Honeycomb Patents (Class 264/177.12)
  • Patent number: 10472289
    Abstract: A method for firing a ceramic honeycomb body including heating a green ceramic honeycomb body from a first temperature to a second temperature at a first heating rate and at a first oxygen level. Then, the green ceramic honeycomb body is heated from the second temperature to a third temperature at a second heating rate and at a second oxygen level. In this firing schedule, the second heating rate is greater than the first heating rate, and the second oxygen level is greater than the first oxygen level. Further, oxygen is introduced into the kiln to increase an oxygen level of the kiln from the first oxygen level to the second oxygen level near a peak of organic volatile release.
    Type: Grant
    Filed: May 3, 2016
    Date of Patent: November 12, 2019
    Assignee: Corning Incorporated
    Inventor: Douglas Richard Wing
  • Patent number: 10358821
    Abstract: The present disclosure generally relates to thermoplastic truss structures and methods of forming the same. The truss structures are formed using thermoplastic materials, such as fiber reinforced thermoplastic resins, and facilitate directional load support based on the shape of the truss structure. In one example, multiple two-dimensional patterns of fiber reinforced thermoplastic resin are disposed on one another in a saw tooth pattern, sinusoidal pattern, or other repeating pattern, and adhered to one another in selective locations. The two dimensional patterns may then be expanded in a third dimension to form a three-dimensional, cross-linked truss structure. The three-dimensional, cross-linked truss structure may then be heated or otherwise treated to maintain the three-dimensional shape.
    Type: Grant
    Filed: March 2, 2015
    Date of Patent: July 23, 2019
    Assignee: THE BOEING COMPANY
    Inventors: Matthew Howard Cawthorne, Christopher Eliot Wummer, Danielle Raiko Craig
  • Patent number: 10328376
    Abstract: A plugged honeycomb structure in which in a cross section of a honeycomb structure body which is perpendicular to an extending direction of cells, inflow cells are disposed to surround an outflow cell, and the number of the inflow cells is larger than the number of the outflow cells, and the cross section has a plurality of intersecting portions of partition walls each defining the inflow cells which are adjacent to each other, and in 60% or more of a total number of the intersecting portions, a relation between a diameter (D1) of a circle inscribed in the intersecting portion and a diameter (D0) of a circle inscribed in the partition wall defining the inflow cell and the outflow cell which are adjacent to each other satisfies D1/(?2×D0)=1.20 to 1.
    Type: Grant
    Filed: March 28, 2017
    Date of Patent: June 25, 2019
    Assignee: NGK Insulators, Ltd.
    Inventors: Yuichi Hamazaki, Takahiro Kondo
  • Patent number: 10301222
    Abstract: Disclosed herein are methods for preparing a titanate compound powder comprising titanate compound particles having a controlled particle size and/or particle size distribution. The methods include mixing at least one first inorganic compound chosen from sources of a first metal or metal oxide, at least one second inorganic compound chosen from sources of titania, and at least one binder to form a mixture; calcining the mixture to form a polycrystalline material comprising a plurality of titanate compound grains and a plurality of microcracks; and breaking the polycrystalline material along at least a portion of the microcracks. Also disclosed are titanate compound powders having a controlled particle size distribution, ceramic batch compositions comprising the powders, and ceramic articles prepared from the batch compositions.
    Type: Grant
    Filed: November 18, 2015
    Date of Patent: May 28, 2019
    Assignee: Corning Incorporated
    Inventors: Monika Backhaus-Ricoult, Robert John Locker, Huthavahana Kuchibhotla Sarma, Patrick David Tepesch
  • Patent number: 10145805
    Abstract: An inspection apparatus and method to automatically inspect ceramic honeycomb bodies during the manufacturing thereof. The apparatus includes a light source to shine light through channels of the ceramic honeycomb body, a lens to receive at least a portion of the light transmitted through channels of the ceramic honeycomb body, a camera to capture images of the transmitted light, a support chuck to support the honeycomb body, and a controller to receive the captured images, to analyze each captured image, to adjust the support chuck and/or the lens based on the analysis, and to align the ceramic honeycomb body channels and the lens optical axis.
    Type: Grant
    Filed: November 19, 2015
    Date of Patent: December 4, 2018
    Assignee: Corning Incorporated
    Inventors: Alan Russell Stanford, Eric Daniel Treacy, Lei Wang
  • Patent number: 9782723
    Abstract: A catalyst converter includes: a substrate (1) having a cell structure formed of a center area (1A) having the highest cell density, a peripheral area (1C) having the lowest cell density, and an intermediate area (1B) having the cell density between that of the center area and that of the peripheral area; a first catalyst layer formed in the center area (1A); a second catalyst layer formed in the intermediate area (1B); and a third catalyst layer formed in the peripheral area (1C). A length in a longitudinal direction of the second catalyst layer is longer than that of the first catalyst layer. A length in the longitudinal direction of the third catalyst layer is longer than that of the second catalyst layer. A ratio of the length in the longitudinal direction of the first catalyst layer to the length of the substrate is 65% or more.
    Type: Grant
    Filed: March 20, 2014
    Date of Patent: October 10, 2017
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yuki Aoki, Hiromasa Suzuki, Hiroyuki Matsubara
  • Patent number: 9757675
    Abstract: A partial wall-flow filter has an inlet end, an outlet end, and a plurality of parallel channels disposed and configured to flow fluid from the inlet end to the outlet end. The channels are defined by a plurality of porous walls. A first portion of the channels have a first hydraulic diameter Dh1, a second portion of the channels have a second hydraulic diameter Dh2 smaller than the first hydraulic diameter Dh1, and the ratio of Dh1:Dh2 is in the range of 1.1 to 1.6. At least a portion of channels having hydraulic diameter Dh1 are plugged at the outlet end, and channels having hydraulic diameter Dh2 are flow-through channels.
    Type: Grant
    Filed: January 23, 2014
    Date of Patent: September 12, 2017
    Assignee: Corning Incorporated
    Inventors: Suhao He, Achim Karl-Erich Heibel, Pushkar Tandon
  • Patent number: 9700820
    Abstract: A plurality of inlet-side octagonal cells and outlet-side quadrangular cells partitioned by partition walls on an upper surface and a lower surface are opened in a green honeycomb molded body in which a plurality of through-holes partitioned from each other by the partition walls are open in an end surface of a columnar body. Four outlet-side quadrangular cells having a smaller opening area adjoin around one inlet-side octagonal cell through the partition walls. The partition walls are joined together and the inlet-side octagonal cells are opened while closing the outlet-side quadrangular cells on the inlet side and the outlet-side quadrangular cells are opened while closing the inlet-side octagonal cells on the outlet side in a particulate-matter-removing filter such as a diesel particulate filter.
    Type: Grant
    Filed: April 11, 2016
    Date of Patent: July 11, 2017
    Assignee: Sumitomo Chemical Company, Limited
    Inventors: Hiroyuki Ikawa, Masahi Inoue, Teruo Komori
  • Patent number: 9663408
    Abstract: In a cross section of a honeycomb structure body, shape of the cells is polygonal, and the honeycomb structure body is constituted so that thickness of partition walls in circumferential region is larger than in central region. In the cross section, when among the cells arranged on a first line segment passing the center of gravity and extending in a direction perpendicular to the partition walls each constituting one side of the cells, cell pitch of the respective five or less cells each arranged on the first line segment toward each of the central region side and the circumferential region side from boundary between the central region and the circumferential region has a size of 70% or more and 95% or less to cell pitch in the extending direction of the first line segment of the cells in the central region of the honeycomb structure.
    Type: Grant
    Filed: September 22, 2014
    Date of Patent: May 30, 2017
    Assignee: NGK Insulators, Ltd.
    Inventors: Yasushi Kato, Takahiro Kondo
  • Patent number: 9630145
    Abstract: A catalyst converter includes: a substrate (1) having a cell structure formed of a center area (1A) having the highest cell density, a peripheral area (1C) having the lowest cell density, and an intermediate area (1B) having the cell density between that of the center area and that of the peripheral area; a first catalyst layer formed in the center area (1A); a second catalyst layer formed in the intermediate area (1B); and a third catalyst layer formed in the peripheral area (1C). A length in a longitudinal direction of the second catalyst layer is longer than that of the first catalyst layer. A length in the longitudinal direction of the third catalyst layer is longer than that of the second catalyst layer. A ratio of the length in the longitudinal direction of the first catalyst layer to the length of the substrate is 65% or more.
    Type: Grant
    Filed: March 20, 2014
    Date of Patent: April 25, 2017
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yuki Aoki, Hiromasa Suzuki, Hiroyuki Matsubara
  • Patent number: 9586339
    Abstract: A method comprising: a) determining the bow (28) in the extension direction of one or more linear paths on an outer surface or outer surfaces (11,13,14,16) of an extruded ceramic part (10) so that maximum extrusion direction bow (28) of the one of more linear paths or outer surfaces (11,13,14,16) may be determined of the extruded ceramic greenware part (10); b) identifying the linear path on the outer surface or the outer surfaces (11,13,14,16) having maximum convex bow; c) placing the greenware part (10) on a carrier with the linear path on the outer surface or the outer surface location having the maximum convex shape in contact with the carrier; and d) processing the greenware part (10) while disposed on the carrier with the linear path on the outer surface or the surface having the convex shape on the carrier, such that the bow (28) is reduced as a result of the process.
    Type: Grant
    Filed: August 23, 2012
    Date of Patent: March 7, 2017
    Assignee: Dow Global Technologies LLC
    Inventors: Myron J. Maurer, Joshua R. Weyburne
  • Patent number: 9486794
    Abstract: A die has two surfaces, in a forming material supplying surface which is one surface, a plurality of back holes to introduce a forming material of a honeycomb formed body into the die are formed, and in a honeycomb formed body extruding surface which is the other surface, lattice-shaped slits corresponding to cell partition walls are formed, the back holes communicate with the slits in slit intersecting portions of the slits, polygonal cell blocks defined by the slits include chamfered portions in which parts of corner portions and the like are chamfered at a chamfering angle ? of 1.0 to 8.0° to the extruding direction, from the honeycomb formed body extruding surface toward a slit depth direction, and straight portions which are not chamfered, and a ratio of a length L of the straight portion to a slit depth D is from 20 to 60%.
    Type: Grant
    Filed: October 16, 2015
    Date of Patent: November 8, 2016
    Assignee: NGK Insulators, Ltd.
    Inventors: Takehiko Watanabe, Seiichiro Hayashi, Kazuhiko Hamatsuka
  • Patent number: 9465050
    Abstract: An assembling method for a vertical probe device includes steps of disposing a lower die on a jig by inserting supporting columns through jig holes of the lower die, fastening a positioning film on the supporting columns, installing probe needles and an upper die in a way that the positioning film is located between the upper and lower dies without contacting the upper die, unfastening the positioning film, and removing the jig so that the upper and lower dies, positioning film and probe needles constitute the device. A maintaining method for the device includes steps of inserting the supporting columns through the jig holes, fastening the positioning film to the jig, and removing the upper die. The probe needles and upper die are easily removed and installed and the probe needles are reliable. The vertical probe device is applicable for accommodating electronic components on the top thereof.
    Type: Grant
    Filed: March 10, 2015
    Date of Patent: October 11, 2016
    Assignee: MPI CORPORATION
    Inventors: Tsung-Yi Chen, Horng-Kuang Fan, Ching-Hung Yang, Chung-Tse Lee, Chia-Yuan Kuo, Tien-Chia Li, Ting-Ju Wu
  • Patent number: 9393716
    Abstract: Disclosed apparatus and method to extrude a honeycomb, providing correction in bowing of the extruded honeycomb structure, employs a deflector device having a base plate including an opening aligned in a direction parallel to the extrusion axis through which the plastic material is conveyed to the die. The deflector device includes a bow plate movably mounted to the downstream or upstream side of the base plate. The bow plate includes a constant area aperture. The deflector device positioned upstream of extrusion die imparts a degree of bow reduction by the position of the constant area aperture over the opening imparting a pressure drop gradient on the flow stream entering the die.
    Type: Grant
    Filed: October 23, 2013
    Date of Patent: July 19, 2016
    Assignee: Corning Incorporated
    Inventors: Kevin John Beecher, Jeffrey Owen Foster, Gilbert Franklin Gordon, III, Kevin Bruce Sterner, David Robertson Treacy, Jr.
  • Patent number: 9375862
    Abstract: The manufacturing method of the honeycomb structure includes a forming step of a honeycomb formed body with non-fired electrodes where there is performed twice a non-fired electrode forming operation in which an electrode paste is attached to a plate including a printing screen, a side surface of a honeycomb formed body, the side surface being a curved side surface, is brought into a pressed state by a squeegee via the printing screen of the plate, in the state, the body is rotated and the plate is linearly moved along the side surface of the body, and the squeegee allows the electrode paste to permeate the printing screen and coat the side surface of the body; and a forming step of the honeycomb structure where the body with the non-fired electrodes is fired to obtain the honeycomb structure.
    Type: Grant
    Filed: August 17, 2012
    Date of Patent: June 28, 2016
    Assignee: NGK Insulators, Ltd.
    Inventors: Shinya Yoshida, Shuhei Fujita, Toru Ogawa
  • Patent number: 9095993
    Abstract: The extrusion-molding device of the invention is for producing a green honeycomb molded body with a cell structure, and the device includes a housing, a screw, a die with slits, a resistance tube and a fragmenting board having through-passages through which a raw material composition passes from the upstream end side to the downstream end side. The through-passages of the fragmenting board have upstream channels composed of a plurality of flow passages extending downstream from the upstream end side, and downstream channels extending up to the downstream end side and having flow passage cross-sectional shapes different from those of the upstream channels.
    Type: Grant
    Filed: April 27, 2012
    Date of Patent: August 4, 2015
    Assignee: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventors: Teruo Komori, Hajime Yoshino
  • Publication number: 20150108680
    Abstract: Disclosed apparatus and method to extrude a honeycomb, providing correction in bowing of the extruded honeycomb structure, employs a deflector device having a base plate including an opening aligned in a direction parallel to the extrusion axis through which the plastic material is conveyed to the die. The deflector device includes a bow plate movably mounted to the downstream or upstream side of the base plate. The bow plate includes a constant area aperture. The deflector device positioned upstream of extrusion die imparts a degree of bow reduction by the position of the constant area aperture over the opening imparting a pressure drop gradient on the flow stream entering the die.
    Type: Application
    Filed: October 23, 2013
    Publication date: April 23, 2015
    Applicant: Corning Incorporated
    Inventors: Kevin John Beecher, Jeffrey Owen Foster, Gilbert Franklin Gordon, III, Kevin Bruce Sterner, David Roobertson Treacy, JR.
  • Publication number: 20150099620
    Abstract: A parallel passage fluid contactor structure for chemical reaction processes has one or more segments, where each segment has a plurality of substantially parallel fluid flow passages oriented in an axial direction; cell walls between each adjacent fluid flow passages and each cell wall has at least two opposite cell wall surfaces. The structure also includes at least one active compound in the cell walls and multiple axially continuous conductive filaments either embedded within the cell walls or situated between the cell wall surfaces. The conductive filaments are at least one of thermally and electrically conductive, are oriented in axially, and are in direct contact with the active compound, and are operable to transfer thermal energy between the active material and the conductive filaments. Heating of the conductive filaments may be used to transfer heat to the active material in the cell walls. Methods of manufacturing the structure are discussed.
    Type: Application
    Filed: December 9, 2014
    Publication date: April 9, 2015
    Inventors: Andre BOULET, Soheil KHIAVI
  • Publication number: 20150028526
    Abstract: A composition which is suitable for extrusion molding comprises a) a ceramic-forming material, and b) a cellulose derivative that has a median particle length of from 110 to 300 micrometers. Advantageously a cellulose ether is used that has been obtained by providing a moist cellulose derivative having a moisture content of from 35 to 90 percent, based on the total weight of the moist cellulose derivative, and drying-grinding the moist cellulose derivative in a gas-swept impact mill to a median particle length of from 110 to 300 micrometers.
    Type: Application
    Filed: January 31, 2013
    Publication date: January 29, 2015
    Applicant: Dow Global Technologies LLC
    Inventors: Roland Bayer, Yvonne M. Goerlach-Doht, Juergen Hermanns
  • Patent number: 8914966
    Abstract: A die having large numbers of grooves for molding a material to a honeycomb structure, wherein a surface having the grooves has an outer periphery in a polygonal shape having 6 or more corners, and wherein the grooves are crossing the outer periphery at an angle of 30° or more.
    Type: Grant
    Filed: October 29, 2007
    Date of Patent: December 23, 2014
    Assignee: Hitachi Metals, Ltd.
    Inventors: Kazuyuki Kurakake, Tomohisa Ogata
  • Publication number: 20140333000
    Abstract: A ceramic honeycomb filter including a ceramic honeycomb structure having large numbers of flow paths partitioned by porous cell walls, and plugs disposed in the flow paths alternately on the exhaust gas inlet or outlet side, to remove particulate matter from an exhaust gas passing through the porous cell walls; the porous cell walls having porosity of 45-75%, the median pore diameter A (?m) of the cell walls measured by mercury porosimetry, and the median pore diameter B (?m) of the cell walls measured by a bubble point method meeting the formula of 35<(A?B)/B×100?70, and the maximum pore diameter of the cell walls measured by a bubble point method being 100 ?m or less.
    Type: Application
    Filed: July 24, 2014
    Publication date: November 13, 2014
    Applicant: HITACHI METALS, LTD.
    Inventors: Shunji OKAZAKI, Toshitaka ISHIZAWA
  • Patent number: 8864488
    Abstract: A honeycomb extrusion apparatus includes first and second vanes with respective first and second face portions. First and second axial widths of a circumferential feed area are respectively defined between the first and second face portions and the outer feed surface of the die body. In further examples, methods include the steps of selectively adjusting the first axial width and the second axial width of the circumferential feed area by respectively adjusting the first and second vane relative to the mask. In further examples, a honeycomb extrusion apparatus includes a plurality of mask segments that each includes an inner peripheral surface portion. Each of the plurality of mask segments are independently adjustable along a respective radial axis.
    Type: Grant
    Filed: May 8, 2012
    Date of Patent: October 21, 2014
    Assignee: Corning Incorporated
    Inventors: Thomas William Brew, Conor James Walsh
  • Patent number: 8864486
    Abstract: A twin screw extruder includes a barrel having a chamber, a discharge port, an extrusion molding die coupled to the discharge port of the barrel, axially extending first and second screw shafts, and a screw shaft support. The screw shaft support includes first and second spacer bearings disposed on the first and second screw shafts, and a first cross member including first and second loops slidably coupled to the first and second spacer bearings. A second cross member is spaced apart from the first cross member by a connection member, and also includes first and second loops slidably coupled to the first and second spacer bearings. The connection member is situated between the first spacer bearing and the second spacer bearing, and connected to the first cross member and the second cross member.
    Type: Grant
    Filed: March 15, 2013
    Date of Patent: October 21, 2014
    Assignee: Corning Incorporated
    Inventors: Matthew Joseph Dispenza, Christopher John Malarkey, Kenneth Charles Sariego
  • Patent number: 8851877
    Abstract: Provided is a die for extrusion forming for extrusion forming of a honeycomb formed body comprising a honeycomb forming die having a structure that there is provided at a surface a groove-like slit in a form of a cell block as well as there is provided at a backside a clay introduction hole in communication with the slit, and a frame-shaped presser plate that is disposed at an outer peripheral portion of the honeycomb forming die and that regulates a shape and dimension of a honeycomb formed body. Among the cell blocks, in an extrusion direction of forming clay, a cell block which end face is positioned to be overlapped with an inner circumferential surface of the presser plate is formed to be shorter than the other cell blocks resided inside the inner circumferential surface of the presser plate.
    Type: Grant
    Filed: July 28, 2009
    Date of Patent: October 7, 2014
    Assignee: NGK Insulators, Ltd.
    Inventor: Kazuhiko Hamatsuka
  • Patent number: 8813339
    Abstract: Multi-layered cellular metallic glass structures and methods of preparing the same are provided. In one embodiment, the cellular metallic glass structure includes at least one patterned metallic glass sheet and at least one additional sheet. The at least one patterned metallic glass sheet may include multiple sheets connected together to form a group of sheets, and the structure may include a group of sheets sandwiched between two outer sheets. The patterned metallic glass sheets may be patterned by thermoplastically forming two- and/or three-dimensional patterns in the metallic glass sheets.
    Type: Grant
    Filed: September 21, 2012
    Date of Patent: August 26, 2014
    Assignee: California Institute of Technology
    Inventors: Robert D. Conner, Marios D. Demetriou, LeRoy A. Dunning, William L. Johnson
  • Patent number: 8696962
    Abstract: A method of reducing the defects in ceramic articles and precursors, particularly ceramic articles and precursors made using a batch composition containing an oil phase material. The method includes increasing the concentration of a water insoluble soap in the batch composition, which can increase the cohesive strength of the oil phase, leading to a reduction in the incidence of defects in the ceramic articles and precursors.
    Type: Grant
    Filed: September 16, 2011
    Date of Patent: April 15, 2014
    Assignee: Corning Incorporated
    Inventor: Kevin Ying Chou
  • Patent number: 8668855
    Abstract: A product (10) made from an extruded sheet or web of material (42) having a non-linear cross-section, and the process of making the product (10) is provided. The extruded web or extrudate (42) is plastically deformed in selected areas and then folded. When folded into the appropriate shape, the extrudate (42) is formed into a product (10) having a plurality of cells (14). The cells (14a) may have one or more openings (34a), allowing access to an interior of the cell (14a) and reducing the weight of the product (10a).
    Type: Grant
    Filed: January 6, 2012
    Date of Patent: March 11, 2014
    Assignee: Bradford Company
    Inventor: Judson A. Bradford
  • Patent number: 8663523
    Abstract: A product 10 made from an extruded sheet or web of material 42 having a non-linear cross-section, and the process of making the product 10 is provided. The extruded web or extrudate 42 is plastically deformed in selected areas and then folded. When folded into the appropriate shape, the extrudate 42 is formed into a product 10 having a plurality of cells 14. Optionally, the cells 14a can include one or more openings 34a, allowing access to an interior of the cell 14a and reducing the weight of the product 10a.
    Type: Grant
    Filed: October 24, 2012
    Date of Patent: March 4, 2014
    Assignee: Bradford Company
    Inventors: Judson A. Bradford, Calvin D. Nyeboer
  • Publication number: 20140050812
    Abstract: The extrusion-molding device of the invention is for producing a green honeycomb molded body with a cell structure, and the device includes a housing, a screw, a die with slits, a resistance tube and a fragmenting board having through-passages through which a raw material composition passes from the upstream end side to the downstream end side. The through-passages of the fragmenting board have upstream channels composed of a plurality of flow passages extending downstream from the upstream end side, and downstream channels extending up to the downstream end side and having flow passage cross-sectional shapes different from those of the upstream channels.
    Type: Application
    Filed: April 27, 2012
    Publication date: February 20, 2014
    Applicant: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventors: Teruo Komori, Hajime Yoshino
  • Publication number: 20130300016
    Abstract: A honeycomb extrusion apparatus includes a die body and a mask defining a peripheral gap. The peripheral gap includes a first extrusion cross section at a first radial location relative to the extrusion axis and a second extrusion cross section at a second radial location relative to the extrusion axis. An overall flow area of the first extrusion cross section is less than an overall flow area of the second extrusion cross section. In further examples, methods include co-extruding a honeycomb body with an integral skin with the overall flow area of the first extrusion cross section being less than the overall flow area of the second extrusion cross section. In further examples, methods include compensating for different skin flow characteristics associated with a particular honeycomb network configuration of discharge slots in a die body.
    Type: Application
    Filed: May 8, 2012
    Publication date: November 14, 2013
    Inventors: Thomas William Brew, Timothy Michael Miller
  • Publication number: 20130300023
    Abstract: A honeycomb extrusion apparatus includes first and second vanes with respective first and second face portions. First and second axial widths of a circumferential feed area are respectively defined between the first and second face portions and the outer feed surface of the die body. In further examples, methods include the steps of selectively adjusting the first axial width and the second axial width of the circumferential feed area by respectively adjusting the first and second vane relative to the mask. In further examples, a honeycomb extrusion apparatus includes a plurality of mask segments that each includes an inner peripheral surface portion. Each of the plurality of mask segments are independently adjustable along a respective radial axis.
    Type: Application
    Filed: May 8, 2012
    Publication date: November 14, 2013
    Inventors: Thomas William Brew, Conor James Walsh
  • Patent number: 8556615
    Abstract: A die for forming a honeycomb structure, comprising a platy die base member having a clay supply face on back surface thereof and including a plurality of introduction holes for introducing a mixed raw material for forming; and a clay forming face on upper surface including a plurality of slits for extrusion of the material being connected to the introduction holes and formed lattice-like partition regions; at least a part of lattice-like partition regions being provided in such a position that the extended line of at least part of a plurality of lattice-like regions overlap with the slits at edges thereof as top view, slits including inner peripheral slits formed in the inner peripheral region, and outer peripheral slits formed in the outer peripheral region surrounding the inner peripheral region and having a width-enlarged portion having a width larger than that of the inner peripheral slit, and production method thereof.
    Type: Grant
    Filed: March 25, 2010
    Date of Patent: October 15, 2013
    Assignee: NGK Insulators, Ltd.
    Inventors: Seiichiro Hayashi, Tomoki Nagae, Masanari Iwade
  • Publication number: 20130207034
    Abstract: An absorbent structure for CO2 capture includes a honeycomb substrate having a plurality of partition walls extending in an axial direction from an inlet end to an outlet end thereby forming a plurality of flow channels. The honeycomb substrate comprises a powder component and a binder that are solidified. The absorbent structure also includes a functional mer group dispersed throughout the powder component of the partition walls of the honeycomb substrate. The functional mer group is positioned in and on the partition walls such that, when a gas stream containing CO2 flows in the flow channels from the inlet end to the outlet end, the functional mer group absorbs the CO2 by forming a coordinated bond that forms carbonate, bicarbonate, carbamates, or another coordinated or ionic compound with the CO2.
    Type: Application
    Filed: February 7, 2013
    Publication date: August 15, 2013
    Applicant: Corning Incorporated
    Inventor: Corning Incorporated
  • Patent number: 8491295
    Abstract: An extrusion apparatus including a die and a mask are provided such that no slots feed directly into the longitudinal skin forming gap between the mask and the die. In a method of forming a die adapted to improve skin uniformity of extruded cellular ceramic substrates a slotted block of die material is provided including central slots adapted to form a cellular matrix of the substrate and peripheral slots located outwardly of the central slots designed to be covered by a skin former mask and adapted to extrude peripheral batch material. An arcuate skin former is cut corresponding to a target shrinkage so as to intersect the slotted block such that skin flow from tangent slots at 90 degree positions of the die is limited to the peripheral batch material.
    Type: Grant
    Filed: May 25, 2010
    Date of Patent: July 23, 2013
    Assignee: Corning Incorporated
    Inventor: Michael James Lehman
  • Patent number: 8460589
    Abstract: A method for producing a ceramic honeycomb filter by immersing an end surface of a ceramic honeycomb structure having a lot of flow paths partitioned by cell walls in a plugging material slurry in a container to introduce the plugging material slurry into the predetermined flow paths to form plugs, and taking the ceramic honeycomb structure provided with the plugs out of the container horizontally.
    Type: Grant
    Filed: September 28, 2006
    Date of Patent: June 11, 2013
    Assignee: Hitachi Metals, Ltd.
    Inventor: Shinya Tokumaru
  • Patent number: 8449283
    Abstract: A die for forming an extrusion includes a die body, a body feed section and an extrusion forming section. The die body may include an inlet and an outlet defining an extrudate flow path through the die body. The body feed section may be positioned between the inlet and outlet and includes an arrangement of body feed channels. The extrusion forming section may be positioned between the body feed section and the outlet and includes a thin-wall forming portion fluidly coupled to at least one thick-wall forming portion. The thin-wall forming portion may include an array of pins extending from the body feed section towards the outlet and the thick-wall forming portion may include at least one baffle section positioned in the extrudate flow path through the thick-wall forming portion. The area of the thick-wall forming portion may be greater than an interstitial area between the pins.
    Type: Grant
    Filed: June 12, 2009
    Date of Patent: May 28, 2013
    Assignee: Corning Incorporated
    Inventors: Stephen Charles Currie, Mircea Despa, Paul Martin Elliott, Richard Curwood Peterson
  • Publication number: 20130099412
    Abstract: The extrusion-molding device of the invention includes a flow passage for transporting a paste raw material composition; a screw provided at an upstream side of the flow passage to knead the raw material composition and transport it to a downstream side; a die provided at a downstream side of the flow passage to extrude a molded body composed of the raw material composition therefrom; a resistive tube for connecting the flow passage and the die; and a current plate provided between the screw and the die. The current plate comprises a plurality of through-holes that penetrate from a upstream end side to a downstream end side, and an opening of the through-hole on the upstream end side has a larger open area than an opening on the downstream end side.
    Type: Application
    Filed: June 16, 2011
    Publication date: April 25, 2013
    Applicant: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventors: Teruo Komori, Hajime Yoshino
  • Patent number: 8419988
    Abstract: A method of producing a honeycomb structure includes producing a honeycomb structure using methyl cellulose as at least part of a binder, the methyl cellulose having a weight average molecular weight (Mw) of 4,000,000 to 5,000,000, and having an integral molecular weight distribution value of components having a molecular weight of 100,000 or less in the integral molecular weight distribution curve of 15 or less.
    Type: Grant
    Filed: January 28, 2010
    Date of Patent: April 16, 2013
    Assignee: NGK Insulators, Ltd.
    Inventors: Toshikazu Ito, Yasushi Noguchi
  • Patent number: 8398390
    Abstract: A die for forming the honeycomb structure includes: a plate-like die main body including an introducing portion provided on the side of one surface thereof and having a plurality of back holes and a forming portion provided on the side of the other surface thereof and having slits; and a back plate detachably attached to the surface of the introducing portion and having a plurality of through holes connected to the back holes of the introducing portion. Through hole opening portions of the through holes formed in the back plate in the one surface of the die main body have such an enlarging shape as to enlarge toward the one surface of the die main body. The die for forming the honeycomb structure can decrease the resistance of a forming material during extrusion.
    Type: Grant
    Filed: February 10, 2010
    Date of Patent: March 19, 2013
    Assignee: NGK Insulators, Ltd.
    Inventors: Seiichiro Hayashi, Takashi Matsukubo, Takao Saito
  • Patent number: 8371835
    Abstract: There is provided a mold for extrusion forming of ceramic articles which is excellent in wear resistance and can remarkably decrease forming defects in the vicinity of outer peripheries thereof. The mold for the extrusion forming of the ceramic articles includes a die 1 having a plurality of back holes 9, and slits 8; a back pressing plate 12 and a back spacer 13 to adjust the amount of the kneaded clay to be supplied; and a pressing plate 11 and a spacer 10 to regulate the shape and size of the formed ceramic article. At least a portion of the supply end 22 of the die 1 which overlaps with the back pressing plate 12 is flattened, and a surface roughness (Ra) thereof is in a range of 0.05 ?m to 10 ?m.
    Type: Grant
    Filed: January 12, 2009
    Date of Patent: February 12, 2013
    Assignee: NGK Insulators, Ltd.
    Inventors: Takao Saito, Teruyoshi Mori, Takehide Shimoda
  • Publication number: 20130019579
    Abstract: A ceramic honeycomb filter comprising a ceramic honeycomb structure having large numbers of flow paths partitioned by porous cell walls, and plugs disposed in the flow paths alternately on the exhaust gas inlet or outlet side, to remove particulate matter from an exhaust gas passing through the porous cell walls; the porous cell walls having porosity of 45-75%, the median pore diameter A (?m) of the cell walls measured by mercury porosimetry, and the median pore diameter B (?m) of the cell walls measured by a bubble point method meeting the formula of 35<(A?B)/B×100?70, and the maximum pore diameter of the cell walls measured by a bubble point method being 100 ?m or less.
    Type: Application
    Filed: March 30, 2011
    Publication date: January 24, 2013
    Applicant: HITACHI METALS, LTD.
    Inventors: Shunji Okazaki, Toshitaka Ishizawa
  • Patent number: 8353695
    Abstract: A joined article in which a first metal member made of a tungsten carbide base cemented carbide and a second metal member made of a martensitic stainless steel having a carbon equivalent of 2.5 to 3.5 and containing 0.030 mass % or less of sulfur are joined. The martensitic stainless steel having the carbon equivalent of 2.5 to 3.5 is preferably at least one selected from the group consisting of SUS431, SUS420J1, SUS420J2, SUS410, SUS410J1, S-STAR, PROVA-400, HPM38, STAVAX ESR, and SUS403 in the joined article. There is disclosed a joined article in which the lowering of the strength of a second metal member around a joining interface thereof is prevented.
    Type: Grant
    Filed: September 18, 2009
    Date of Patent: January 15, 2013
    Assignee: NGK Insulators, Ltd.
    Inventor: Hironori Takahashi
  • Patent number: 8298647
    Abstract: Multi-layered cellular metallic glass structures and methods of preparing the same are provided. In one embodiment, the cellular metallic glass structure includes at least one patterned metallic glass sheet and at least one additional sheet. The at least one patterned metallic glass sheet may include multiple sheets connected together to form a group of sheets, and the structure may include a group of sheets sandwiched between two outer sheets. The patterned metallic glass sheets may be patterned by thermoplastically forming two- and/or three-dimensional patterns in the metallic glass sheets.
    Type: Grant
    Filed: August 20, 2007
    Date of Patent: October 30, 2012
    Assignee: California Institute of Technology
    Inventors: Robert D. Conner, Marios D. Demetriou, LeRoy A. Dunning, William L. Johnson
  • Patent number: 8282385
    Abstract: A die comprising molding grooves arranged in a lattice pattern and moldable-material-supplying holes communicating with the molding grooves for molding a ceramic honeycomb structure, the molding grooves having width of 0.05-0.5 mm, the moldable-material-supplying holes being arranged in every intersecting portions of the molding grooves, or in every other intersecting portions of the molding grooves in a checkerboard pattern, and an average distance between the centers of the intersecting portions of the molding grooves, at which the moldable-material-supplying holes are arranged, and the center axes of the moldable-material-supplying holes being 10-100 ?m.
    Type: Grant
    Filed: March 18, 2009
    Date of Patent: October 9, 2012
    Assignee: Hitachi Metals, Ltd.
    Inventor: Tomohisa Ogata
  • Patent number: 8257629
    Abstract: A manufacturing method of a honeycomb structure that can improve a manufacturing efficiency and a raw material yield is provided. There is provided a manufacturing method of a honeycomb structure comprising: subjecting a raw material to extrusion forming to form a honeycomb formed body 100 having a partition wall that partitions a plurality of cells that serve as flow paths for a fluid and are extended from one end surface to the other end surface; forming a plurality of notches extended in a direction along which the cells are extended in the honeycomb formed body 100 to form a partial segment aggregate 120 in such a manner that a plurality of partial segments 3 are partitioned; and forming a buffer portion 5 between respective partial segments 3 adjacent to each other in the partial segment aggregate 120 to fill an entire space between the respective partial segments adjacent to each other, thereby obtaining a honeycomb structure 130.
    Type: Grant
    Filed: February 26, 2009
    Date of Patent: September 4, 2012
    Assignee: NGK Insulators, Ltd.
    Inventors: Yutaka Ogura, Satoshi Yamada, Hiroshi Kurachi
  • Patent number: 8257623
    Abstract: An extrusion die is processed to alter the flow of extrudable material through the die by collecting data reflecting flow variations across the face of the die, constructing a graded resistance flow restrictor utilizing the data, and forcing an abrasive machining medium through the flow restrictor and die with the flow restrictor being arranged to deliver higher abrasive flow through die portions initially exhibiting low extrusion rates, the resulting die being useful for the manufacture of ceramic honeycomb bodies exhibiting a reduced incidence of shape defects attributable to die flow variations.
    Type: Grant
    Filed: August 27, 2009
    Date of Patent: September 4, 2012
    Assignee: Corning Incorporated
    Inventors: John Charles Rector, David Robertson Treacy, Jr., Kevin Lee Wasson
  • Patent number: 8226400
    Abstract: A die for extrusion-forming a honeycomb structure which includes: a die base provided with ceramic puddle introducing holes and slits in communication with the ceramic puddle introducing holes; and a substrate layer, which roughly defines the final width of the slits, and a surface layer, which precisely defines the final width of the slits, formed on the die base in this order so that the final width of the slits becomes 15 to 200 ?m, wherein the surface layer is made up of tungsten carbide particles which are 5 ?m or less in average particle diameter and contain W3C as a main ingredient. According to this invention, there is provided a die for extrusion-forming a honeycomb structure which can restrain fluctuation in extrusion-forming speed among its parts and resistance to pushing force, both caused at the time of extrusion-forming, to be very small and is superior in productivity and durability.
    Type: Grant
    Filed: January 14, 2010
    Date of Patent: July 24, 2012
    Assignee: NGK Insulators, Ltd.
    Inventors: Susumu Matsuoka, Seiichi Inoue, Haremi Ito, Keiji Matsumoto
  • Patent number: 8216499
    Abstract: A structural filler is installed in a gap between at least first and second composite members by extruding a flowable filler material, placing the extruded filler on one of the composite structural members, and assembling the composite members.
    Type: Grant
    Filed: December 9, 2008
    Date of Patent: July 10, 2012
    Assignee: The Boeing Company
    Inventors: Travis J. Sherwood, Brian G. Robins, Darrell D. Jones, Joseph D. Brennan, Michael R. Anderson
  • Patent number: 8133422
    Abstract: A batch mixture including ceramic-forming ingredients, a pore former, a binder comprising an ammonium salt of an alkylated cellulose binder, and a liquid vehicle, as defined herein. Also disclosed is a method for producing a ceramic precursor article as defined herein having excellent extrusion properties.
    Type: Grant
    Filed: October 30, 2008
    Date of Patent: March 13, 2012
    Assignee: Corning Incorporated
    Inventors: Patricia Ann Beauseigneur, Kevin Ying Chou
  • Patent number: 8128395
    Abstract: A honeycomb segment-forming die includes: an introducing portion provided on an introduction face side and having a plurality of back holes, and a forming portion provided on an formation face side and having slits communicating with the back holes. The forming portion has a polygonal outer peripheral shape and forms a prismatic honeycomb segment by passing kneaded clay for forming which is introduced from the back holes of the introducing portion through the slits of the forming portion, and a gap between slits formed in each of corner portions including a vertex of the polygonal forming portion is larger than a gap of slits formed in the central portion of the forming portion. This enables to form a honeycomb segment having high compressive strength.
    Type: Grant
    Filed: November 12, 2009
    Date of Patent: March 6, 2012
    Assignee: NGK Insulators, Ltd.
    Inventors: Hiroyuki Shindo, Tomoki Nagae