Honeycomb Patents (Class 264/177.12)
  • Publication number: 20080131654
    Abstract: A product made from an extruded sheet or web of material having a non-linear cross-section, and the process of making the product is provided. The extruded web or extrudate is plastically deformed in selected areas and then folded. When folded into the appropriate shape, the extrudate is formed into a product having a plurality of cells. Optionally, the cells can include one or more openings, allowing access to an interior of the cell and reducing the weight of the product.
    Type: Application
    Filed: December 5, 2006
    Publication date: June 5, 2008
    Applicant: BRADFORD COMPANY
    Inventors: Judson A. Bradford, Calvin D. Nyeboer
  • Publication number: 20080116601
    Abstract: A molded body treating apparatus includes a support, at least one flat plate and a first movement mechanism. The support is configured to support a honeycomb molded body which has a first end portion and a second end portion in a longitudinal direction of the honeycomb molded body and which includes a plurality of cells each extending along the longitudinal direction from a first end at the first end portion to a second end at the second end portion. Either the first end or the second end of each of the plurality of cells is sealed with a plug material paste. The first movement mechanism is configured to move the at least one flat plate along the longitudinal direction to press the either one of the first and second end portions.
    Type: Application
    Filed: May 10, 2007
    Publication date: May 22, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazuya Naruse, Syuhei Hayakawa
  • Patent number: 7366340
    Abstract: A method and system for inspecting a honeycomb structure having a plurality of parallel channels includes aligning the honeycomb structure with an image sensing device such that the channels of the honeycomb structure are tilted with respect to the parallel channels of the honeycomb structure. An image of the honeycomb structure is then acquired. The image is processed in order to determine the perpendicularity of the end surface of the honeycomb structure.
    Type: Grant
    Filed: June 22, 2004
    Date of Patent: April 29, 2008
    Assignee: Reflect Scientific (DBA) Miralogix
    Inventor: Brian Smithgall
  • Publication number: 20080006964
    Abstract: Ceramic honeycomb structure bodies are produced by using a die composed of ceramic batch supplying holes through which a ceramic batch is supplied and slit grooves through which the ceramic batch is extruded and shaped in a honeycomb structure shape. In a method of producing such a die, hardening is performed onto at least a slit groove formation surface of a die member in order to form a hardening treated film on the slit groove formation surface of the die member. After the completion of the hardening process, plural slit grooves are formed in the slit groove formation surface of the die member. A hardness of the hardening treated film of the die member is not less than 1.5 times of a hardness of the die member.
    Type: Application
    Filed: June 26, 2007
    Publication date: January 10, 2008
    Applicant: DENSO CORPORATION
    Inventor: Hitoshi Kanmura
  • Patent number: 7294301
    Abstract: A method for forming honeycomb structures, such as wall-flow honeycomb filters, which utilizes extrusion of multiple material supplies at once. Such methods may be used to form intermittent plugs or other structures in the cell channels during the extrusion process, for example. A die assembly is provided which includes secondary feedholes machined in the pins for intermittently or periodically injecting secondary material (e.g., plug material) into the cell channels of the honeycomb structure while it is being extruded.
    Type: Grant
    Filed: June 14, 2005
    Date of Patent: November 13, 2007
    Assignee: Corning Incorporated
    Inventors: Thierry Luc Alain Dannoux, Michael Fischer, Thomas Dale Ketcham, Kenneth Richard Miller, Robert John Paisley
  • Patent number: 7294304
    Abstract: There is disclosed a die for forming a honeycomb structure and a method of manufacturing the honeycomb structure by use of the die, in which variations of cell pitches are suppressed in a central portion and the vicinity of an outer periphery after drying and firing an extruded honeycomb structure, and the honeycomb structure having a uniform cell pitch can be manufactured. A die 1 for forming a honeycomb structure has a front surface provided with groovy slits 2 formed between cell blocks 3 and a back surface provided with back holes 4a communicating with the slits 2. The die 1 has a structure in which a pitch P of the adjacent cell blocks 3 is enlarged from a central portion of the front surface toward an outer periphery in a stepwise manner.
    Type: Grant
    Filed: November 8, 2005
    Date of Patent: November 13, 2007
    Assignee: NGK Insulators, Ltd.
    Inventors: Yukihisa Wada, Tomohiro Iida, Jiro Maeda
  • Publication number: 20070235895
    Abstract: A molded body cutting apparatus according to the present invention comprising a first conveyer member that conveys an extrusion-molded pillar-shaped ceramic molded body a cutting member that moves in a direction parallel to a movement direction of the above mentioned first conveyer member while moving also in a vertical direction, and cuts the above mentioned ceramic molded body to a predetermined length by passing through the interior of the above mentioned ceramic molded body and a second conveyer member that conveys a cut ceramic molded body cut to a predetermined length by the above mentioned cutting member, wherein a conveyance speed of the above mentioned first conveyer member and a movement speed of the above mentioned cutting member in the above mentioned parallel direction are almost the same, before the above mentioned ceramic molded body is cut, and each of the conveyance speed of the above mentioned first conveyer member, the movement speed of the above mentioned cutting member in the above mentio
    Type: Application
    Filed: April 6, 2007
    Publication date: October 11, 2007
    Applicant: IBIDEN CO., LTD.
    Inventors: Norihiko Yamamura, Kazuya Naruse, Eiji Sumiya
  • Patent number: 7276194
    Abstract: A method is provided for manufacturing a thin-walled honeycomb ceramic substrate by extruding a plasticized ceramic batch material through a filter screen having wedge shaped filter wires to remove foreign particulate and agglomerated batch material. The filter wires are supported by a set of support wires attached substantially perpendicular to the filter wires. The support wires are may also be advantageously wedge shaped. The filter screen of the present invention may have a wear resistant layer at the surface of the screen, typically a boride or a nitride. The wear resistant coating may also be a nickel-based coating.
    Type: Grant
    Filed: August 29, 2003
    Date of Patent: October 2, 2007
    Assignee: Corning Incorporated
    Inventor: Mark A Shalkey
  • Patent number: 7208108
    Abstract: A method for producing a porous ceramic article involves a step of kneading raw materials including a raw material for a ceramic and a processing aid, to prepare a body, a step of forming the body, to prepare a ceramic formed product, a step of drying the formed product, to prepare a ceramic dried article, and a step of firing the ceramic dried article, to preparing a porous ceramic article, characterized in that the processing aid is a starch having been subjected to a crosslinking treatment or a material comprising a starch having been subjected to a crosslinking treatment and a foamed resin. The method allows the production of a porous ceramic article which is suppressed in the deformation during drying and is excellent in dimensional accuracy.
    Type: Grant
    Filed: December 6, 2002
    Date of Patent: April 24, 2007
    Assignee: NGK Insulators, Ltd.
    Inventors: Aiko Otsuka, Shuichi Ichikawa, Takashi Harada
  • Patent number: 7169341
    Abstract: A process is provided for producing extruded honeycomb bodies with passages, in particular as catalyst carrier bodies for the cleaning of exhaust gas from an internal combustion engine. The passages are bounded by wall regions which are at least partly provided with structures. The honeycomb body is extruded with an extrusion die in such a way that an additional relative movement between the honeycomb body and the extrusion die takes place, leading to a deformation of the wall regions of the passages. An extrusion die for producing extruded honeycomb bodies includes a multiplicity of secured profiled pins and a housing, which together form an extrusion mask. The extrusion mask is variable during the production process, so that wall regions with the structures can be formed. Honeycomb bodies which have structures in the interior that are suitable for influencing a stream of fluid flowing through can therefore be produced in a manner which is simple in terms of production engineering.
    Type: Grant
    Filed: September 3, 2003
    Date of Patent: January 30, 2007
    Assignee: Emitec Gesellschaft fuer Emissionstechnologie mbH
    Inventors: Rolf Brück, Wolfgang Maus
  • Patent number: 7163389
    Abstract: An extrusion die for extrusion molding of a honeycomb structure has back holes for introducing a raw material to be molded and slits for extruding the raw material. The extrusion die comprises an inside section, an outer peripheral section, and an outermost peripheral section; the width of the slit 14 disposed in the outer peripheral section is wider than the width of the slit disposed in the inside section; and when the surface roughness (Ra) of the slits in the inside section and the outer peripheral section is 0.1 ?m or smaller, or when the surface roughness (Ra) of the slits in the inside section and the outer peripheral section exceeds 0.1 ?m, the relationship between the surface roughness a of slit in the inside section and the surface roughness b of slit in the outer peripheral section satisfies the condition that 0.1<a/b<10.
    Type: Grant
    Filed: August 28, 2002
    Date of Patent: January 16, 2007
    Assignee: NGK Insulators, Ltd.
    Inventors: Makoto Miyazaki, Koji Okada
  • Patent number: 7162787
    Abstract: A honeycomb extrusion die includes an inlet face having a plurality of feed channels, and a discharge face having an array of intersecting honeycomb discharge slots. The extrusion die also includes a bonded array of pin elements each exposed on the discharge face of the die and juxtaposed to form the discharge slots of the discharge face and the array of feed channels, wherein the discharge slots extend from the feed channels, and wherein the feed channels communicate with the discharge slots so as to guide an extrudable material toward the discharge face. Each pin element includes a plurality of discharge slot surfaces, a plurality of feed channel surfaces continuous with the discharge slot surfaces for guiding the extrudable material toward the discharge face, and a plurality of spacing surfaces for spacing each pin element from adjacent pin elements.
    Type: Grant
    Filed: April 6, 2004
    Date of Patent: January 16, 2007
    Assignee: Corning Incorporated
    Inventor: Rodney I. Frost
  • Patent number: 7001442
    Abstract: There is provided a particulate filter for trapping particulates contained in an exhaust gas discharged from a combustion chamber of an engine, comprising a plurality of exhaust gas flow passages each formed by three porous partitions extending substantially parallel with each other, each of the exhaust gas flow passages having a triangular cross section, wherein the partitions defining one of the adjacent exhaust gas flow passages are deformed at one end area of the filter so that the partitions at one end area of the filter approach each other toward one of the ends of the filter, the deformed portions of the partitions are connected to each other at their ends, thereby an opening of one of the adjacent exhaust gas flow passages is at least partially closed, the partitions defining the other exhaust gas flow passage are deformed at the other end area of the filter so that the partitions at the other end area of the filter approach each other toward the other end of the filter, and the deformed portions of t
    Type: Grant
    Filed: June 16, 2003
    Date of Patent: February 21, 2006
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Koichiro Nakatani, Haruo Ooishi, Shuji Watanabe, Shinya Hirota
  • Patent number: 6991448
    Abstract: An extrusion apparatus which satisfactorily adjusts differences in skin-body flow rates at multiple locations around the die, and allows for the external manipulation of the interior components controlling batch flow, during the production without having to stop manufacturing operations to effect the necessary changes thereat.
    Type: Grant
    Filed: April 1, 2003
    Date of Patent: January 31, 2006
    Assignee: Corning Incorporated
    Inventor: Robert B. Lubberts
  • Patent number: 6991450
    Abstract: Honeycomb structures are formed at reduced extrusion pressures and high extrusion rates via extrusion through open cavity honeycomb extrusion dies incorporating large, closely spaced feed channels delivering extrudable material to die honeycomb forming sections incorporating extrudate distribution means in the form of inverted conical or pyramidal flow dividers incorporating inclined flow-guiding surfaces that guide the extrudate into the base ends of plural discharge slot intersections and/or slot segments in direct line with the feed channels.
    Type: Grant
    Filed: August 31, 2004
    Date of Patent: January 31, 2006
    Assignee: Corning Incorporated
    Inventor: Alan T. Stephens, II
  • Patent number: 6989119
    Abstract: Extruded honeycomb products are formed by means of an extrusion die incorporating a pin support section positioned between the die body and the pin array forming the die discharge slots, the pin support providing enlarged support segments that improve pin stability and die resistance to pin damage without overly restricting batch flow through the die.
    Type: Grant
    Filed: April 9, 2003
    Date of Patent: January 24, 2006
    Assignee: Corning Incorporated
    Inventors: James J. Bernas, David W. Folmar, Kenneth C. Sariego
  • Patent number: 6977043
    Abstract: Hollow fiber membranes having a skinned surface on one diameter, and a porous surface on the opposite diameter are produced from perfluorinated thermoplastic polymers by extruding a heated solution of the polymer having a low critical solution temperature directly into a cooling bath to form the porous membrane by liquid-liquid phase separation. Extrusion can be conducted either vertically or horizontally. The hollow fiber membranes are useful as ultrafiltration membranes and as membrane contactors.
    Type: Grant
    Filed: March 17, 2004
    Date of Patent: December 20, 2005
    Assignee: Mykrolis Corporation
    Inventors: Kwok-Shun Cheng, T. Dean Gates, Larry Y. Yen, Rajnikant B. Patel
  • Patent number: 6972045
    Abstract: A method of fabricating a substrate used for purifying an exhaust gas is provided. This method comprises the step of transforming a pre-mold having a first end, a second end, a plurality of partition walls extending between the first end and the second end, the first transforming step for transforming the end portions of the partition walls at the first end in such a manner that the ends of the partition walls defining one of two adjacent passages at the first end of the pre-mold are collected toward the center of a corresponding passage and connected to each other, and the second transforming step for transforming the ends of the partition walls at the first end in such a manner that the end surfaces of the partition walls at the first end are depressed toward the center of each of the end surfaces.
    Type: Grant
    Filed: September 8, 2003
    Date of Patent: December 6, 2005
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventor: Kazuhiro Itoh
  • Patent number: 6863705
    Abstract: A ceramic material containing organic binder is formed by extrusion, dried and cut off so as to make the honeycomb body 100 having the bulkheads 11 and a plurality of cells 12 partitioned by the bulkheads 11 and penetrating between both end faces of the honeycomb body 100. The tapered jig 3 having a tapered forward end portion 31 is inserted into the opening 13 of the cell 12 of the honeycomb body 100. Then, the bulkheads 11 are heated and softened and deformed by a pushing force given by the tapered jig 3 so that the opening 13 of the cell 12 is expanded to form the large opening 131, and the opening 13 of the adjoining cell 12 is reduced at the same time so as to form the small opening 132. After that, the honeycomb body 100 is fired. In this way, the exhaust gas purifying filter for collecting particulates is manufactured.
    Type: Grant
    Filed: August 21, 2002
    Date of Patent: March 8, 2005
    Assignee: Denso Corporation
    Inventors: Mikio Ishihara, Mamoru Nishimura
  • Patent number: 6814562
    Abstract: A honeycomb structure molding apparatus being free from defects in cells and having a higher strength with thin partition walls forming the cells and having a small cell density; and the apparatus having a plate-like spinneret provided with back pores for introducing a molding material and slits for extruding the molding material, and a press plate for fixing spinneret, the spinneret comprising an inner side and outer peripheral parts, the inner side part protruding downstream to form a level difference part therebetween, the press plate opening opposing the inner side part of the spinneret and presses the outer peripheral part of the spinneret downstream, and width W (mm) of slits, length L 1 (mm) of slits of the inner side part and length L 2 (mm) of slits of the outer peripheral part satisfying following two formulas: L1−L2≧0.4 mm L2≧0.015/W×L1.
    Type: Grant
    Filed: March 22, 2002
    Date of Patent: November 9, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Yukinari Shibagaki, Takeyuki Ishii, Yoshimasa Kondo
  • Patent number: 6803003
    Abstract: Methods for preparing fibrous monolith composite materials include continuously extruding cell and boundary material compositions. A filament is formed from a cell material composition and passed through a chamber of an extrusion assembly. A boundary material composition is extruded generally about the cell material composition filament and the two material compositions are co-extruded to form an extruded coated filament.
    Type: Grant
    Filed: December 4, 2001
    Date of Patent: October 12, 2004
    Assignee: Advanced Ceramics Research, Inc.
    Inventors: Mark J. Rigali, Manish P. Sutaria, Felix H. Gafner, Ronald A. Cipriani, Randy Egner, Randy C. Cook
  • Publication number: 20040195719
    Abstract: An apparatus for producing a honeycomb structure having an extruder, at least one cradle and a cutting device comprising a small-gage wire for cutting the honeycomb structure and a notching member; said cradle is provided with a means capable of moving the honeycomb structure extruded from the extruder in the lengthwise direction of the honeycomb structure at nearly the same speed as the extrusion speed of the honeycomb structure, said cutting device is constructed so that the cutting small-gage wire is moved to the honeycomb structure side on the same plane as the plane of stretched small-gage wire, a cutting induction groove is formed on the outer peripheral side surface of the honeycomb structure by the notching member, and immediately thereafter the cutting small-gage wire is positioned in the induction groove, and the cutting small-gage wire is pressed into the honeycomb structure to cut the honeycomb structure.
    Type: Application
    Filed: February 17, 2004
    Publication date: October 7, 2004
    Inventors: Takeyuki Ishii, Yuji Asai, Eiji Ito
  • Patent number: 6800233
    Abstract: An improvement in a process of making honeycomb articles, which process utilizes a co-rotating, intermeshing twin screw extrusion apparatus to mix, screen, and extrude a batch of ceramic materials through a die, the improvement which comprises the steps of separating the mixing and screening phase from the extrusion phase, by passing the batch through a first co-rotating, intermeshing twin screw extruder or a mixer extruder to mix and screen the batch, and then directly passing the mixed and screened batch through a second co-rotating, intermeshing twin screw extruder or a pumping extruder to extrude said batch through a die assembly to produce a honeycomb article.
    Type: Grant
    Filed: January 30, 2002
    Date of Patent: October 5, 2004
    Assignee: Corning Incorporated
    Inventors: Nancy A. Golomb, Christopher J. Malarkey
  • Patent number: 6786713
    Abstract: A honeycomb structure molding die that can mold a thin-walled honeycomb structure without degrading the moldability has been provided. A honeycomb structure molding die 8 comprises at least supply holes 81 to supply materials and slit grooves 82 that are communicated with the supply holes 81 and mold the materials into a honeycomb shape, wherein the groove width of the slit grooves 82 is not more than 100 &mgr;m and simultaneously, recesses 41 and protrusions 42 that extend in the direction in which the materials are extruded are provided on a pair of opposing side surfaces 820 of the slit grooves 82.
    Type: Grant
    Filed: April 26, 2002
    Date of Patent: September 7, 2004
    Assignee: Denso Corporation
    Inventors: Takeshi Fukushima, Akira Sasaki
  • Publication number: 20040164464
    Abstract: A device and method for correcting extrudate bowing in any direction to true “zero” magnitude. The bow deflector device includes a base having an aperture sufficiently large for a feed stream of plastic batch material to pass therethrough, and a plurality of adjustable plates movably mounted to the base, each adjustable plate being capable of independent movement, wherein by passing through the bow deflector device a unique flow velocity is superimposed on the feed stream of plastic batch material, as determined by the diameter of the aperture, and the position of the adjustable plates. The bow deflector device optionally includes a cover for the adjustable plates, securely mounted to the base. In an apparatus for extruding a honeycomb structure, the bow deflector device is positioned upstream a honeycomb die, such that a feed stream of plastic batch material passes through the bow deflector device prior to entering the die.
    Type: Application
    Filed: February 21, 2003
    Publication date: August 26, 2004
    Inventors: Robert B. Lubberts, Watson L. Robbins
  • Publication number: 20040161583
    Abstract: There is provided ceramic honeycomb body including a plurality of parallel cells defined by intersecting internal walls, and arranged in horizontal and vertical rows at and between opposing ends of the honeycomb body, an outer peripheral wall surrounding the cells, and further being interconnected to the internal walls, wherein the cells are divided into a first region including a portion of the cells adjacent the outer peripheral wall, and a second region including the remaining cells, wherein the cells in the first region have a wall thickness that is continuously increased along an axis extending to the outer peripheral wall, and, wherein fillets are formed at least at intersections between the interior walls in the first region of cells.
    Type: Application
    Filed: February 11, 2004
    Publication date: August 19, 2004
    Inventors: Thomas W. Brew, Mark L. Humphrey, Weiguo Miao, David R. Treacy
  • Publication number: 20040150133
    Abstract: Extruded honeycomb products are formed by means of an extrusion die incorporating a pin support section positioned between the die body and the pin array forming the die discharge slots, the pin support providing enlarged support segments that improve pin stability and die resistance to pin damage without overly restricting batch flow through the die.
    Type: Application
    Filed: April 9, 2003
    Publication date: August 5, 2004
    Inventors: James J. Bernas, David W. Folmar, Kenneth C. Sariego
  • Publication number: 20040131772
    Abstract: There are disclosed a method for plugging a cell of a honeycomb structure and a method for manufacturing a honeycomb plugged structure. By the methods, plug portion having arbitrary depth and/or shape can exactly and relatively easily be formed. There is disclosed the method for plugging cell 3 of a honeycomb structure 1 having a plurality of cells surrounded by partition walls and extending through an axial direction. In the method for plugging the cells of the honeycomb structure, plugging member 6 molded in predetermined shape is inserted into the cell 3, and the plugging member 6 is bonded to the peripheral partition walls 3 to form plug portions. There is also provided the method for manufacturing the honeycomb plugged structure, including the steps of: plugging at least a certain cells of the honeycomb structure by this plugging method.
    Type: Application
    Filed: October 29, 2003
    Publication date: July 8, 2004
    Applicant: NGK INSULATORS, LTD.
    Inventors: Toshio Yamada, Yasushi Noguchi
  • Publication number: 20040115392
    Abstract: A process for producing a formed honeycomb body, which comprises mixing, by a mixer, a raw material for forming a honeycomb body structure containing at least a ceramic raw material powder, a binder and water, to obtain a compounded mixture for forming a green body, and kneading and extruding the compounded mixture for forming a green body into a honeycomb shape by a continuous extruder, to obtain a formed honeycomb body, wherein there is added, to the raw material for forming a honeycomb body structure, a crushed green body obtained by crushing a green body having substantially the same composition as the compounded mixture for forming a green body, into the maximum particle diameter of 50 mm or smaller and the resulting mixture is mixed by a mixer to obtain a compounded mixture for forming a green body.
    Type: Application
    Filed: November 21, 2003
    Publication date: June 17, 2004
    Applicant: NGK INSULATORS, LTD.
    Inventors: Takashi Miyakawa, Satoru Inoue
  • Patent number: 6716512
    Abstract: A honeycomb structure having, in the axial direction, a number of through-channels separated by partition walls, which honeycomb structure contains refractory particles and a vitreous component and is porous. Although the honeycomb structure contains refractory particles such as silicon carbide particles or the like, it can be produced at a relatively low firing temperature; therefore, the honeycomb structure has a low production cost and a high yield and can be provided at a low price.
    Type: Grant
    Filed: September 14, 2001
    Date of Patent: April 6, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Yoshinori Yamamoto, Naomi Noda, Takashi Harada
  • Publication number: 20040051196
    Abstract: A method for producing a porous ceramic article involves a step of kneading raw materials including a raw material for a ceramic and a processing aid, to prepare a body, a step of forming the body, to prepare a ceramic formed product, a step of drying the formed product, to prepare a ceramic dried article, and a step of firing the ceramic dried article, to preparing a porous ceramic article, characterized in that the processing aid is a starch having been subjected to a crosslinking treatment or a material comprising a starch having been subjected to a crosslinking treatment and a foamed resin. The method allows the production of a porous ceramic article which is suppressed in the deformation during drying and is excellent in dimensional accuracy.
    Type: Application
    Filed: July 28, 2003
    Publication date: March 18, 2004
    Inventors: Aiko Otsuka, Shuichi Ichikawa, Takashi Harada
  • Publication number: 20040041296
    Abstract: A process is provided for producing extruded honeycomb bodies with passages, in particular as catalyst carrier bodies for the cleaning of exhaust gas from an internal combustion engine. The passages are bounded by wall regions which are at least partly provided with structures. The honeycomb body is extruded with an extrusion die in such a way that an additional relative movement between the honeycomb body and the extrusion die takes place, leading to a deformation of the wall regions of the passages. An extrusion die for producing extruded honeycomb bodies includes a multiplicity of secured profiled pins and a housing, which together form an extrusion mask. The extrusion mask is variable during the production process, so that wall regions with the structures can be formed. Honeycomb bodies which have structures in the interior that are suitable for influencing a stream of fluid flowing through can therefore be produced in a manner which is simple in terms of production engineering.
    Type: Application
    Filed: September 3, 2003
    Publication date: March 4, 2004
    Inventors: Rolf Bruck, Wolfgang Maus
  • Patent number: 6699559
    Abstract: An inorganic particulate, having strong absorption in the thermal infrared region of the radiative spectrum and low absorption in the solar or visible portion of the radiative spectrum, is combined with a plastic resin, to create a composite material. This composite is used in whole or in part to manufacture a honeycomb transparent insulation material, or is applied as a coating to a honeycomb transparent insulation material. The resulting honeycomb transparent insulation can have similar visible or solar light transmittance, and will have improved thermal radiant suppression relative to an identical honeycomb made of plastic resin only.
    Type: Grant
    Filed: July 19, 2002
    Date of Patent: March 2, 2004
    Assignee: Advanced Glazings Ltd.
    Inventor: Douglas I. Milburn
  • Patent number: 6641385
    Abstract: A metal mold for molding a hexagonal honeycomb structure, having feed holes for feeding a material, pool grooves formed in the shape of a triangular lattice and communicated with the feed holes, and slit grooves formed in the shape of a hexagonal lattice and communicated with the pool grooves. Each hexagonal lattice of the slit grooves is so formed as to come into agreement with a hexagon shaped by combining six triangular lattices of the pool grooves.
    Type: Grant
    Filed: June 24, 2002
    Date of Patent: November 4, 2003
    Assignee: Denso Corporation
    Inventors: Masayoshi Fujita, Mitsutoshi Miyazaki, Yosiyasu Andou
  • Publication number: 20030189269
    Abstract: A process for producing a honeycomb structure, which comprises adding, to a particulate ceramic raw material, a fatty acid salt-containing dispersing agent and at least water, kneading the mixture to obtain a puddle, and extruding the puddle, wherein the fatty acid salt constituting the dispersing agent comprises:
    Type: Application
    Filed: November 22, 2002
    Publication date: October 9, 2003
    Inventors: Kyoko Makino, Yoichi Ishibashi
  • Patent number: 6621034
    Abstract: The method includes the steps of preparing a die main body; performing batch supply hole machining with respect to one principal plane of the die main body to form batch supply holes; using a cutting apparatus to perform slit machining with respect to the other principal plane of the die main body to form slits; without removing the cutting apparatus from the die main body, continuously performing lateral hole machining to form the batch bold portions, which are arranged at least at intersecting portions in the die main body between the batch supply holes and the slits and are arranged corresponding to the slits; and there after removing the cutting apparatus from the die main body to thereby form an integral die. Alternatively, the above slit machining and continuously performing lacteral hole machining steps can be performed first and followed by performing the batch supply hole machining step.
    Type: Grant
    Filed: December 8, 2000
    Date of Patent: September 16, 2003
    Assignee: NGK Insulators, Ltd.
    Inventors: Yukinari Shibagaki, Yoshimasa Kondo, Takeyuki Ishii
  • Patent number: 6589465
    Abstract: The raw materials for forming a cordierite composition are dissolved into water with a dispersing agent to prepare a slurry, and the thus prepared slurry is passed through the sieve having a mesh of 45 &mgr;m or less. After that, the slurry after sieving is dried by means of the spray drying to obtain dry powders, and the batch for forming is obtained by using the dry powders. Or, the batch for forming is obtained by the filter pressing. That is to say, the batch for forming is obtained by using the raw material powders which are passed through the sieve in a wet state. Therefore, it is possible to prevent agglutination of the raw material particles and to remove the coarse raw material particles effectively. As a result, if the extrusion molding is performed by using the thus obtained batch for forming, it is possible to form the ceramic honeycomb structural body having an extremely thin wall thickness with no defects.
    Type: Grant
    Filed: January 17, 2002
    Date of Patent: July 8, 2003
    Assignee: NGK Insulators, Ltd.
    Inventors: Kazuhiko Kumazawa, Yasushi Noguchi
  • Publication number: 20030102602
    Abstract: A method and an apparatus for manufacturing a ceramic honeycomb molding having many cells formed by arranging cell walls in a honeycomb pattern. Deformation, wrinkles, cracks, etc., of the cell walls and the like are prevented from occurring. The method for manufacturing the ceramic honeycomb molding having many cells formed by arranging cells walls in a honeycomb pattern comprises an extruding process in which clayey honeycomb moldings 1 are extruded, a drying process in which the honeycomb moldings 1 are dried, and a storage process, between the extruding process and the drying process, in which the honeycomb moldings 1 are maintained in a high humidity atmosphere.
    Type: Application
    Filed: November 26, 2002
    Publication date: June 5, 2003
    Inventor: Yasunao Miura
  • Patent number: 6572357
    Abstract: An apparatus permits production of the complete monolithic cross flow trap module in a single extrusion process followed by firing to sinter the plasticized ceramic material and remove the plastics to achieve open porosity. Consequently, the trap modules can be made in large production quantities at minimal cost.
    Type: Grant
    Filed: February 27, 2001
    Date of Patent: June 3, 2003
    Assignee: Illinois Valley Holding Comany
    Inventor: John M. Bailey
  • Patent number: 6562284
    Abstract: 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: Grant
    Filed: December 19, 2001
    Date of Patent: May 13, 2003
    Assignee: Corning Incorporated
    Inventors: Douglas M. Beall, Gregory A. Merkel, Brian E. Stutts
  • Publication number: 20030057592
    Abstract: Apparatus and a method for extruding a honeycomb, providing correction in bowing of the extruded honeycomb structure, employs a deflector device having a base plate including an aperture aligned in a direction parallel to the extrusion axis through which the plastic material is conveyed to the die, the aperture having a varying diameter; and, a slide plate movably mounted to the base plate, the deflector device positioned upstream of the extrusion die, the degree of bow reduction depending on the diameter or width of the aperture imparting a pressure drop gradient on the flow stream entering the die.
    Type: Application
    Filed: September 27, 2001
    Publication date: March 27, 2003
    Inventors: Eugene C. Grover, Robert B. Lubberts, Richard D. Putt, Mary Ann Putt
  • Publication number: 20030021948
    Abstract: A honeycomb structure made of a silicon carbide-based porous body and having a number of through-holes extending in the axial direction, separated by partition walls.
    Type: Application
    Filed: August 12, 2002
    Publication date: January 30, 2003
    Inventors: Shuichi Ichikawa, Takahiro Tomita, Shinji Kawasaki, Hiroaki Sakai
  • Patent number: 6506336
    Abstract: 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: Grant
    Filed: August 31, 2000
    Date of Patent: January 14, 2003
    Assignee: Corning Incorporated
    Inventors: Douglas M. Beall, Gregory A. Merkel
  • Publication number: 20020187303
    Abstract: A honeycomb formed body is obtained by subjecting a mixture of a raw material powder and a forming binder to extrusion, wherein the forming binder is a mixture of a wax and a thermoplastic resin and the mixing ratio of the thermoplastic resin in the forming binder is 5 to 50% by weight. A honeycomb formed body having a partition wall as thin as 25 to 100 &mgr;m can be mass-produced efficiently without generating cracks or deforming the die of extruder.
    Type: Application
    Filed: March 7, 2002
    Publication date: December 12, 2002
    Inventors: Shigeki Kato, Sadaaki Hirai, Takayuki Kawae
  • Publication number: 20020185776
    Abstract: A honeycomb structure molding apparatus being free from defects in cells and having a higher strength with thin partition walls forming the cells and having a small cell density; and the apparatus having a plate-like spinneret provided with back pores for introducing a molding material and slits for extruding the molding material, and a press plate for fixing spinneret, the spinneret comprising an inner side and outer peripheral parts, the inner side part protruding downstream to form a level difference part therebetween, the press plate opening opposing the inner side part of the spinneret and presses the outer peripheral part of the spinneret downstream, and width W (mm) of slits, length L 1 (mm) of slits of the inner side part and length L 2 (mm) of slits of the outer peripheral part satisfying following two formulas:
    Type: Application
    Filed: March 22, 2002
    Publication date: December 12, 2002
    Applicant: NGK Insulators, Ltd.
    Inventors: Yukinari Shibagaki, Takeyuki Ishii, Yoshimasa Kondo
  • Publication number: 20020180119
    Abstract: The raw materials for forming a cordierite composition are dissolved into water with a dispersing agent to prepare a slurry, and the thus prepared slurry is passed through the sieve having a mesh of 45 &mgr;m or less. After that, the slurry after sieving is dried by means of the spray drying to obtain dry powders, and the batch for forming is obtained by using the dry powders. Or, the batch for forming is obtained by the filter pressing. That is to say, the batch for forming is obtained by using the raw material powders which are passed through the sieve in a wet state. Therefore, it is possible to prevent agglutination of the raw material particles and to remove the coarse raw material particles effectively. As a result, if the extrusion molding is performed by using the thus obtained batch for forming, it is possible to form the ceramic honeycomb structural body having an extremely thin wall thickness with no defects.
    Type: Application
    Filed: January 17, 2002
    Publication date: December 5, 2002
    Inventors: Kazuhiko Kumazawa, Yasushi Noguchi
  • Publication number: 20020167102
    Abstract: In a method of producing a ceramic molding 8 having a desired shape by extruding a ceramic material 80 pressure-fed into a resistance pipe 3 from a mold 4 by using a production apparatus including a screw type extruder 10 and the mold 4 connected to the distal end of the extruder 10 through the resistance pipe 3, the ceramic material 80 pressure-fed from the extruder 10 into the resistance pipe 3 is heated or cooled from round the periphery of the resistance pipe 3 so as to control the shape of the ceramic molding 8 extruded from the mold 4.
    Type: Application
    Filed: July 1, 2002
    Publication date: November 14, 2002
    Applicant: Denso Corporation
    Inventors: Satoru Yamaguchi, Hiromi Katou, Nobutoshi Matsui
  • Publication number: 20020130447
    Abstract: 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: Application
    Filed: December 19, 2001
    Publication date: September 19, 2002
    Inventors: Douglas M. Beall, Gregory A. Merkel, Brian E. Stutts
  • Publication number: 20020121726
    Abstract: The flow regulation portion includes a diameter reducing portion, a cylinder portion and a diameter expanding portion arranged from an upstream side, wherein: (1) an inlet shape of the diameter reducing portion at a side of the biaxial screw portion is equal to an outlet shape of the biaxial screw portion; (2) an outlet shape of the diameter reducing portion at a side of the cylinder portion is equal to an inlet shape of the cylinder portion; (3) an inlet shape of the diameter expanding portion at a side of the cylinder portion is equal to an outlet shape of the cylinder portion; and (4) an outlet shape of the diameter expanding portion at a side of the foreign substance removal portion is equal to an inlet shape of the foreign substance removal portion. The flow regulation portion is formed by a cassette mechanism, thereby reducing a maintenance cost and a delivery date.
    Type: Application
    Filed: February 26, 2002
    Publication date: September 5, 2002
    Applicant: NGK Insulators, Ltd.
    Inventors: Satoru Inoue, Kenji Yamada
  • Patent number: 6432341
    Abstract: A method of producing a ceramic molding having a desired shape involves extruding a ceramic material that has been pressure-fed into a resistance pipe. By using a production apparatus including a screw type extruder and mold, connected to the distal end of the extruder through the resistance pipe, the ceramic material is pressure-fed from the extruder into the resistance pipe. The resistance pipe is heated or cooled at its periphery so as to control the shape of the ceramic molding extruded from the mold.
    Type: Grant
    Filed: February 24, 2000
    Date of Patent: August 13, 2002
    Assignee: Denso Corporation
    Inventors: Satoru Yamaguchi, Hiromi Katou, Nobutoshi Matsui