Abstract: A structure made predominately of an NZP-type phase having the general formula RxZ4P6−ySiyO24, where 0≦x≦8, 0≦y≦6, R is Li, Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Y, and/or lanthanides, and Z is Zr, Ti, Nb, Ta, Y, and/or lanthanidess, and optionally a sintering additive. The structure has an open porosity of at least 20% by volume, median pore diameter in micrometers of at least a value defined by the quantity [10−0.10(% open porosity)], both as measured by mercury porosimetry, and four-point modulus of rupture as measured on a solid rod of circular cross section, of at least 300 psi. Method of making the structure involves forming a mixture of NZP-forming raw material powders that are metal oxide sources capable of reacting to form an NZP-type reaction product, and/or pre-reacted powder having the above general formula.

Abstract: The present invention provides a production process of a hexagonal honeycomb structure having low deformation of hexagonal cells. This process comprises an extrusion step for obtaining moldings (7) in which partitions (71) are provided in the form of a hexagonal matrix by extrusion molding of a mixed raw material using a horizontal extruder having an extrusion die provided with slits in the form of a hexagonal matrix and in which the direction of extruding is substantially the horizontal direction, a drying step for drying moldings (7), and a baking step for baking moldings (7). The extrusion step is performed such that c axis (700) parallel to two parallel sides (702) and (705) of the six sides (701) through (706) of each hexagon formed by partitions (71) of extruded moldings (7) is substantially vertical relative to the horizontal plane.

Abstract: An extrusion die for forming a cellular honeycomb structure having a finned protrusion extending from at least one cell wall of the honeycomb structure. The extrusion die is a composite extrusion die that comprises a primary extrusion die body having an inlet face and an outlet face, and at least a first insert member that is secured into a first intersection formed by a pair of intersecting slots at the outlet face of the primary extrusion die body. More preferably, a plurality of insert members are secured into a plurality of intersections, each intersection being formed by a pair of intersecting slots and each of the intersections being defined by four pegs/pins at the outlet face of the primary extrusion die body.

Abstract: A die for extruding ceramic honeycomb structural bodies, have a plurality of ceramic batch discharge slits, a plurality of ceramic batch supply holes communicated with the ceramic batch discharge slits, and a plurality of pipes fitted into at least some of the ceramic batch holes. In the die, the pipes are inserted into the ceramic batch supply holes in such a manner that tip portions of the pipes are located apart from bottom portions of the ceramic batch supply holes.

Abstract: A silicon nitride porous body which is a body having a generally columnar outer shape and at least two through-holes mutually parallel to one another and which has generally perpendicularly oriented columnar crystals on the surface of the through-holes.

Abstract: The present invention provides a production process of a hexagonal honeycomb structure having low deformation of hexagonal cells. This process comprises an extrusion step for obtaining moldings (7) in which partitions (71) are provided in the form of a hexagonal matrix by extrusion molding of a mixed raw material using a horizontal extruder having an extrusion die provided with slits in the form of a hexagonal matrix and in which the direction of extruding is substantially the horizontal direction, a drying step for drying moldings (7), and a baking step for baking moldings (7). The extrusion step is performed such that c axis (700) parallel to two parallel sides (702) and (705) of the six sides (701) through (706) of each hexagon formed by partitions (71) of extruded moldings (7) is substantially vertical relative to the horizontal plane.

Abstract: Honeycomb extrusion dies for the extrusion of honeycomb ceramics of high cell density and reduced cell wall thickness are machined from fully consolidated powder metallurgy (P/M) stainless steels, providing dies with reduced feed hole roughness, improved feed hole straightness, and superior discharge slot finish, with the result that significantly enhanced extrusion performance and higher quality honeycomb extrusions are realized.

Abstract: A honeycomb extrusion die comprising a die body incorporating an inlet face, a discharge face opposite the inlet face, a plurality of feedholes extending from the inlet face into the body, and an array of intersecting discharge slots extending into the body from the discharge face and interconnecting with the feed holes, the intersecting discharge slots being formed by the side surfaces of a plurality of pins bounded by the slots and extending into the die body from the discharge face, wherein a plurality of the pins include one or more multi-textured side surfaces, each side surface including at least two surface regions differing in surface finish from each other.

Abstract: A plasticizable raw material mixture for use in preparing a substrate having cordierite as its primary phase with the mixture comprised of a chemical composition, percent by weight, of 11 to 17% MgO, 33 to 41% Al2O3 and, 46 to 53% SiO2. The raw material mixture specifically comprises the following: (1) one source of Al2O3 and SiO2 comprising a clay mixture having less than about 22%, by weight based on the total raw materials in the plasticizable mixture, of calcined clay; (2) an alumina yielding precursor comprising alumina having an average particle diameter of about 1 &mgr;m or less; and, (3) at least one source of magnesia having an average particle diameter of between about 3 to 15 microns.

Abstract: A method for manufacturing a honeycomb structure having slits, which permits accurate forming of fine slits to cut or grind a targeted cell array alone and moreover is suitable for application to mass production, is to be provided. It is a method for manufacturing a honeycomb structure having slits and a plurality of arrays of numerous cells aligned in parallel; the slits communicating with external space and being formed along the arrays. Slits 5 are formed by protruding a slit forming member 4 toward a molded article 3 during the step of extruding the honeycomb structure.

Abstract: A die for manufacturing honeycomb bodies includes; a die main body having batch supply holes which are opened to a backside surface of the die, slit channels which are communicated with the batch supply holes and are opened to a foreside surface of the die and a taper worked portion which is formed by working an outer peripheral portion of the foreside surface of the die in a taper manner; and a control plate arranged at a portion opposed to the taper worked portion. In the die having the construction mentioned above, slit channel expanding portions are formed at open ends of the slit channels existing in the taper worked portion in such a manner that the slit channel is expanded gradually toward the open end.

Abstract: There is provided a process for obtaining a cordierite honeycomb structural body with thin cell walls and no molding defects such as cell breakage or the like. Cell breakage is prevented by limiting the maximum particle size of the cordierite starting material powder to no greater than 85% of the slit width of the extrusion molding die so that the starting material particles will not clog inside the slits or the introduction port of the slits. As one cordierite starting material, talc with a mean particle size of 5 &mgr;m or greater is used to give a honeycomb structural body with a void volume of greater than 30%, for production of a honeycomb structural body, with good moldability, having a small thickness and a low heat capacity. It is preferred to add to the starting material at least a lubricant/humectant, a binder and/or a mixture of a water-soluble polyhydric alcohol derivative and a polyhydric alcohol.

Abstract: A binder system for use in the formation of ceramic or other powder-formed greenware including a binder, a solvent for the binder, a surfactant, and a component that is non-solvent with respect to the binder and solvent. The non-solvent component exhibits a lower viscosity than the solvent when containing the binder and includes a low molecular weight oil having a 90% recovered distillation temperature range of between about 220 to 400° C. Also disclosed is a process of forming and shaping plasticized powder mixtures and a process for forming ceramic articles utilizing the binder system.

Abstract: The invention relates to an extrusion die for the manufacture of monolithic adsorption tubes having a solid body portion with a multiplicity of tunnels for the passage of gas. The die comprises a multiplicity of rods positioned within an outer cylindrical housing and oriented parallel thereto. The rods are supported near the entrance end of the housing, by at least two sets of ribs, each set of ribs arranged in a geometric pattern and oriented perpendicular to the cylindrical housing. The rods provide the form for tunnels in the extruded monolithic adsorption tube.

Abstract: A honeycomb extrusion die 1 for extruding a honeycomb structural body, having: a plurality of intersecting slits 2 arranged in a front surface thereof, each of the slits 2 being formed by cell blocks 3; a plurality of raw material feeding holes 4 arranged in a back surface thereof, each of the raw material feeding holes 4 being communicated with the slits 2; and a round portion formed in corners 3a of each of the cell blocks 3; is disclosed. In the honeycomb extrusion die 1, each of the cell blocks 3 includes, a cell block body 11, a first coating layer 12 formed by electroless plating on the cell block body 11, and a second coating layer 13 formed by chemical vapor deposition on the first coating layer 12, and a width of each of the slits is 45-120 &mgr;m.

Abstract: A rigid or semi-rigid plastics sheet material comprises a pair of opposed faces (20,22) between which run elongate voids defined by interconnections (24,25) between the two opposite faces, the cross sectional shape of at least some of the voids being a polygon with more than four sides, preferably a repeating pattern of regular hexagons or octagons joined in a line at adjacent sides or apices and including triangular secondary voids therebetween. Advantages include higher strength, lighter weight and faster cooling during the extrusion process.