Producing Honeycomb Shape Patents (Class 264/630)
  • Publication number: 20140363620
    Abstract: A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and a binder such that a raw material paste containing the titania particles, the alumina particles and the binder is prepared, forming a body made of the raw material paste and having the honeycomb structure, and sintering the body having the honeycomb structure such that a ceramic body having the honeycomb structure and made of aluminum titanate is formed. The titania particles are secondary titania particles each comprising primary titania particles aggregated such that the secondary titania particles have a mean volume particle diameter in the range of from 5 ?m to 20 ?m, and the alumina particles have a mean volume particle diameter in the range of from 2 ?m to 5 ?m.
    Type: Application
    Filed: August 22, 2014
    Publication date: December 11, 2014
    Applicant: IBIDEN CO., LTD.
    Inventor: Kazunori YAMAYOSE
  • Publication number: 20140363619
    Abstract: A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and a binder such that a raw material paste containing the titania particles, the alumina particles and the binder is prepared, forming a body made of the raw material paste and having the honeycomb structure, and sintering the body having the honeycomb structure such that a ceramic body having the honeycomb structure and made of aluminum titanate is formed. The kneading includes combining the binder, a titania powder containing the titania particles and an alumina powder containing the alumina particles, and the titania powder includes magnesium in an amount of 500 ppm or less with respect to the titania powder in a weight ratio based on conversion from MgO.
    Type: Application
    Filed: August 22, 2014
    Publication date: December 11, 2014
    Applicant: IBIDEN CO., LTD.
    Inventor: Kazunori YAMAYOSE
  • Publication number: 20140363617
    Abstract: A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and a binder such that a raw material paste containing the titania particles, the alumina particles and the binder is prepared, forming a body made of the raw material paste and having the honeycomb structure, and sintering the body having the honeycomb structure such that a ceramic body having the honeycomb structure and made of aluminum titanate is formed. The kneading includes combining the binder, a titania powder containing the titania particles and an alumina powder containing the alumina particles, and the titania powder includes sodium in an amount of from 200 ppm to 1,000 ppm with respect to the titania powder in a weight ratio based on conversion from Na2O.
    Type: Application
    Filed: August 22, 2014
    Publication date: December 11, 2014
    Applicant: IBIDEN CO., LTD.
    Inventor: Kazunori YAMAYOSE
  • Patent number: 8894916
    Abstract: A method for producing an aluminum-titanate-based ceramic honeycomb structure comprising blending TiO2 source powder and Al2O3 source powder with a TiO2/Al2O3 molar ratio of 45/55 to 55/45, and a sintering aid and/or a molding aid to prepare a moldable material, extrusion-molding the moldable material, and drying and sintering the resultant extrudate, the TiO2 source powder having a particle size distribution (mass-based frequency distribution relative to [log(particle size)]), in which both the maximum frequency in a particle size range of 0.2-4 ?m and the maximum frequency in a particle size range of 10-100 ?m are larger than those in other ranges than the two particle size ranges.
    Type: Grant
    Filed: December 25, 2007
    Date of Patent: November 25, 2014
    Assignee: Hitachi Metals, Ltd.
    Inventors: Hirohisa Suwabe, Masaru Yoshida, Tomomasa Kumagai
  • Patent number: 8894915
    Abstract: A honeycomb structure is made of cordierite and has a plurality of cells separated from each other by porous partition walls and functioning as fluid passages. The honeycomb structure has a thermal expansion coefficient of 0.25×10?6/° C. or less, an average pore diameter is 3 to 8 ?m, and a porosity of 25% or more. The honeycomb structure is made of cordierite excellent in thermal shock resistance even with large pore diameters and high porosity.
    Type: Grant
    Filed: August 21, 2008
    Date of Patent: November 25, 2014
    Assignee: NGK Insulators, Ltd.
    Inventor: Yoshiro Ono
  • Patent number: 8894895
    Abstract: This disclosure is directed to porous ceramic processing; and in particular to a method using selected pore forming materials to avoid high exotherms during the ceramic firing process, and the green bodies formed using the selected pore forming materials. The selected pore forming materials are homogeneous wax/non-ionic surfactant particles formed by a prilling process in which the wax is melted and the non-ionic surfactant is mixed into the wax prior to prilling. The disclosure is useful in the manufacture porous ceramic honeycomb bodies including ceramic honeycomb filter traps.
    Type: Grant
    Filed: May 18, 2011
    Date of Patent: November 25, 2014
    Assignee: Corning Incorporated
    Inventors: Michele Fredholm, David Henry, Maxime Moreno
  • Publication number: 20140319742
    Abstract: Skins and/or adhesive layers are formed on a porous ceramic honeycomb by applying a layer of a cement composition to a surface of the honeycomb and firing the cement composition. The cement composition contains a water-swellable clay, high aspect inorganic filler particles and water, and are nearly or completely devoid of particles smaller than 100 nm and a cellulosic polymer.
    Type: Application
    Filed: December 10, 2012
    Publication date: October 30, 2014
    Applicant: Dow Global Technologies LLC
    Inventors: Aleksander J. Pyzik, Sharon Allen, Peter C. Saucier
  • Publication number: 20140314988
    Abstract: A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and binder ingredient such that raw material paste including the titania particles, alumina particles and binder ingredient is prepared, forming a body made of the raw material paste and having a honeycomb structure such that the body has the honeycomb structure having through-holes extending in the longitudinal direction of the body and partition portions between the through-holes, positioning the body on a base such that one end surface of the body in the longitudinal direction faces the base and a space is formed between the base and the end surface of the body, and sintering under oxygen atmosphere the body on the base with the space between the base and the body such that a ceramic body having the honeycomb structure is formed on the base.
    Type: Application
    Filed: June 30, 2014
    Publication date: October 23, 2014
    Applicant: IBIDEN CO., LTD.
    Inventor: Kazunori YAMAYOSE
  • Publication number: 20140314987
    Abstract: A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and binder ingredient such that raw material paste including the titania particles, alumina particles and binder ingredient is prepared, forming a body made of the raw material paste and having a honeycomb structure such that the body has the honeycomb structure having through-holes extending in the longitudinal direction of the body and partition portions between the through-holes, positioning on a base having zirconia granules the body made of the raw material paste and having the honeycomb structure such that the zirconia are interposed between the body and the base, and sintering the body made of the raw material paste and having the honeycomb structure on the base with the zirconia granules interposed between the body and the base such that a ceramic body having the honeycomb structure is formed on the base with the zirconia granules.
    Type: Application
    Filed: June 30, 2014
    Publication date: October 23, 2014
    Applicant: IBIDEN CO., LTD.
    Inventor: Kazunori YAMAYOSE
  • Patent number: 8864914
    Abstract: A method for cleaning a ceramic component includes generating a computer solid model of a component, converting the computer solid model to a stereo-lithographic instruction file, and preparing the component in a stereo-lithography machine in response to the stereo-lithographic instruction file. The method further includes providing an amount of solvent, where a residue left from preparing the component is at least partially soluble in the solvent. The method includes immersing at least part of the component in the solvent, heating the solvent in a liquid state, and reducing a pressure of the solvent sufficiently to boil the solvent. The method further includes heat-curing the component.
    Type: Grant
    Filed: August 9, 2010
    Date of Patent: October 21, 2014
    Assignee: Rolls-Royce Corporation
    Inventor: Max Eric Schlienger
  • Patent number: 8865054
    Abstract: A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and binder such that raw material paste including the titania particles, the alumina particles and the binder is prepared, extruding the raw material paste through a die for forming a honeycomb structure such that a body made of the raw material paste and having the honeycomb structure is formed, supporting the body extruded from the die on a holder while moving the holder along extrusion direction at a moving speed relative to an extruding speed of the raw material based on a target diameter size set for the body such that the diameter of the body held by the holder changes to the target diameter size, and sintering the body having the honeycomb structure with the target diameter size such that a ceramic body having the honeycomb structure with the target diameter size is formed.
    Type: Grant
    Filed: April 29, 2013
    Date of Patent: October 21, 2014
    Assignee: Ibiden Co., Ltd.
    Inventor: Kazunori Yamayose
  • Patent number: 8852486
    Abstract: A molded discrete low stress gasket is constructed of restructured filled PTFE for use in corrosive or severe chemical environments under relatively low bolt loads. The gasket has a gasket surface and includes a raised outer sealing ring and a raised inner sealing ring. The gasket may constructed from a restructured filled PTFE material, with the sealing rings deforming at lower pressures than the remaining portions of the gasket.
    Type: Grant
    Filed: November 6, 2007
    Date of Patent: October 7, 2014
    Assignee: Garlock Sealing Technologies, LLC
    Inventors: T. Scott Tanner, Stefan Pitolaj
  • Publication number: 20140295132
    Abstract: A method for producing a ceramic honeycomb structure comprising a ceramic honeycomb body having large numbers of longitudinal cells partitioned by porous cell walls having porosity of 50% or more, and a peripheral wall formed on a peripheral surface of the ceramic honeycomb body, comprising the steps of extruding moldable ceramic material to form a honeycomb-structured ceramic green body; machining a peripheral portion of the green body or a sintered body obtained from the green body to remove part of cell walls in the peripheral portion to obtain a ceramic honeycomb body having longitudinal grooves on a peripheral surface; applying colloidal metal oxide to a peripheral surface of the ceramic honeycomb body and drying it, and then applying a coating material comprising ceramic aggregate having an average particle size of 1 ?m or more to form the peripheral wall.
    Type: Application
    Filed: October 9, 2012
    Publication date: October 2, 2014
    Inventor: Shunji Okazaki
  • Patent number: 8845952
    Abstract: A method of manufacturing a honeycomb structure including a honeycomb unit includes causing inorganic particles to contain water. The inorganic particles have a specific surface area of approximately 50 m2/g or more. Raw material paste for the honeycomb unit is prepared. The raw material paste includes a molding aid, water, and the inorganic particles containing water. The raw material paste is molded into a honeycomb molded body. The honeycomb molded body is fired to obtain the honeycomb unit. The honeycomb unit have a plurality of cells extending from a first end face to a second end face of the honeycomb unit along a longitudinal direction of the honeycomb unit and is separated by a plurality of cell walls.
    Type: Grant
    Filed: September 23, 2011
    Date of Patent: September 30, 2014
    Assignee: Ibiden Co., Ltd.
    Inventors: Yuki Fujita, Koichi Uemura
  • Patent number: 8834783
    Abstract: A molding apparatus for producing a ceramic molding comprising a material-flowing path, a molding die disposed at one end of the material-flowing path, and a pressurizing means for extrusion-molding the molding material; the material-flowing path comprising pluralities of porous plates for passing the molding material and a screen fixed therebetween, and a method for producing a ceramic molding using this apparatus.
    Type: Grant
    Filed: September 17, 2009
    Date of Patent: September 16, 2014
    Assignee: Hitachi Metals, Ltd.
    Inventor: Wataru Soga
  • Publication number: 20140252695
    Abstract: A method for firing a green honeycomb ceramic body in a kiln may include heating the green honeycomb ceramic body in four stages. The first stage may include heating the green honeycomb ceramic body from room temperature to a first temperature that at a first heating rate that is greater than or equal to about 75° C./hr. The second stage may include heating the green honeycomb ceramic body from the first temperature to a second temperature at a second heating rate that is less than or equal to the first heating rate. The third stage may include heating the green honeycomb ceramic body from the second temperature to a hold temperature at a third heating rate that is less than or equal to the first heating rate. The fourth stage may include holding the green honeycomb ceramic body at the hold temperature to remove residual carbon.
    Type: Application
    Filed: March 4, 2014
    Publication date: September 11, 2014
    Applicant: CORNING INCORPORATED
    Inventors: Douglas Munroe Beall, David Jack Bronfenbrenner, Margaret Kathleen Faber, Sriram Rangarajan Iyer, Patrick David Tepesch, Douglas Richard Wing
  • Publication number: 20140252694
    Abstract: There is provided a honeycomb structure including a honeycomb base material including a porous partition wall parent material; plugged portions; and a porous collecting layer disposed on the surface of the partition wall parent material in the remaining cells. A melting point of a material constituting the collecting layer is higher than that of a material constituting the partition wall parent material, a pore surface area per unit volume of the collecting layer is 2.0 times or more a pore surface area per unit volume of the partition wall parent material, and a thickness of a portion of the collecting layer which penetrates into pores of the partition wall parent material is 6% or smaller of that of each of partition walls including the partition wall parent material and the collecting layer.
    Type: Application
    Filed: May 20, 2014
    Publication date: September 11, 2014
    Applicant: NGK Insulators, Ltd.
    Inventor: Yoshio KIKUCHI
  • Patent number: 8821661
    Abstract: A method of manufacturing a honeycomb structure including a honeycomb unit includes forming a honeycomb molded body having a plurality of cells extending from a first end face to a second end face of the honeycomb molded body along a longitudinal direction of the honeycomb molded body and separated by a plurality of cell walls, placing the honeycomb molded body in a degreasing apparatus so that the first end face faces downward and the second end face faces upward, feeding introduced gas into the degreasing apparatus, degreasing the honeycomb molded body at a temperature of approximately 200° C. to approximately 400° C., and firing the degreased honeycomb molded body at a temperature of approximately 500° C. to approximately 900° C. to obtain the honeycomb unit.
    Type: Grant
    Filed: October 21, 2011
    Date of Patent: September 2, 2014
    Assignee: Ibiden Co., Ltd.
    Inventors: Yuji Haga, Yusuke Fujii, Tadafumi Ohashi
  • 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: 8808613
    Abstract: A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and binder ingredient such that raw material paste including the titania particles, alumina particles and binder ingredient is prepared, forming a body made of the raw material paste and having a honeycomb structure such that the body has the honeycomb structure having multiple through-holes extending in the longitudinal direction of the body and multiple partition portions formed between the through-holes, positioning on a base having granules the body made of the raw material paste and having the honeycomb structure such that the granules are interposed between the body and the base, and sintering the body made of the raw material paste and having the honeycomb structure on the base with the granules interposed between the body and the base such that a ceramic body having the honeycomb structure is formed on the base with the granules.
    Type: Grant
    Filed: May 6, 2013
    Date of Patent: August 19, 2014
    Assignee: Ibiden Co., Ltd.
    Inventor: Kazunori Yamayose
  • Patent number: 8747729
    Abstract: This invention provides a production method for a ceramic structure capable of making a extrusion rate coefficient, in extruding of a ceramic structure, greater than that of prior art technologies. In a production method for a ceramic structure by the steps of mixing and kneading a ceramic batch material containing at least ceramic powder and water, extruding the mixture so kneaded, and drying and sintering a resulting extrudate, a water-insoluble liquid lubricant consisting of acyl glycerin and/or a derivative is added to the ceramic batch material.
    Type: Grant
    Filed: December 22, 2009
    Date of Patent: June 10, 2014
    Assignee: Denso Corporation
    Inventor: Kazuhiro Inoguchi
  • Patent number: 8741209
    Abstract: A mixture for making a ceramic article includes a ceramic forming component, a liquid vehicle, a cellulosic binder, and a stabilizer comprising an acetate salt. The disclosure also provides a method of making the ceramic article including extruding the mixture to form a ceramic green body, drying the ceramic green body to remove at least a portion of the liquid vehicle, and optionally firing to form the ceramic article. The ceramic green body possesses excellent strength and excellent skin properties without increasing the organic load or the addition of hydrated clays.
    Type: Grant
    Filed: November 30, 2007
    Date of Patent: June 3, 2014
    Assignee: Corning Incorporated
    Inventor: Kevin Ying Chou
  • Publication number: 20140147673
    Abstract: An object of the invention is to provide a honeycomb structure that has excellent NOx purification performance and can suppress the breakage of a honeycomb unit due to the adsorption or desorption of water, a method for manufacturing the honeycomb structure, and an exhaust gas purifying apparatus including the honeycomb structure. In addition, the honeycomb structure of the invention includes a honeycomb unit provided with a plurality of through holes arrayed in a longitudinal direction with a partition wall therebetween, in which the honeycomb unit is produced by extruding and firing raw material paste containing silicoaluminophosphate particles and an inorganic binder, and the silicoaluminophosphate particles have a ratio of an amount of Si to a sum of amounts of Al and P in a range of 0.16 to 0.33, a specific surface area in a range of 200 m2/g to 400 m2/g, and an average diameter of original silicoaluminophosphate particles in a range of 2.0 ?m to 6.0 ?m.
    Type: Application
    Filed: August 18, 2011
    Publication date: May 29, 2014
    Applicant: IBIDEN CO., LTD.
    Inventors: Masafumi Kunieda, Yoshitoyo Nishio
  • Patent number: 8729436
    Abstract: A method and system for drying a honeycomb structure having an original liquid vehicle content includes exposing the honeycomb structure to a first electromagnetic radiation source until the liquid vehicle content is between about 20% and about 60% of the original liquid vehicle content, exposing the honeycomb structure to a second electromagnetic radiation source different from the first electromagnetic radiation source until the liquid vehicle content is between about 0% and about 30% of the original liquid vehicle content, and exposing the honeycomb structure to convection heating until the liquid vehicle content is between about 0% and about 30% of the original liquid vehicle content.
    Type: Grant
    Filed: May 28, 2009
    Date of Patent: May 20, 2014
    Assignee: Corning Incorporated
    Inventors: Paul Andreas Adrian, Rebecca Lynn Burt, James Anthony Feldman, Elizabeth Marie Vileno
  • Publication number: 20140117594
    Abstract: A ceramic precursor batch composition comprising inorganic ceramic-forming ingredients, a binder, an aqueous solvent and a heteroatom polyol agent. The heteroatom polyol agent can be represented by X(R) where X is at least one of S, N, and P, and R is at least two of CH3, CH2CH2OH, CH2CH2CH2OH, CH2(CHOH)CH3, C(CH2OH)1-3, CH2OH, CH(CH2OH)CHOH, C(O)(CHOH)1-4CH2OH, and CH2CH2CH2OCH3. The presence of the heteroatom polyol agent provides a composition with a lower viscosity and/or a greater batch stiffening temperature (Tonset) allowing for increased rates of extrusion. Methods for producing a ceramic honeycomb body using this ceramic precursor batch composition are also provided.
    Type: Application
    Filed: March 15, 2013
    Publication date: May 1, 2014
    Applicant: Corning Incorporated
    Inventor: Mark Alan Lewis
  • Patent number: 8673207
    Abstract: A porous ceramic honeycomb article comprising a honeycomb body formed from cordierite ceramic, wherein the honeycomb body has a porosity P %?55% and a cell channel density CD?150 cpsi. The porous channel walls have a wall thickness T, wherein (11+(300?CD)*0.03)?T?(8+(300?CD)*0.02), a median pore size ?20 microns, and a pore size distribution with a d-factor of ?0.35. The honeycomb body has a specific pore volume of VP?0.22. The porous ceramic honeycomb article exhibits a coated pressure drop increase of ?8 kPa at a flow rate of 26.5 cubic feet per minute when coated with 100 g/L of a washcoat catalyst and loaded with 5 g/L of soot.
    Type: Grant
    Filed: November 14, 2013
    Date of Patent: March 18, 2014
    Assignee: Corning Incorporated
    Inventors: Thorsten Rolf Boger, Weiguo Miao, Zhen Song, Jianguo Wang
  • Patent number: 8673206
    Abstract: Methods of extruding a honeycomb body with an extruder comprise the step of feeding batch material to the extruder, wherein the batch material comprises a ceramic or ceramic-forming material. The methods further include the step of rotating at least one mixing screw to cause the batch material to travel along a flow path defined by a barrel of the extruder. The methods further include the step of indexing a carriage to remove a first device from the flow path and introduce a second device into the flow path of the batch material. In one example, the pressure of the batch material changes less than about 25% as a result of indexing the carriage. In addition or alternatively, further methods include the step of reducing a decrease in temperature of the batch material resulting from the step of indexing. In further examples, the method includes the step of pre-filling a second honeycomb extrusion die held by the carriage with a plugging material.
    Type: Grant
    Filed: November 24, 2010
    Date of Patent: March 18, 2014
    Assignee: Corning Incorporated
    Inventors: James Frederick Avery, Ronald Alan Boyko, Daniel Wayne Corbett, Christopher John Malarkey, Kenneth Charles Sariego, David Robertson Treacy, Jr.
  • Publication number: 20140070466
    Abstract: There is disclosed a manufacturing method of a honeycomb structure including a formed honeycomb body preparing step of extruding a forming raw material containing a ceramic raw material and an organic binder, to prepare a formed honeycomb body having partition walls with which a plurality of cells are formed to define through channels of a fluid, and an outer peripheral wall; a dried honeycomb body preparing step of drying the formed honeycomb body; a honeycomb body with unfired electrodes preparing step of applying an electrode forming slurry containing a ceramic raw material and water to a side surface of the dried honeycomb body, and then maintaining the honeycomb body in a temperature range of 0 to 80° C. for three seconds to 48 hours to form the unfired electrodes; and a honeycomb structure preparing step of drying and firing the honeycomb body with the unfired electrodes.
    Type: Application
    Filed: September 5, 2013
    Publication date: March 13, 2014
    Applicant: NGK INSULATORS, LTD.
    Inventors: Yusuke HOSOI, Takashi NORO, Tsuyoshi WATANABE
  • Patent number: 8658550
    Abstract: An oxide-ceramic forming clay comprising an oxide-ceramic forming material, a layered double hydroxide, a pore-forming agent, and water, wherein the amount of the pore-forming agent is between 3 and 50 parts by mass by superaddition to 100 parts by mass of a sum of the oxide-ceramic forming material and the layered double hydroxide and a sum of the pore-forming agent and an organic binder is between 5 and 55 parts by mass also by superaddition which has environment-friendly characteristics in a forming firing step, and usage thereof.
    Type: Grant
    Filed: April 1, 2009
    Date of Patent: February 25, 2014
    Assignee: NGK Insulators, Ltd.
    Inventor: Takahiro Tomita
  • Publication number: 20140001683
    Abstract: A contour of an outer diameter dimension of a dried ceramic honeycomb body is measured in a first measuring portion Q1 and a second measuring portion Q2 of the surface of an outer wall of the dried ceramic honeycomb body; a total of absolute values of differences between respective values of four contours C1x, C1y, C2x and C1y measured at a first measurement point P1x and a second measurement point P1y of the first measuring portion Q1 and a third measurement point P2x and a fourth measurement point P2y of the second measuring portion Q2 is obtained; and one end surface and the other end surface are subjected to finishing step in a state where four measurement points of the outer wall, at which the total of the absolute values is minimum, are fixed by a first fixture and a second fixture.
    Type: Application
    Filed: June 10, 2013
    Publication date: January 2, 2014
    Inventor: Shigeki KATO
  • Patent number: 8617455
    Abstract: A method of forming a templated casting involves incorporating a liquid feedstock into the channels of a honeycomb substrate to form a feedstock-laden substrate, solidifying the liquid feedstock within the channels, and then locally melting and directionally re-solidifying the feedstock.
    Type: Grant
    Filed: May 28, 2009
    Date of Patent: December 31, 2013
    Assignee: Corning Incorporated
    Inventor: Prantik Mazumder
  • Publication number: 20130320600
    Abstract: A method for reducing shrinkage variability of aluminum titanate honeycombs includes preparing an aluminum titanate-forming batch material that includes least one alkaline earth carbonate having a particle size distribution. The particle size distribution of the at least one alkaline earth carbonate is selected based on the predicted shrinkage during sintering of the aluminum titanate honeycombs.
    Type: Application
    Filed: May 31, 2012
    Publication date: December 5, 2013
    Inventors: Daniel Edward McCauley, Patrick David Tepesch, Christopher John Warren, Jeffrey S. White
  • Patent number: 8591820
    Abstract: Particulate filters for reducing NOx and particulate matter in diesel exhaust and methods for forming the same are disclosed. In one embodiment, a particulate filter may include a honeycomb body with a plurality of channel walls extending from an inlet end to an outlet end. At least a first set of the channels are plugged proximate at least one of the inlet end or the outlet end. A filter zone may extend from the inlet end in an axial direction of the particulate filter. A DeNOx zone may be located downstream of the filter zone. The channel walls of the particulate filter may include a DeNOx functional catalyst in the DeNOx zone and a ratio of the permeability ?fz of the channel walls in the filter zone to the permeability ?Dz of the channel walls in the DeNOx zone (?fz:?Dz) is at least 2.
    Type: Grant
    Filed: March 11, 2011
    Date of Patent: November 26, 2013
    Assignee: Corning Incorporated
    Inventors: Thorsten Rolf Boger, Suhao He, Min Shen
  • Patent number: 8584375
    Abstract: The drying method performs drying the honeycomb formed article by such an arrangement that superheated steam or mixed gas of steam and hot air, temperature and humidity of which is regulated so that wet-bulb temperature thereof becomes 70° C. or higher, is made to pass through the cells of the honeycomb formed article. The drying apparatus includes a steam supply unit that supplies the superheated steam, a buffer chamber that aligns the superheated steam supplied from the steam supply unit, an upper chamber disposed above the buffer chamber to locate the honeycomb formed article, and a hood unit that recovers the superheated steam which has passed through the honeycomb formed article.
    Type: Grant
    Filed: September 2, 2009
    Date of Patent: November 19, 2013
    Assignee: NGK Insulators, Ltd.
    Inventors: Yasuhiro Horiba, Hiromi Shimada, Yohei Takemori, Shinzou Hayashi
  • Patent number: 8574386
    Abstract: A method for manufacturing a honeycomb structure includes molding a ceramic raw material to manufacture at least one honeycomb molded body having a plurality of cell walls extending along a longitudinal direction of the at least one honeycomb molded body to define cells. The honeycomb molded body is fired to manufacture a honeycomb fired body. A honeycomb block is manufactured by using the honeycomb fired body. The honeycomb fired body is cut before manufacturing the honeycomb block or the honeycomb block is cut after manufacturing the honeycomb block.
    Type: Grant
    Filed: February 12, 2009
    Date of Patent: November 5, 2013
    Assignee: Ibiden Co., Ltd.
    Inventor: Hiroki Sato
  • Publication number: 20130241120
    Abstract: The method for producing a fired body of the invention has the steps of: preparing a starting material mixture; molding the mixture to obtain a green molded body; a first heating step to make the molded body contain residual carbon-containing substances in a furnace by increasing the temperature of the furnace while introducing an oxygen containing gas; and a second heating step to obtain a fired body by further increasing the temperature of the furnace without introducing the oxygen containing gas; wherein the conditions for the first heating step are set so that when the molded body is allowed to stand after the first heating step in an oxygen-containing atmosphere at 900° C., the temperature at the center section of the molded body is at least 20° C. higher than the temperature of the atmosphere in the furnace.
    Type: Application
    Filed: October 25, 2011
    Publication date: September 19, 2013
    Applicant: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventors: Osamu Yamanishi, Keiichiro Suzuki
  • Publication number: 20130224431
    Abstract: Disclosed herein are methods for controlling and/or predicting the shrinkage and/or growth of a ceramic honeycomb structure between a green body state and a fired state by adjusting the hydrated alumina content of the batch composition. Also disclosed herein is substantially clay-free cordierite honeycombs produced in accordance with such methods.
    Type: Application
    Filed: February 19, 2013
    Publication date: August 29, 2013
    Inventors: David J. Bronfenbrenner, Michael James Lehman
  • Patent number: 8518855
    Abstract: A honeycomb structure includes aluminum titanate, cell walls, and pore portions. The cell walls extend along a longitudinal direction of the honeycomb structure to define cells between the cell walls. The pore portions have an average pore diameter of about 10 ?m to about 20 ?m. A length of a longest pore portion among the pore portions in a binary image including substrate portions and the pore portions is about 8 times or less of the average pore diameter. The binary image is converted from a microscopic image of a cross section of the cell walls in parallel with the longitudinal direction. The length is measured along a line drawn in a direction perpendicular to a thickness direction of the cell walls.
    Type: Grant
    Filed: April 8, 2010
    Date of Patent: August 27, 2013
    Assignee: Ibiden Co., Ltd.
    Inventors: Kazushige Ohno, Kazunori Yamayose
  • Patent number: 8518322
    Abstract: There is provided a method for manufacturing a honeycomb structure comprising the steps of: forming kneaded clay containing a forming mixture of cordierite-forming materials and an organic binder to manufacture a honeycomb formed article, and firing the honeycomb formed article. The forming mixture contains at least hydrophilic talc. The method enables to perform extrusion forming at a high rate even without raising an apparatus load in order to improve productivity and can provide a honeycomb structure.
    Type: Grant
    Filed: February 18, 2010
    Date of Patent: August 27, 2013
    Assignee: NGK Insulators, Ltd.
    Inventor: Yoshio Kikuchi
  • Publication number: 20130216769
    Abstract: A methyl cellulose having a DS(methyl) of from 1.10 to 1.61 is useful for increasing the wet green modulus of an extrusion-molded hollow body, particularly an extrusion-molded hollow body having a ceramic honeycomb structure.
    Type: Application
    Filed: October 27, 2011
    Publication date: August 22, 2013
    Applicant: DOW GLOBAL TECHNOLOGIES LLC
    Inventors: Roland Bayer, Grit Grote
  • Publication number: 20130214463
    Abstract: A ceramic honeycomb structure having a large number of flow paths partitioned by porous cell walls, the cell walls comprising at least main crystals of aluminum titanate, in which MgO and SiO2 are dissolved to form a solid solution, and glass phases, the glass phases containing 40-80% by mass of SiO2 and 1-20% by mass of MgO, the average size of the glass phases being 30 ?m or less in a cross section of the cell walls, and the area ratio of the glass phases to the total area of the main crystals of aluminum titanate and the glass phases being 2-12% in a cross section of the cell walls, and its production method.
    Type: Application
    Filed: March 18, 2013
    Publication date: August 22, 2013
    Applicant: HITACHI METALS, LTD.
    Inventor: HITACHI METALS, LTD.
  • Publication number: 20130207322
    Abstract: Provided is a method for producing a silicon carbide ceramic easily and simply producing a silicon carbide ceramic having a small amount in resistivity change due to temperature change and being capable of generating heat by current application; and having a forming raw material preparing step of mixing two or more kinds of silicon carbide ceramic powders containing 4H—SiC silicon carbide crystals at respectively different content ratio to prepare a forming raw material; a forming step of forming the forming raw material into a formed body; and a firing step of firing the formed body to produce a silicon carbide ceramic being adjusted at a content ratio of 4H—SiC silicon carbide crystal to a desired value.
    Type: Application
    Filed: March 28, 2013
    Publication date: August 15, 2013
    Applicant: NGK INSULATORS, LTD.
    Inventor: NGK INSULATORS, LTD.
  • Publication number: 20130207323
    Abstract: To provide a plugging material that is hardened at low temperature (e.g., 100 to 300° C.), can obtain excellent adhesion to partition walls of a ceramic honeycomb sintered body, and can obtain excellent heat resistance. A plugging material comprising a water-based inorganic adhesive and aluminum titanate-based ceramic particles.
    Type: Application
    Filed: October 14, 2011
    Publication date: August 15, 2013
    Applicant: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventor: Kousuke Uoe
  • Patent number: 8481454
    Abstract: A honeycomb structure includes aluminum titanate and cell walls. The cell walls extend along a longitudinal direction of the honeycomb structure to form a plurality of cells between the cell walls. A porosity of the honeycomb structure is from about 40% to about 60%. In a binary image of substrate portions and pore portions of each of the cell walls, an area ratio (%) of the pore portions to a whole area in a rectangularly-divided image is in a range from (the porosity?about 25%) to (the porosity+about 25%). The binary image is converted from a microscopic image of a cross section of each of the cell walls in parallel with the longitudinal direction. The rectangularly-divided image is formed by dividing the binary image in a direction parallel to a thickness direction of each of the cell walls at a predetermined width.
    Type: Grant
    Filed: May 12, 2010
    Date of Patent: July 9, 2013
    Assignee: Ibiden Co., Ltd.
    Inventors: Kazushige Ohno, Kazunori Yamayose
  • Publication number: 20130140747
    Abstract: Manufacture of ceramic honeycomb fired body. Green molded body is placed on a firing base and fired. The firing base and green molded body are each a column containing a ceramic raw material and having a partition wall forming a plurality of flow paths, and patterns of end surfaces of the two partition walls are the same as each other as seen from an extending direction of the flow paths. The green molded body is placed on the firing base displaced in a horizontal direction by a predetermined distance, or rotated around a vertical axis V of the green molded body by a predetermined angle ?, so that only a part of the lower side end surface of the partition wall of the green molded body is in contact with the upper side end surface of the partition wall of the firing base.
    Type: Application
    Filed: January 29, 2013
    Publication date: June 6, 2013
    Applicant: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventor: SUMITOMO CHEMICAL COMPANY, LIMITED
  • Patent number: 8454886
    Abstract: A method for manufacturing an inorganic honeycomb structure that resists water damage after drying comprises compounding a base batch mixture including inorganic powders, a batch cross-link agent, an aqueous vehicle, and a cross-linkable batch constituent, and forming the batch mixture into a honeycomb core or skin component while reacting the cross-link agent with cross-linkable batch constituent.
    Type: Grant
    Filed: November 29, 2006
    Date of Patent: June 4, 2013
    Assignee: Corning Incorporated
    Inventors: Margaret Kathleen Faber, Robert Gordon Lawrence, Weiguo Miao, Jianguo Wang
  • Patent number: 8454887
    Abstract: A method for producing high porosity ceramic substrate articles including a fire-cycle or firing schedule that includes fast-heating rates, as defined herein.
    Type: Grant
    Filed: November 18, 2010
    Date of Patent: June 4, 2013
    Assignee: Corning Incorporated
    Inventor: Sumalee Likitvanichkul
  • Patent number: 8449645
    Abstract: A ceramic honeycomb structure having a large number of flow paths defined by porous cell walls; said porous cell walls being composed of cordierite crystals, mullite crystals, corundum crystals and/or spinel crystals; the percentage of the X-ray diffraction intensity of the cordierite crystals being 72% or more and less than 85%, the percentage of the X-ray diffraction intensity of the mullite crystals being 15-25%, and the percentage of the total X-ray diffraction intensity of the corundum crystals and the spinel crystals being 5% or less, per the total X-ray diffraction intensity of these crystals; said porous cell walls having a true density of 2.55-2.70 g/cm3, a mean pore diameter of 10-20 ?m, and a porosity of 50-65%; the volume of pores having diameters exceeding 50 ?m being 8-25% of the total pore volume, the volume of pores having diameters of less than 10 ?m being 16-25% of the total pore volume, and the pore diameter distribution deviation ? being 0.5 or less.
    Type: Grant
    Filed: March 31, 2010
    Date of Patent: May 28, 2013
    Assignee: Hitachi Metals, Ltd.
    Inventor: Shunji Okazaki
  • Patent number: 8435441
    Abstract: Disclosed are compositions for applying to honeycomb bodies. The compositions can be used as plugging mixtures for forming a ceramic wall flow filter. Alternatively, the compositions can be used to form skin coatings on exterior portions of a honeycomb body. The disclosed compositions include an inorganic powder batch composition, an organic binder, a liquid vehicle, and a rheology modifier. The compositions exhibit improved rheological properties, including an increased yield strength and reduced viscosity under shear, which, among various embodiments, can enable the manufacture of sintered phase end plugs having reduced levels of dimple and pinhole formations in the final dried and fired end plugs as well as end plugs having relatively uniform and desired depths. Also disclosed are methods for forming end plugged ceramic wall flow filters from the plugging mixtures disclosed herein.
    Type: Grant
    Filed: July 25, 2008
    Date of Patent: May 7, 2013
    Assignee: Corning Incorporated
    Inventors: Dana Craig Bookbinder, James Arthur Griffin, Jr., David Lambie Tennent, Lung-Ming Wu
  • Patent number: 8425830
    Abstract: The invention is directed to a honeycomb comprising cordierite and beta-spudomene, the honeycomb a having total porosity of greater than 30% and a mean pore diameter of less than 5 ?m. The honeycomb is made from a mixture of activated kaolin and a mineral selected from the group consisting of lithium fluorhectorite, lithium hydroxyhectorite and mixtures thereof. In one embodiment up to 20 wt % SiO2, based on the total weight of the kaolin and minerals (fluarhectorite, hydroxyhectorite) is added and mixed therein prior to the formation of the green body. In another embodiment the amount of added SiO2 is up to 10 wt %. In one embodiment the total porosity is greater than 50% and the mean pore diameter is less than 5 ?m.
    Type: Grant
    Filed: February 26, 2009
    Date of Patent: April 23, 2013
    Assignee: Corning Incorporated
    Inventors: George Halsey Beall, Steven Alvin Tietje