, 2024
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Elizabeth Marie Vileno
  • Publication number: 20230365472
    Abstract: A coated ceramic honeycomb body comprising a honeycomb structure comprising a matrix of intersecting porous walls forming a plurality of axially-extending channels, at least some of the plurality of axially-extending channels being plugged to form inlet channels and outlet channels, wherein a total surface area of the outlet channels is greater than a total surface area of the inlet channels, and wherein a catalyst is preferentially located within the outlet channels. and preferentially disposed on non-filtration walls of the outlet channels. Methods and apparatus configured to preferentially apply a catalyst-containing slurry to the outlet channels and non-filtration walls are provided, as are other aspects.
    Type: Application
    Filed: July 25, 2023
    Publication date: November 16, 2023
    Inventors: Douglas Munroe Beall, Achim Karl-Erich Heibel, Konstantin Vladimirovich Khodosevich, Kenneth Richard Miller, Hrushikesh Govindrao Pimpalgaonkar, Kunal Upendra Sakekar, Min Shen, Todd Parrish St Clair
  • Patent number: 11813597
    Abstract: A honeycomb body (300) including a plurality of radially-extending walls (322) intersecting with a plurality of circumferentially-extending walls (324), the plurality of radially-extending walls (322) and the plurality of circumferentially-extending walls (324) form a plurality of circumferential zones (334A, 334B, 334C) of cells (308). The plurality of circumferential zones (334A, 334B, 334C) of cells (308) includes a first zone of cells (334A) including two or more first rings of cells (330) and having a first cell density, and a second zone of cells (334B) including two or more rings of cells (330) having varying cell densities across the two or more rings of cells. Other structures and extrusion dies are disclosed.
    Type: Grant
    Filed: March 28, 2019
    Date of Patent: November 14, 2023
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Priyank Paras Jain, Kenneth Richard Miller, Artemii Alexandrovitch Shamkin
  • Publication number: 20230358154
    Abstract: A method of manufacturing a ceramic honeycomb structure by mixing a ceramic precursor batch composition having a median particle diameter less than or equal to about 10 ?m and at least one starch-based pore former having a median particle diameter greater than or equal to about 10 ?m. The method also includes forming a mixture of ceramic precursor batch composition and a starch-based pore former into a green ceramic structure having a web structure, and firing the green ceramic structure to yield a ceramic honeycomb structure.
    Type: Application
    Filed: July 6, 2023
    Publication date: November 9, 2023
    Inventors: Douglas Munroe Beall, Achim Karl-Erich Heibel, David John Thompson
  • Publication number: 20230294324
    Abstract: A particulate filter having a honeycomb structure of a matrix of interconnected porous walls including inlet cells and outlet cells defining a plurality of inlet channels and outlet channels, respectively, wherein at least a portion of the outlet cells are larger than any of the inlet cells, and a cross-sectional shape of at least some of the outlet channels is rectangular. Honeycomb extrusion dies, honeycomb bodies, honeycomb structures, and methods of manufacture are described, as are other aspects.
    Type: Application
    Filed: April 14, 2023
    Publication date: September 21, 2023
    Inventors: Douglas Munroe Beall, Suhao He, Achim Karl-Erich Heibel, Kenneth Richard Miller, Pushkar Tandon, David John Thompson
  • Patent number: 11746061
    Abstract: A coated ceramic honeycomb body comprising a honeycomb structure comprising a matrix of intersecting porous walls forming a plurality of axially-extending channels, at least some of the plurality of axially-extending channels being plugged to form inlet channels and outlet channels, wherein a total surface area of the outlet channels is greater than a total surface area of the inlet channels, and wherein a catalyst is preferentially located within the outlet channels, and preferentially disposed on non-filtration walls of the outlet channels. Methods and apparatus configured to preferentially apply a catalyst-containing slurry to the outlet channels and non-filtration walls are provided, as are other aspects.
    Type: Grant
    Filed: May 3, 2019
    Date of Patent: September 5, 2023
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Achim Karl-Erich Heibel, Konstantin Vladimirovich Khodosevich, Kenneth Richard Miller, Hrushikesh Govindrao Pimpalgaonkar, Kunal Upendra Sakekar, Min Shen, Todd Parrish St Clair
  • Patent number: 11739670
    Abstract: A ceramic honeycomb structure having a web structure including a plurality of intersecting channel walls forming channels. The ceramic honeycomb structure has a total porosity greater than or equal to about 55%, an average channel wall thickness less than or equal to about 150 ?m, a median pore diameter greater than or equal to about 10 ?m, a df less than or equal to about 0.45, where df=(d50?d10)/d50, and a strength (MOR/CFA) greater than or equal to about 900 psi. A method of manufacturing a ceramic honeycomb structure by mixing a ceramic precursor batch composition having a median particle diameter less than or equal to about 10 ?m and at least one starch-based pore former having a median particle diameter greater than or equal to about 10 ?m. The method also includes forming a mixture of ceramic precursor batch composition and a starch-based pore former into a green ceramic structure having a web structure, and firing the green ceramic structure to yield a ceramic honeycomb structure.
    Type: Grant
    Filed: March 17, 2017
    Date of Patent: August 29, 2023
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Achim Karl-Erich Heibel, David John Thompson
  • Patent number: 11698015
    Abstract: Ceramic honeycomb bodies and methods for canning the bodies are disclosed herein. The honeycomb bodies comprise a porous ceramic honeycomb structure. The honeycomb structure comprises a network of cells defined by walls that extend in an axial direction about a longitudinal axis from an inlet end to an outlet end of the honeycomb structure. The honeycomb structure also comprises a portion of cells with protrusions. The portion of cells with protrusions supports a greater concentration of catalyst, as compared to a portion of cells without protrusions. The portion of cells with protrusions is disposed off-center with respect to the longitudinal axis of the honeycomb structure such that the portion of cells with protrusions (and greater concentration of catalyst) corresponds to areas of high exhaust flow through the structure.
    Type: Grant
    Filed: October 2, 2018
    Date of Patent: July 11, 2023
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Kenneth Richard Miller
  • Publication number: 20230201771
    Abstract: A composite structure, exhaust aftertreatment system, and method of manufacture. The composite structure includes a body that includes an array of intersecting walls that form a plurality of channels extending in an axial direction through the body such that adjacent channels are located on opposite sides of each wall. A composite material of the body includes a first phase of a porous glass or ceramic containing material. The first phase includes an internal interconnected porosity. A second phase of an electrically conductive material is included that is a continuous, three-dimensional, interconnected, electrically conductive phase at least partially filling the internal interconnected porosity of the first phase, which creates an electrical path through at least some of the walls in a lateral direction perpendicular to the axial direction between the opposite sides of the walls.
    Type: Application
    Filed: March 3, 2023
    Publication date: June 29, 2023
    Inventors: Douglas Munroe Beall, Vishwanath Ganpat Deshmane
  • Patent number: 11673132
    Abstract: A ceramic honeycomb body, suitable for use in exhaust gas processing, includes a honeycomb structure having a plurality of through-channels, a first portion of the plurality of through-channels have a first hydraulic diameter dh1, a second portion of the plurality of through-channels have a second hydraulic diameter that is smaller than the first hydraulic diameter dh1, the first hydraulic diameter dh1 is equal to or greater than 1.1 mm, and the first and second portions of through-channels, taken together, have a geometric surface area GSA greater than 2.9 mm?1. Diesel oxidation catalysts and methods of soot removal are also provided, as are other aspects.
    Type: Grant
    Filed: November 6, 2019
    Date of Patent: June 13, 2023
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Dana Craig Bookbinder, Achim Karl-Erich Heibel, Pushkar Tandon
  • Patent number: 11666897
    Abstract: A honeycomb body with a honeycomb structure having an inner zone of a first plurality of walls and an outer zone of a second plurality of walls at least partially surrounding the inner zone. The honeycomb structure has Pi that is greater than Po and MPSi that is greater than MPSo, wherein Pi is an average bulk porosity of the first plurality of walls, Po is an average bulk porosity of the second plurality of walls, MPSi is a median pore size of pores in the first plurality of walls, and MPSo is a median pore size of pores in the second plurality of walls. Various honeycomb structures, honeycomb extrusion apparatus, and co-extrusion methods are disclosed.
    Type: Grant
    Filed: May 28, 2019
    Date of Patent: June 6, 2023
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, David John Thompson
  • Patent number: 11654592
    Abstract: A particulate filter having a honeycomb structure of a matrix of interconnected porous walls including inlet cells and outlet cells defining a plurality of inlet channels and outlet channels, respectively, wherein at least a portion of the outlet cells are larger than any of the inlet cells, and a cross-sectional shape of at least some of the outlet channels is rectangular. Honeycomb extrusion dies, honeycomb bodies, honeycomb structures, and methods of manufacture are described, as are other aspects.
    Type: Grant
    Filed: September 22, 2021
    Date of Patent: May 23, 2023
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Suhao He, Achim Karl-Erich Heibel, Kenneth Richard Miller, Pushkar Tandon, David John Thompson
  • Patent number: 11642813
    Abstract: A method and extrusion die to form a laminar integral skin of a honeycomb structure is provided. The method includes extruding a ceramic precursor batch through a die with feedholes in entry side and slots in exit face of the die to form the honeycomb structure. In a region on the periphery of the die configured to form the cell matrix, a series of concentric slots around the matrix in the exit face of the die are configured to feed skin onto the matrix. Ring sections between concentric slots are angled away from the center and a mask is disposed on top of the periphery producing a channel for extruded skin to meet and bond to extruded matrix. Optionally, slots in the skin-forming ring sections enhance knitting between laminar skin layers.
    Type: Grant
    Filed: August 18, 2021
    Date of Patent: May 9, 2023
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Dana Craig Bookbinder, Thomas William Brew, Kenneth Richard Miller
  • Patent number: 11628401
    Abstract: A composite structure, exhaust aftertreatment system, and method of manufacture. The composite structure includes a body that includes an array of intersecting walls that form a plurality of channels extending in an axial direction through the body such that adjacent channels are located on opposite sides of each wall. A composite material of the body includes a first phase of a porous glass or ceramic containing material. The first phase includes an internal interconnected porosity. A second phase of an electrically conductive material is included that is a continuous, three-dimensional, interconnected, electrically conductive phase at least partially filling the internal interconnected porosity of the first phase, which creates an electrical path through at least some of the walls in a lateral direction perpendicular to the axial direction between the opposite sides of the walls.
    Type: Grant
    Filed: July 28, 2021
    Date of Patent: April 18, 2023
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Vishwanath Ganpat Deshmane
  • Publication number: 20230061436
    Abstract: An exhaust treatment apparatus for treating exhaust gas flowing through an exhaust line housing from an upstream location to a downstream location in a downstream direction, the exhaust treatment apparatus comprising a ceramic filter body having a honeycomb structure of a plurality of intersecting porous ceramic walls extending from a first end to a second end in an axial direction and defining a plurality of channels extending in the axial direction, wherein a first transverse face at the first end comprises metal oxide particles affixed to a portion of the intersecting walls. The metal oxide particles may be affixed to the upstream end, or the downstream end, or both the upstream and downstream ends. Preferably the metal oxide particles provide reinforcement to the underlying portion of the walls, and of the honeycomb structure itself.
    Type: Application
    Filed: August 30, 2022
    Publication date: March 2, 2023
    Inventors: Douglas Munroe Beall, Vishwanath Ganpat Deshmane, Sam George, Achim Karl-Erich Heibel, Sandeep Viswanathan
  • Publication number: 20230030980
    Abstract: A composite structure, exhaust aftertreatment system, and method of manufacture. The composite structure includes a body that includes an array of intersecting walls that form a plurality of channels extending in an axial direction through the body such that adjacent channels are located on opposite sides of each wall. A composite material of the body includes a first phase of a porous glass or ceramic containing material. The first phase includes an internal interconnected porosity. A second phase of an electrically conductive material is included that is a continuous, three-dimensional, interconnected, electrically conductive phase at least partially filling the internal interconnected porosity of the first phase, which creates an electrical path through at least some of the walls in a lateral direction perpendicular to the axial direction between the opposite sides of the walls.
    Type: Application
    Filed: July 28, 2021
    Publication date: February 2, 2023
    Inventors: Douglas Munroe Beall, Vishwanath Ganpat Deshmane
  • Patent number: 11554339
    Abstract: A plugged honeycomb structure includes intersecting porous walls extending in an axial direction between an inlet end and an outlet end of the honeycomb structure, the intersecting porous walls forming a matrix of repeating unit cells arranged in a repeating pattern. The repeating unit cells comprise: three or four channels, each channel formed by four walls, wherein the three or four channels comprise more inlet channels than outlet channels, at least one wall of an inlet channel or an outlet channel is intersected midwall by a wall, an area of an outlet channel is equal to or less than an area of any of the inlet channels, and continuous line segments extending along walls of at least three repeating unit cells. Other plugged honeycomb structures, plugged honeycomb bodies, honeycomb extrusion dies, and methods are disclosed.
    Type: Grant
    Filed: November 1, 2019
    Date of Patent: January 17, 2023
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Dana Craig Bookbinder, Pushkar Tandon
  • Publication number: 20230001401
    Abstract: A particulate filter having a porous ceramic honeycomb structure with a first end, a second end, and a plurality of walls having wall surfaces defining a plurality of inner channels. Filtration material deposits are disposed on one or more of the wall surfaces of the honeycomb body. The highly porous deposits provide durable high clean filtration efficiency with small impact on pressure drop through the filter.
    Type: Application
    Filed: August 24, 2022
    Publication date: January 5, 2023
    Inventors: Douglas Munroe Beall, Thorsten Rolf Boger, Dana Craig Bookbinder, Thomas Jean Glasson, Dale Robert Powers, Pushkar Tandon, Jianguo Wang, Huiqing Wu, Xinfeng Xing
  • Patent number: 11536176
    Abstract: A honeycomb body having intersecting porous walls and repeating structural units. Each repeating structural unit has a plurality of inlet channels and outlet channels that extend parallel to each other in an axial direction from an inlet face to an outlet face. Each of the repeating structural units has 2.0<I/O<3.0, wherein I/O is a ratio of a number of inlet channels to a number of the outlet channels, each of the inlet and outlet channels have a same cross-sectional size and shape, and each inlet channel of a particular repeating structural unit directly abuts an outlet channel of the particular repeating structural unit or an outlet channel of an adjacent repeating structural unit. Particulate filters including the honeycomb body, honeycomb extrusion dies, and methods of capturing soot in the honeycomb body are provided, as are other aspects.
    Type: Grant
    Filed: November 20, 2018
    Date of Patent: December 27, 2022
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Achim Karl-Erich Heibel, Pushkar Tandon