Patents by Inventor Gregory A. Merkel
Gregory A. Merkel 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: 20040029707Abstract: A ceramic filter for trapping and combusting diesel exhaust particulates composed of an end-plugged cordierite honeycomb structure exhibiting a pore size distribution as determined by mercury porosimetry in which the quantity d50/(d50+d90) as related to pore size distribution is less than 0.70, a soot loaded permeability factor Sf, as defined by the equation [d50/(d50+d90)]/[% porosity/100], of less than 1.55, and, a coefficient of thermal expansion (25-800° C.) of no greater than 17×10−7/° C. The ceramic filter further exhibits a median pore diameter, d50, of at least 4 micrometers and up to 40 micrometers. A method of making the filter is provided.Type: ApplicationFiled: June 26, 2003Publication date: February 12, 2004Inventors: Douglas M. Beall, Gregory A. Merkel, Martin J. Murtagh
-
Patent number: 6576579Abstract: A ceramic including a first phase having a general formula R1+(x/2)Zr4P6-xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦x≦2, wherein the first phase has a volumetric heat capacity (Cp1), and at least 10 weight percent of a second phase having a volumetric heat capacity (Cp2), wherein Cp2>Cp1. The ceramic has a coefficient of thermal expansion from 22° to 1000° C. of −15×10−7/° C. to +15×10−7/° C., a permeability of at least 0.25×10−12 m2, a total porosity of at least 35% by volume, and a median pore diameter of at least 6 micrometers, and a volumetric heat capacity of the solid Cp(solid) of at least 3.15 J/cm3 K.Type: GrantFiled: October 1, 2001Date of Patent: June 10, 2003Assignee: Corning IncorporatedInventor: Gregory A. Merkel
-
Patent number: 6562284Abstract: This invention relates to a method of producing a honeycomb ceramic body exhibiting a predetermined radial dimension comprising producing a green ceramic honeycomb body that exhibits a radial dimension at least 9% greater than the predetermined radial dimension and a cell density of at least 500 cpsi. The method further involves shrinking the green body during firing to form a sintered honeycomb ceramic body exhibiting the final predetermined radial dimension. This invention also relates to a method of producing a ceramic body comprising the following steps: (a) compounding and plasticizing a ceramic raw material mixture and forming the plasticizable raw material mixture into a green ceramic body by extrusion through an extrusion die; (b) drying the green body and thereafter firing the green body at a time and at a temperature sufficient to sinter the ceramic body resulting in a radial shrinkage of the green ceramic body in the radial dimension due to the firing of at least 9%.Type: GrantFiled: December 19, 2001Date of Patent: May 13, 2003Assignee: Corning IncorporatedInventors: Douglas M. Beall, Gregory A. Merkel, Brian E. Stutts
-
Patent number: 6541407Abstract: A ceramic comprising predominately a cordierite-type phase approximating the stoichiometry Mg2Al4Si5O18 and having a coefficient of thermal expansion (25-800° C.) of greater than 4×10−7/° C. and less than 13×10−7/° C. and a permeability and a pore size distribution which satisfy the relation 2.108 (permeability)+18.511 (total pore volume)+0.1863 (percentage of total pore volume comprised of pores between 4 and 40 micrometers)>24.6. The ceramic is suitable in the fabrication of cellular, wall-flow, diesel particulate filters having a pressure drop in kPa that at an artificial carbon soot loading of 5 grams/liter and a flow rate of 26 scfm is less than 8.9−0.035 (number of cells per square inch)+300 (cell wall thickness in inches), a bulk filter density of at least 0.60 g/cm3 and a volumetric heat capacity of at least 0.67 J cm−3 K−1 as measured at 500° C.Type: GrantFiled: May 29, 2001Date of Patent: April 1, 2003Assignee: Corning IncorporatedInventors: Douglas M. Beall, David L. Hickman, Gregory A. Merkel
-
Publication number: 20030012923Abstract: A sintered ceramic that exhibits an average linear coefficient of thermal expansion (25-800 ° C.) below about 5.0×10−7° C., a total porosity between the range of 20% to about 30%. Furthermore, the sintered ceramic article exhibits a pore size distribution such that at least about 86% of pores are of a pore size of less than about 2 &mgr;m. Lastly, the ceramic article exhibits an interconnected pore structure with the pores exhibiting a generally elongated shape, i.e., the pores are predominately oriented with their long axis in the plane of the webs. This invention also relates to a method for producing a sintered cordierite ceramic article involving first compounding and plasticizing a cordierite-forming inorganic powder batch comprising a platy talc having median particle of size less than about 2 &mgr;m, and preferably a talc morphology index greater than about 0.75.Type: ApplicationFiled: June 17, 2002Publication date: January 16, 2003Inventors: Douglas M. Beall, Christopher J. Malarkey, Gregory A. Merkel
-
Patent number: 6506336Abstract: A plasticizable raw material mixture for use in preparing a substrate having cordierite as its primary phase with a mixture of a chemical composition, percent by weight, of 11 to 17% MgO, 33 to 41% Al2O3 and, 46 to 53% SiO2, the mixture including the following (1) a platy talc having a morphology index of greater than 0.8 and exhibiting a mean particle size of less than about 5 &mgr;m; (2) an Al2O3 forming source comprising an alumina having a mean particle size of less than about 5 &mgr;m selected from the group consisting of ∝-alumina, transition aluminas, aluminum oxide monohydroxide, or aluminum trihydrate having; and, (3) one or more of the components of delaminated kaolin having a mean particle size of less than about 2 &mgr;m, calcined kaolin exhibiting a mean particle size of less than about 2 &mgr;m and a surface area of greater than about 10 m2/g and/or silica having a mean particle size of less than about 5 &mgr;m.Type: GrantFiled: August 31, 2000Date of Patent: January 14, 2003Assignee: Corning IncorporatedInventors: Douglas M. Beall, Gregory A. Merkel
-
Patent number: 6468325Abstract: The present invention provides a method of making a ceramic filter, by forming a mixture from NZP-forming raw material powders selected from metal oxide sources capable of reacting to form a reaction product comprising an NZP-type phase having the general formula R1+(y/2)Zr4P6−ySiyO24 where 0≦y≦1.0 and R is one or more of the metals Ca, Sr, and Ba, pre-reacted powder having the same general formula, and mixtures thereof; and a precursor additive selected from the group consisting of silica precursor, zirconia precursor, and mixtures thereof; shaping the mixture into a green structure; and, firing the green structure to produce a ceramic filter having an open porosity of at least 35% by volume, a median pore size of at least 8 micrometers and a permeability of at least 0.30×10−12 m2, and being suitable as a diesel particulate filter.Type: GrantFiled: October 5, 2000Date of Patent: October 22, 2002Assignee: Corning IncorporatedInventors: Willard A. Cutler, Gregory A. Merkel
-
Publication number: 20020132720Abstract: A structure made predominately of an NZP-type phase having the general formula RxZ4P6−ySiyO24, where 0≦x≦8, 0 ≦y≦6, R is Li, Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Y, and/or lanthanides, and Z is Zr, Ti, Nb, Ta, Y, and/or lanthanidess, and optionally a sintering additive. The structure has an open porosity of at least 20% by volume, median pore diameter in micrometers of at least a value defined by the quantity [10-0.10 (% open porosity)], both as measured by mercury porosimetry, and four-point modulus of rupture as measured on a solid rod of circular cross section, of at least 300 psi. Method of making the structure involves forming a mixture of NZP-forming raw material powders that are metal oxide sources capable of reacting to form an NZP-type reaction product, and/or pre-reacted powder having the above general formula.Type: ApplicationFiled: August 29, 2001Publication date: September 19, 2002Inventors: Willard A. Cutler, Gregory A. Merkel
-
Publication number: 20020130447Abstract: This invention relates to a method of producing a honeycomb ceramic body exhibiting a predetermined radial dimension comprising producing a green ceramic honeycomb body that exhibits a radial dimension at least 9% greater than the predetermined radial dimension and a cell density of at least 500 cpsi. The method further involves shrinking the green body during firing to form a sintered honeycomb ceramic body exhibiting the final predetermined radial dimension.Type: ApplicationFiled: December 19, 2001Publication date: September 19, 2002Inventors: Douglas M. Beall, Gregory A. Merkel, Brian E. Stutts
-
Patent number: 6432856Abstract: A sintered ceramic honeycomb article that exhibits an average linear coefficient of thermal expansion (25-800° C.) below about 5.0×10−7° C.−1, a total porosity between the range of 20% to about 30%, and a pore size distribution such that at least about 86% of pores are of a pore size of less than about 2 &mgr;m with the pores exhibiting a generally elongated shape oriented with their long axis in the plane of the webs, the article being made from a cordierite-forming inorganic powder batch comprising a platy talc having median particle of size less than about 2 &mgr;m, at least 4% by weight of a dispersible Al2O3-forming source having a specific surface area in excess of 50 m2/g, and one or more of the components of kaolin, calcined kaolin, silica, and corundum, each having a median particle sizes less than 5 &mgr;m.Type: GrantFiled: June 8, 2000Date of Patent: August 13, 2002Assignee: Corning IncorporatedInventors: Douglas M. Beall, Christopher J. Malarkey, Gregory A. Merkel
-
Patent number: 6413895Abstract: A structure made predominately of an NZP-type phase having the general formula RxZ4P6−ySiyO24, where 0≦x≦8, 0≦y≦6, R is Li, Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Y, and/or lanthanides, and Z is Zr, Ti, Nb, Ta, Y, and/or lanthanidess, and optionally a sintering additive. The structure has an open porosity of at least 20% by volume, median pore diameter in micrometers of at least a value defined by the quantity [10−0.10(% open porosity)], both as measured by mercury porosimetry, and four-point modulus of rupture as measured on a solid rod of circular cross section, of at least 300 psi. Method of making the structure involves forming a mixture of NZP-forming raw material powders that are metal oxide sources capable of reacting to form an NZP-type reaction product, and/or pre-reacted powder having the above general formula.Type: GrantFiled: September 27, 2000Date of Patent: July 2, 2002Assignee: Corning IncorporatedInventor: Gregory A. Merkel
-
Publication number: 20020061811Abstract: A ceramic including a first phase having a general formula R1+(x/2)Zr4P6−xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦x≦2, wherein the first phase has a volumetric heat capacity (Cp1), and at least 10 weight percent of a second phase having a volumetric heat capacity (Cp2), wherein Cp2>Cp1. The ceramic has a coefficient of thermal expansion from 22° to 1000° C. of −15×10−7/° C. to +15×10−7/° C., a permeability of at least 0.25×10−12 m2, a total porosity of at least 35% by volume, and a median pore diameter of at least 6 micrometers, and a volumetric heat capacity of the solid Cp(solid) of at least 3.15 J/cm3 K.Type: ApplicationFiled: October 1, 2001Publication date: May 23, 2002Inventor: Gregory A. Merkel
-
Patent number: 6391813Abstract: The invention is directed at sintered ceramic articles exhibiting a primary crystalline phase of cordierite and an analytical oxide composition, in weight percent, of 44-53% SiO2, 30-38 Al2O3, 11-16% MgO and 0.05 to 10% of a metal oxide. The ceramic article exhibits a coefficient of thermal expansion in at least one direction no greater than about 15.0×10−7° C. over the temperature range of about 25° C. to about 800° C. The sum of the weight percentages of residual mullite, corundum, and spinel, as measured by X-ray diffractometry of the crushed and powdered body, is not greater than 15%.Type: GrantFiled: December 28, 1999Date of Patent: May 21, 2002Assignee: Corning IncorporatedInventor: Gregory A. Merkel
-
Patent number: 6377729Abstract: Negative thermal expansion materials, methods of preparation and uses therefor are disclosed. The materials are useful for negative thermal expansion substrates, such as those used for optical fiber gratings.Type: GrantFiled: December 22, 2000Date of Patent: April 23, 2002Assignee: Corning IncorporatedInventor: Gregory A. Merkel
-
Publication number: 20020010073Abstract: Disclosed is sintered ceramic article that exhibits a primary crystalline phase of cordierite and analytical oxide composition, in weight percent, of 49-53% SiO2, 33-38% Al2O3, 12-16% MgO and exhibits a coefficient of thermal expansion no greater than about 4.0×10−7/° C. over the temperature range of about 25° C. to about 800° C. and a transverse-I ratio of not less than about 0.92. Also disclosed is a method for producing a sintered cordierite ceramic article involving preparing a plasticizable raw material, comprising a magnesium source, a SiO2-forming source and an additional component of either: (a) a clay-free, Al2O3-forming source having a surface area of greater than about 5 m2/g; or, (b) a clay and Al2O3-forming source combination wherein the clay comprises no greater than about 30%, by weight, of the total inorganic mixture, and the Al2O3-forming source exhibits a surface area of greater than about 40 m2/g.Type: ApplicationFiled: May 31, 2001Publication date: January 24, 2002Inventors: Douglas M. Beall, Gregory A. Merkel
-
Publication number: 20020004445Abstract: A ceramic comprising predominately a cordierite-type phase approximating the stoichiometry Mg2Al4Si5O18 and having a coefficient of thermal expansion (25-800° C.) of greater than 4×10−7/° C. and less than 13×10−7/° C. and a permeability and a pore size distribution which satisfy the relation 2.108 (permeability)+18.511 (total pore volume)+0.1863 (percentage of total pore volume comprised of pores between 4 and 40 micrometers)>24.6. The ceramic is suitable in the fabrication of cellular, wall-flow, diesel particulate filters having a pressure drop in kPa that at an artificial carbon soot loading of 5 grams/liter and a flow rate of 26 scfm is less than 8.9−0.035 (number of cells per square inch)+300 (cell wall thickness in inches), a bulk filter density of at least 0.60 g/cm3 and a volumetric heat capacity of at least 0.67 J cm−3 K−1 as measured at 500° C.Type: ApplicationFiled: May 29, 2001Publication date: January 10, 2002Inventors: Douglas M. Beall, David L. Hickman, Gregory A. Merkel
-
Patent number: 6328779Abstract: A filter for trapping and combusting diesel exhaust particulates and method of making the same. The filter comprises a monolithic substrate coated with a refractory oxide material which at a frequency of 2.45 GHz heats up said filter from room temperature to about 600° C. in 5 minutes or less, and wherein said refractory oxide material has a loss tangent which decreases with increasing temperature such that an equilibrium in said filter temperature is reached at no greater than 1100° C.Type: GrantFiled: May 31, 2000Date of Patent: December 11, 2001Assignee: Corning IncorporatedInventors: Lin He, Gregory A. Merkel, Cameron W. Tanner, Dale R. Wexell
-
Patent number: 6322605Abstract: A filter for trapping and combusting diesel exhaust particulates comprising a microwave-absorbing filter body formed from a ceramic material having a general formula selected from the group consisting of A1−xMxB1−yM′yO3−&agr;, where A and M are selected from the group consisting of Na, K, Rb, Ag, Ca, Sr, Ba, Pb, La, Pr, Nd, Bi, Ce, Th and combinations thereof; where B and M′ are selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Rh, Ru, Pt, Zn, Nb, Ta, Mo, W and combinations thereof; wherein, the chemical formula is electrostatically balanced; (A′aRrM″m)(Z)4(X)6O24, where A′ is from Group IA metals; where R is selected from Group IIA metals; where M″ is selected from the group consisting of Mn, Co, Cu, Zn, Y, lanthanides and combinations thereof; where Z is selected from the group consisting of Zr, Hf, Ti, Nb, Ta, Y, lanthanides, Sn, Fe, Co, Al, Mn, Zn, Ni, and combinations thereof; where X is selected from the group consisting of P, Si, As,Type: GrantFiled: May 31, 2000Date of Patent: November 27, 2001Assignee: Corning IncorporatedInventors: Lin He, Gregory A. Merkel, Cameron W. Tanner, Dale R. Wexell
-
Patent number: 6300263Abstract: A crystalline glass-ceramic article composed of a cordierite phase of cordierite crystals or aggregates of near-parallel crystallites, having a formula of either Mg2Al4Si5O18 or AxByMg2Al4+x+2ySi5−x−2yO18. With the first formula, the average size of the cordierite crystals or aggregates is less than 70 micrometers, and the mean coefficient of thermal expansion from 22° C. to 800° C. (CTE) is less than 9×10−7/° C. With the second formula, A is either sodium or potassium, B is either strontium or barium, the sum of x and y is not less than 0.01, and when either x or y equal zero, the CTE is not more than 14×10−7/° C. The article is especially suitable as a filter or catalyst substrate.Type: GrantFiled: December 16, 1999Date of Patent: October 9, 2001Assignee: Corning IncorporatedInventor: Gregory A. Merkel
-
Publication number: 20010021292Abstract: Negative thermal expansion materials, methods of preparation and uses therefor are disclosed. The materials are useful for negative thermal expansion substrates, such as those used for optical fiber gratings.Type: ApplicationFiled: December 22, 2000Publication date: September 13, 2001Applicant: Corning Incorporated.Inventor: Gregory A. Merkel