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).
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Publication number: 20200300138Abstract: 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: ApplicationFiled: November 20, 2018Publication date: September 24, 2020Inventors: Douglas Munroe Beall, Achim Karl-Erich Heibel, Pushkar Tandon
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Publication number: 20200230587Abstract: 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: ApplicationFiled: October 2, 2018Publication date: July 23, 2020Inventors: Douglas Munroe Beall, Kenneth Richard Miller
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Publication number: 20190374896Abstract: A honeycomb body having intersecting porous walls which includes first through fourth cells, wherein the cells extend from inlet to outlet face and are plugged to define a repeating structural unit with three inlets and one outlet channel. Repeating structural unit includes a first channel including length L1, width W2, and area A1, a second channel including length L2, the width W2, and area A2, a third channel including the length L1, width W1, and area A3, and a fourth channel including the length L2, the width W1, and A4, wherein the first through third channels are inlets and the fourth channel is a rectangular outlet and at least one of W1>W2 and L1?L2, i.e. W1>W2, or L1?L2, or W1>W2 and L1?L2. Repeating structural unit has a quadrilateral outer perimeter. Particulate filters including the honeycomb body, honeycomb extrusion dies, and methods of manufacturing the honeycomb body are provided.Type: ApplicationFiled: January 31, 2018Publication date: December 12, 2019Inventors: Douglas Munroe Beall, Dana Craig Bookbinder, Pushkar Tandon
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Patent number: 10479734Abstract: An apparatus and method for debindering a cellular ceramic green body. The apparatus includes a flow modulation member to selectively restrict circulation of a heated oxygen-containing atmosphere through a top of a cellular core section of the green body. The method includes heating the green body in a circulating oxygen-containing atmosphere while selectively restricting circulation of the atmosphere through the top of the cellular core section of the green body.Type: GrantFiled: July 22, 2014Date of Patent: November 19, 2019Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Dana Craig Bookbinder, David John Thompson, Jianguo Wang
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Patent number: 10370304Abstract: A porous cellular body comprising primarily a porous sintered glass material is disclosed. The porous sintered glass material primarily includes a first phase and a second phase, the first phase primarily comprising amorphous fused silica and the second phase comprising amorphous fused silica and a sintering aid.Type: GrantFiled: November 6, 2013Date of Patent: August 6, 2019Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Cameron Wayne Tanner
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Publication number: 20190126186Abstract: 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: ApplicationFiled: April 24, 2017Publication date: May 2, 2019Applicant: Corning IncorporatedInventors: Douglas Munroe Beall, Suhao He, Achim Karl-Erich Heibel, Kenneth Richard Miller, Pushkar Tandon, David John Thompson
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Publication number: 20190076773Abstract: 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: ApplicationFiled: March 17, 2017Publication date: March 14, 2019Inventors: Douglas Munroe Beall, Achim Karl-Erich Heibel, David John Thompson
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Publication number: 20180326343Abstract: A method 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. The die and honeycomb body having uniform integral skin are also provided.Type: ApplicationFiled: August 24, 2016Publication date: November 15, 2018Inventors: Douglas Munroe Beall, Dana Craig Bookbinder, Thomas William Brew, Kenneth Richard Miller
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Patent number: 10000424Abstract: A method for firing a green honeycomb ceramic body in a kiln may include heating the green honeycomb ceramic body in four stages. The first stage may include heating the green honeycomb ceramic body from room temperature to a first temperature that at a first heating rate that is greater than or equal to about 75° C./hr. The second stage may include heating the green honeycomb ceramic body from the first temperature to a second temperature at a second heating rate that is less than or equal to the first heating rate. The third stage may include heating the green honeycomb ceramic body from the second temperature to a hold temperature at a third heating rate that is less than or equal to the first heating rate. The fourth stage may include holding the green honeycomb ceramic body at the hold temperature to remove residual carbon.Type: GrantFiled: March 4, 2014Date of Patent: June 19, 2018Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, David Jack Bronfenbrenner, Margaret Kathleen Faber, Sriram Rangarajan Iyer, Patrick David Tepesch, Douglas Richard Wing
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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: 20170197170Abstract: In one embodiment, a honeycomb structure formed from ceramic material, or ceramic honeycomb structure, includes at least one outer wall defining a perimeter of the honeycomb structure. A plurality of primary zone partitions and secondary zone partitions may extend in an axial direction of the honeycomb structure and across a width of the honeycomb structure. The primary zone partitions and the secondary zone partitions intersect with one another to divide a radial cross section of the honeycomb structure into a plurality of zones. The primary zone partitions and the secondary zone partitions may have a single-wall thickness with a maximum thickness Tzmax. Each zone may comprise a plurality of channel walls intersecting to subdivide the zone into a plurality of through channels extending in the axial direction of the honeycomb structure, the plurality of channel walls within each zone having a thickness of at least tc and TZmax>2tC.Type: ApplicationFiled: July 21, 2015Publication date: July 13, 2017Applicant: CORNING INCORPORATIONInventors: Douglas Munroe Beall, Jason Thomas Harris, Seth Thomas Nickerson, Krishna Hemanth Vepakomma
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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: 9409826Abstract: A porous ceramic honeycomb article includes a primary cordierite phase and an intercrystalline glass phase. In an as-fired condition, the porous ceramic honeycomb article exhibits microcrack parameter Nb3?0.06 and an as-fired E500° C./E25° C. ratio ?0.99. The article exhibits a coated microcrack parameter Nb3?0.14 and a coated E500° C./E25° C. ratio ?1.06 after the porous ceramic honeycomb article has been washcoated and calcined at a temperature of 550° C. After the article is exposed to a thermal treatment at a temperature ?800° C. following washcoating and calcining, at least a first portion of the porous ceramic honeycomb article has a first treated microcrack parameter Nb3?0.18, and a first treated mean coefficient of thermal expansion of not more than 12×10?7/° C. over a temperature range of 25° C. to 800° C. Methods of forming the porous ceramic honeycomb article are also disclosed.Type: GrantFiled: February 25, 2015Date of Patent: August 9, 2016Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Gregory Albert Merkel, Martin Joseph Murtagh
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Patent number: 9221192Abstract: A process for producing a honeycomb ceramic article includes providing a green honeycomb body including ceramic-forming materials and organic pore forming materials and subjecting the green honeycomb body to a firing cycle in a kiln in which steam is added to the kiln atmosphere in an amount from about 10% to about 100%, based on volume. Also provided are ceramic articles produced by the process.Type: GrantFiled: January 6, 2012Date of Patent: December 29, 2015Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Dana Craig Bookbinder, Jianguo Wang
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Publication number: 20150166416Abstract: A porous ceramic honeycomb article includes a primary cordierite phase and an intercrystalline glass phase. In an as-fired condition, the porous ceramic honeycomb article exhibits microcrack parameter Nb3?0.06 and an as-fired E500° C./E25° C. ratio ?0.99. The article exhibits a coated microcrack parameter Nb3?0.14 and a coated E500° C./E25° C. ratio ?1.06 after the porous ceramic honeycomb article has been washcoated and calcined at a temperature of 550° C. After the article is exposed to a thermal treatment at a temperature ?800° C. following washcoating and calcining, at least a first portion of the porous ceramic honeycomb article has a first treated microcrack parameter Nb3?0.18, and a first treated mean coefficient of thermal expansion of not more than 12×10?7/° C. over a temperature range of 25° C. to 800° C. Methods of forming the porous ceramic honeycomb article are also disclosed.Type: ApplicationFiled: February 25, 2015Publication date: June 18, 2015Inventors: Douglas Munroe Beall, Gregory Albert Merkel, Martin Joseph Murtagh
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Patent number: 8999224Abstract: A porous ceramic honeycomb article includes a primary cordierite phase and an intercrystalline glass phase. In an as-fired condition, the porous ceramic honeycomb article exhibits microcrack parameter Nb3?0.06 and an as-fired E500° C./E25° C. ratio ?0.99. The article exhibits a coated microcrack parameter Nb3?0.14 and a coated E500° C./E25° C. ratio ?1.06 after the porous ceramic honeycomb article has been washcoated and calcined at a temperature of 550° C. After the article is exposed to a thermal treatment at a temperature ?800° C. following washcoating and calcining, at least a first portion of the porous ceramic honeycomb article has a first treated microcrack parameter Nb3?0.18, and a first treated mean coefficient of thermal expansion of not more than 12×10?7/° C. over a temperature range of 25° C. to 800° C. Methods of forming the porous ceramic honeycomb article are also disclosed.Type: GrantFiled: November 30, 2010Date of Patent: April 7, 2015Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Gregory Albert Merkel, Martin Joseph Murtagh
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Publication number: 20150050609Abstract: An apparatus and method for debindering a cellular ceramic green body. The apparatus includes a flow modulation member to selectively restrict circulation of a heated oxygen-containing atmosphere through a top of a cellular core section of the green body. The method includes heating the green body in a circulating oxygen-containing atmosphere while selectively restricting circulation of the atmosphere through the top of the cellular core section of the green body.Type: ApplicationFiled: July 22, 2014Publication date: February 19, 2015Inventors: Douglas Munroe Beall, Dana Craig Bookbinder, David John Thompson, Jianguo Wang
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Publication number: 20140252695Abstract: A method for firing a green honeycomb ceramic body in a kiln may include heating the green honeycomb ceramic body in four stages. The first stage may include heating the green honeycomb ceramic body from room temperature to a first temperature that at a first heating rate that is greater than or equal to about 75° C./hr. The second stage may include heating the green honeycomb ceramic body from the first temperature to a second temperature at a second heating rate that is less than or equal to the first heating rate. The third stage may include heating the green honeycomb ceramic body from the second temperature to a hold temperature at a third heating rate that is less than or equal to the first heating rate. The fourth stage may include holding the green honeycomb ceramic body at the hold temperature to remove residual carbon.Type: ApplicationFiled: March 4, 2014Publication date: September 11, 2014Applicant: CORNING INCORPORATEDInventors: Douglas Munroe Beall, David Jack Bronfenbrenner, Margaret Kathleen Faber, Sriram Rangarajan Iyer, Patrick David Tepesch, Douglas Richard Wing
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Patent number: 8814974Abstract: A thin-walled porous ceramic wall-flow filter is disclosed. The filter produces a relatively lower pressure drop coupled with relatively high initial filtration efficiency (FE0), and may enable packaging the filter in a smaller volume. The filter includes a plurality of porous ceramic walls forming cell channels. At least some of the cells are plugged forcing some exhaust gases through the walls, thereby filtering out entrained particulates. The walls have a wall thickness (Twall) wherein 102 ?m?Twall<279 ?m, and a median pore diameter (MPD), and wherein 10<Twall/MPD, and may also be <40. The relatively small median pore diameter (MPD) in comparison to the wall thickness (Twall) allows the use of thinner ceramic walls that provide less flow resistance than thicker walls while maintaining sufficient initial filtration efficiency (FE0). Furthermore, such thin-walled filter structure coupled with unequal inlet/outlet area ratio (Ai/Ao) may allow filter lengths to be additionally shortened.Type: GrantFiled: August 24, 2007Date of Patent: August 26, 2014Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Achim Karl-Erich Heibel, Pushkar Tandon