Abstract: An apparatus for producing a green body of ceramic-forming material can comprise a support device including at least one air bearing including a support surface with a plurality of apertures. In one example, the support surface is configured to circumscribe greater than 180° of a support area for the green body. In another example, the plurality of apertures include at least a quantity of apertures oriented with a fluid emitting axis extending at an oblique angle with respect to an extrusion axis. In still another example, the air bearing is adjustable. Methods for producing a green body also provide an air cushion between a support surface and the green body.

Abstract: An apparatus for producing a green body of ceramic-forming material can comprise a support device including at least one air bearing including a support surface with a plurality of apertures. In one example, the support surface is configured to circumscribe greater than 180° of a support area for the green body. In another example, the plurality of apertures include at least a quantity of apertures oriented with a fluid emitting axis extending at an oblique angle with respect to an extrusion axis. In still another example, the air bearing is adjustable. Methods for producing a green body also provide an air cushion between a support surface and the green body.

Abstract: An apparatus for producing a green body of ceramic-forming material can comprise a support device including at least one air bearing including a support surface with a plurality of apertures. In one example, the support surface is configured to circumscribe greater than 180° of a support area for the green body. In another example, the plurality of apertures include at least a quantity of apertures oriented with a fluid emitting axis extending at an oblique angle with respect to an extrusion axis. In still another example, the air bearing is adjustable. Methods for producing a green body also provide an air cushion between a support surface and the green body.

Abstract: An apparatus for producing a green body of ceramic-forming material can comprise a support device including at least one air bearing including a support surface with a plurality of apertures. In one example, the support surface is configured to circumscribe greater than 180° of a support area for the green body. In another example, the plurality of apertures include at least a quantity of apertures oriented with a fluid emitting axis extending at an oblique angle with respect to an extrusion axis. In still another example, the air bearing is adjustable. Methods for producing a green body also provide an air cushion between a support surface and the green body.

Abstract: An apparatus for producing a green body of ceramic-forming material can comprise a support device including at least one air bearing including a support surface with a plurality of apertures. In one example, the support surface is configured to circumscribe greater than 180° of a support area for the green body. In another example, the plurality of apertures include at least a quantity of apertures oriented with a fluid emitting axis extending at an oblique angle with respect to an extrusion axis. In still another example, the air bearing is adjustable. Methods for producing a green body also provide an air cushion between a support surface and the green body.

Abstract: A plate suitable for positioning with an extruder apparatus is provided in which the plate includes at least one temperature sensor. The plate is upstream of the die located at or near the end of the extruder apparatus. The sensor(s) allow for the simultaneous measurement of batch material temperatures at multiple spatial locations across the face of the plate. The temperature sensors associated with the plate can be used to identify spatial and temporal temperature patterns within the batch flow.

Abstract: Methods and apparatus provide for a conformable polishing head for uniformly polishing a workpiece. The polishing head includes an elastic polishing pad mounted on an elastic membrane that seals a cavity in the polishing head. The cavity is pressurized to expand the membrane and press the polishing pad down on the top surface of the workpiece, such that the polishing pad conforms to the surface and applies a substantially uniform pressure distribution across the workpiece and thereby uniformly removes material across high and low spots on the workpiece.

Abstract: A plate suitable for positioning with an extruder apparatus is provided in which the plate includes at least one temperature sensor. The plate is upstream of the die located at or near the end of the extruder apparatus. The sensor(s) allow for the simultaneous measurement of batch material temperatures at multiple spatial locations across the face of the plate. The temperature sensors associated with the plate can be used to identify spatial and temporal temperature patterns within the batch flow.

Abstract: Methods and apparatus provide for a conformable polishing head for uniformly polishing a workpiece. The polishing head includes an elastic polishing pad mounted on an elastic membrane that seals a cavity in the polishing head. The cavity is pressurized to expand the membrane and press the polishing pad down on the top surface of the workpiece, such that the polishing pad conforms to the surface and applies a substantially uniform pressure distribution across the workpiece and thereby uniformly removes material across high and low spots on the workpiece.

Abstract: An apparatus for producing a green body of ceramic-forming material can comprise a support device including at least one air bearing including a support surface with a plurality of apertures. In one example, the support surface is configured to circumscribe greater than 180° of a support area for the green body. In another example, the plurality of apertures include at least a quantity of apertures oriented with a fluid emitting axis extending at an oblique angle with respect to an extrusion axis. In still another example, the air bearing is adjustable. Methods for producing a green body also provide an air cushion between a support surface and the green body.

Abstract: A multi-station polish system and process for polishing thin, flat (planar) and rigid workpieces. Workpieces are conveyed through multiple polishing stations that include a bulk material removal belt polishing station and finishing rotary polishing station. The bulk of the material is relatively quickly removed at the bulk removal station using a conformable abrasive belt and the workpiece surface is then polished to the desired finish at the finishing station using a conformable annular rotary polishing pad.

Abstract: Methods and apparatus provide for a conformable polishing head for uniformly polishing a workpiece. The polishing head includes an elastic polishing pad mounted on an elastic membrane that seals a cavity in the polishing head. The cavity is pressurized to expand the membrane and press the polishing pad down on the top surface of the workpiece, such that the polishing pad conforms to the surface and applies a substantially uniform pressure distribution across the workpiece and thereby uniformly removes material across high and low spots on the workpiece.

Abstract: A multi-station polish system and process for polishing thin, flat (planar) and rigid workpieces. Workpieces are conveyed through multiple polishing stations that include a bulk material removal belt polishing station and finishing rotary polishing station. The bulk of the material is relatively quickly removed at the bulk removal station using a conformable abrasive belt and the workpiece surface is then polished to the desired finish at the finishing station using a conformable annular rotary polishing pad.

Abstract: A plate suitable for positioning with an extruder apparatus is provided in which the plate includes at least one temperature sensor. The plate is upstream of the die located at or near the end of the extruder apparatus. The sensor(s) allow for the simultaneous measurement of batch material temperatures at multiple spatial locations across the face of the plate. The temperature sensors associated with the plate can be used to identify spatial and temporal temperature patterns within the batch flow.

Abstract: Methods and apparatus provide for: a base on which a substrate may be releasably coupled; a moving belt located with respect to the base such that a contact surface thereof is operable to remove material from a top surface of the substrate; and a plurality of actuators, at least two of which are independently controllable, located with respect to the base and the moving belt such that a corresponding plurality of pressure zones are defined to provide pressure between the moving belt and the top surface of the substrate.

Abstract: Methods and apparatus provide for: a base on which a substrate may be releasably coupled; a moving belt located with respect to the base such that a contact surface thereof is operable to remove material from a top surface of the substrate; and a plurality of actuators, at least two of which are independently controllable, located with respect to the base and the moving belt such that a corresponding plurality of pressure zones are defined to provide pressure between the moving belt and the top surface of the substrate.

Abstract: A method of assembling a catalytic converter comprising a ceramic catalyst substrate supported by a compressed resilient mat within a metal shell comprising the steps of: (1) providing a slave enclosure exhibiting a predetermined shape that substantially matches the shape of the ceramic substrate; (2) providing a layer of resilient supporting mat material on the inner surface of the enclosure; (3) mechanically pre-compressing the encircling mat layer against the inner surface of the slave enclosure; (4) inserting the substrate into the slave enclosure while retaining the encircling mat layer against the inner surface and without further compressing the mat layer; and (5) transferring the substrate and mat layer into the metal shell.

Abstract: A method of assembling a catalytic converter comprising the steps of: (1) providing a metal shell exhibiting a predetermined shape that substantially matches the shape of the ceramic substrate; (2) inserting into the metal shell a sufficient amount of a resilient supporting mat material to form a encircling mat layer; (3) compressing the encircling mat layer to an initial gap bulk density, the initial gap bulk density being higher than the final gap bulk density; (4) releasing the compression-on the mat layer and prior to the mat layer reaching its final gap bulk density, inserting at least a portion of the substrate into the encircling mat layered metal shell and then allowing the mat layer to further release until the mat layer is compressed against the ceramic substrate at the final predetermined gap bulk density.

Abstract: A method of assembling a catalytic converter comprising the steps of: (1) providing a metal shell exhibiting a predetermined shape that substantially matches the shape of the ceramic substrate; (2) inserting into the metal shell a sufficient amount of a resilient supporting mat material to form a encircling mat layer; (3) compressing the encircling mat layer to an initial gap bulk density, the initial gap bulk density being higher than the final gap bulk density; (4) releasing the compression on the mat layer and prior to the mat layer reaching its final gap bulk density, inserting at least a portion of the substrate into the encircling mat layered metal shell and then allowing the mat layer to further release until the mat layer is compressed against the ceramic substrate at the final predetermined gap bulk density.

Abstract: A method of assembling a catalytic converter comprising a ceramic catalyst substrate supported by a compressed resilient mat within a metal shell comprising the steps of: (1) providing a slave enclosure exhibiting a predetermined shape that substantially matches the shape of the ceramic substrate; (2) providing a layer of resilient supporting mat material on the inner surface of the enclosure; (3) mechanically pre-compressing the encircling mat layer against the inner surface of the slave enclosure; (4) inserting the substrate into the slave enclosure while retaining the encircling mat layer against the inner surface and without further compressing the mat layer; and (5) transferring the substrate and mat layer into the metal shell.