Producing Honeycomb Shape Patents (Class 264/630)
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Patent number: 7575618Abstract: Porous ceramic articles such as ceramic filters are provided from ceramic extrusion batches comprising mixtures of oxides and oxide precursors with a reactive binder system, the binder system comprising a cellulosic temporary binder and two or more reactive binder components such as colloidal alumina, carbohydrate pore formers, reactive high charge density polymers, and chemical cross-linkers, the reactive binder system promoting cross-linking or networking reactions in the batch that enhance the fine pore structures of the porous ceramic products.Type: GrantFiled: March 30, 2006Date of Patent: August 18, 2009Assignee: Corning IncorporatedInventors: Weiguo Miao, Jianguo Wang
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Patent number: 7575792Abstract: A honeycomb filter, for removing from exhaust gas fine solid particles containing carbon, is an aluminum magnesium titanate sintered product obtained by firing at from 1000 to 1700° C. a product formed from a mixture comprising a Mg-containing compound, an Al-containing compound and a Ti-containing compound in the same metal component ratio as the metal component ratio of Mg, Al and Ti in aluminum magnesium titanate represented by the empirical formula MgxAl2(1?x)Ti(1+x)O5 (wherein 0<x<1), or a mixture comprising 100 parts by mass, as calculated as oxides, of the above-mentioned mixture and from 1 to 10 parts by mass of an alkali feldspar represented by the empirical formula (NayK1?y)AlSi3O8 (wherein 0?y?1).Type: GrantFiled: July 9, 2004Date of Patent: August 18, 2009Assignee: Ohcera Co., Ltd.Inventors: Tsutomu Fukuda, Masahiro Fukuda, Masaaki Fukuda, Toshinobu Yoko, Masahide Takahashi
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Publication number: 20090202402Abstract: A honeycomb structure includes a honeycomb block which includes at least one honeycomb fired body having a first end face side and a second end face side in a longitudinal direction of the honeycomb fired body. The honeycomb fired body includes a plurality of cell walls extending along the longitudinal direction to define cells. Either one of first and second end portions in the longitudinal direction of each of the cells is sealed. The first end portion provided on the first end face side of the at least one honeycomb fired body is sealed with a first plug which is made from a plug material paste and fired. The second end portion provided on the second end face side of the at least one honeycomb fired body is sealed with a second plug which is made from a plug material paste and unfired.Type: ApplicationFiled: January 30, 2009Publication date: August 13, 2009Applicant: IBIDEN CO., LTD.Inventor: Hiroki SATO
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Publication number: 20090200712Abstract: A method for pretreating an unfired honeycomb formed article of a raw material composition containing a ceramic raw material, water, and a binder and having a plurality of cells separated by partition walls and functioning as fluid passages before firing. The method has a first step of passing superheated steam having a temperature of 100 to 150° C. through the cells to raise temperature of the honeycomb formed article and then maintaining the temperature of the superheated steam at the temperature of the superheated steam passed through the cells or more and 200° C. or less. The method can provide a pretreatment to a honeycomb formed article in a shorter time with inhibiting generation of a defect such as a deformation or a damage.Type: ApplicationFiled: April 23, 2009Publication date: August 13, 2009Applicant: NGK INSULATORS, LTD.Inventors: Shinzou HAYASHI, Takayuki SAKURAI
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Publication number: 20090199953Abstract: 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: ApplicationFiled: February 12, 2009Publication date: August 13, 2009Applicant: IBIDEN CO., LTD.Inventor: Hiroki SATO
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Patent number: 7569201Abstract: A method of manufacturing a honeycomb structure. (1) Water is added to silicon carbide particles and kneaded into a kneaded raw material. The silicon carbide particles have an average particle diameter of not less than 2 ?m and not more than the honeycomb rib thickness×0.23 and a logarithmic standard deviation of the particle size distribution of not less than 0.15 and not more than 0.40 (step S11). (2) The kneaded raw material is extruded by extrusion into a honeycomb extruded body (step S12). (3) The extruded body is dried (step S13), calcined (step S14), and fired (step S15).Type: GrantFiled: May 27, 2004Date of Patent: August 4, 2009Assignee: NGK Insulators, Ltd.Inventors: Aiko Otsuka, Shuichi Ichikawa, Takashi Harada
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Publication number: 20090191368Abstract: The present invention provides a production method that can easily and inexpensively produce a perforated honeycomb structure body while effectively preventing chipping when grinding a hole. A method of producing a perforated honeycomb structure body according to the present invention includes partially grinding an outer wall 2 and a partition wall 3 of a honeycomb structure body 10 from the surface of the outer wall 2 of the honeycomb structure body 10 using a wheel grinder having grooves formed in its surface along a grinding direction, or a ball end mill provided with abrasive grains on its tip, to form a hole 5.Type: ApplicationFiled: January 22, 2009Publication date: July 30, 2009Applicant: NGK INSULATORS, LTD.Inventors: Masayuki HIRONAGA, Masahiro FUJIYAMA, Takahiro INOUE
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Patent number: 7567817Abstract: A porous ceramic substrate is disclosed that is fabricated from biosoluble ceramic fibers. Porosity and permeability of the substrate is provided by intertangled biosoluble fibers, that can be formed into a honeycomb form substrate through an extrusion process. The fibrous structure is formed from mixing biosoluble fibers with additives that include a bonding agent, and a fluid to provide an extrudable mixture. The structure is sintered at a temperature that exceeds the glass formation temperature of the bonding agent, but less than the maximum operational limits of the biosoluble fiber, to form a structure that has sufficient strength and porosity to provide for filtration and/or as a catalytic host.Type: GrantFiled: May 14, 2007Date of Patent: July 28, 2009Assignee: GEO2 Technologies, Inc.Inventors: James Jenq Liu, Bilal Zuberi
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Publication number: 20090176043Abstract: A silicon carbide based porous material, which contains a metal silicide in an amount of 1 to 30% by mass and having a porosity of 38 to 80%, is provided.Type: ApplicationFiled: November 28, 2008Publication date: July 9, 2009Applicant: NGK INSULATORS, LTD.Inventors: Takahiro TOMITA, Kenji MORIMOTO
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Patent number: 7556664Abstract: There is provided a plugged honeycomb structure 1 including: partition walls 2 disposed so as to form a plurality of cells 3 extending from one end face 42 to the other end face 44 in the axial direction, and plugged portions 4 disposed so as to plug the cells 3 at one of the end faces, and a production method thereof. In this honeycomb structure 1, the plugged portions 4 and partition walls surrounding the plugged portions are unitarily formed. The production method includes a forming step, a plugging step for filling a plugging material, and a firing step. The plugging material contains solid particles capable of unitarily joining with at least one kind of solid particles contained in a forming raw material in a firing step. A ratio of a dimensional change (%) upon forming the partition walls out of the partition wall-forming material to a dimensional change (%) upon forming the plugged portions out of the plugging material is controlled to be within the range of 0.7% to 1.3 in the firing step.Type: GrantFiled: March 19, 2004Date of Patent: July 7, 2009Assignee: NGK Insulators, Ltd.Inventors: Yukihito Ichikawa, Yasushi Noguchi
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Patent number: 7556666Abstract: A honeycomb structure including a plurality of porous ceramic members which are bonded through an adhesive layer, each of the porous ceramic members has a plurality of cells, which are arranged in parallel while being separated by cell walls. The cells extend in a longitudinal direction of the honeycomb structure. In the honeycomb structure, the following relationship is satisfied: 2?B?100/3×A?10/3??(1) where A (g/cm3) designates apparent density of the porous ceramic members, and B (GPa) designates Young's modulus of the adhesive layer.Type: GrantFiled: April 5, 2006Date of Patent: July 7, 2009Assignee: Ibiden Co., Ltd.Inventor: Masafumi Kunieda
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Patent number: 7553349Abstract: A ceramic honeycomb product comprising a thin-walled ceramic honeycomb structure incorporating a plurality of parallel channels bounded by thin channel walls traversing the body from a first end face to a second end face thereof; and a composite coating disposed on at least one end face of the structure comprising a powder of an abrasion-resistant ceramic dispersed in a dried siliceous matrix.Type: GrantFiled: August 26, 2005Date of Patent: June 30, 2009Assignee: Corning IncorporatedInventors: Kishor Purushottam Gadkaree, Susan Clair Lauderdale, Joseph Frank Mach, Deborah Lynn Shanley
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Patent number: 7553442Abstract: An exhaust gas purifying filter is made of a ceramic material in a honeycomb structure having introduction passages for introducing exhaust gas that includes particulate matter emitted from an internal combustion engine, porous walls that collect the particulate matter and exhaust passages for exhausting the exhaust gas after the particulate matter has been removed therefrom, with the porous walls supporting a catalyst for oxidizing and removing the particulate matter. The porosity of the porous wall is in a range from 55 to 80%, the mean pore size is in-a range from 30 to 50 ?m, and the total volume X of the pores included in the exhaust gas purifying filter and the volume Y of the pores that are not smaller than 100 ?m satisfy the relation of inequality Y/X?0.05.Type: GrantFiled: March 27, 2007Date of Patent: June 30, 2009Assignee: Denso CorporationInventors: Mamoru Nishimura, Mikio Ishihara, Hirofumi Yamashita, Hiromi Sano
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Patent number: 7550025Abstract: Provided is a honeycomb filter which includes an aluminum titanate sintered product obtained by a process involving firing at a temperature of 1,250-1,700° C. a raw material mixture composed of: 100 wt. % of a first mixture having TiO2 and Al2O3 in a molar ratio of 40-60/60-40; and 1-10 wt. % of a second mixture composed of: an alkali feldspar according to the formula NayK1-yAlSi3O8, wherein 0?y?1; and a component selected from an oxide having a spinel structure composed of Mg and/or MgO, MgO and a precursor compound composed of Mg that is converted to MgO by firing, wherein the honeycomb filter exhibits excellent properties with respect to mechanical strength, thermal decomposition resistance, thermal shock resistance and thermal stability at high and fluctuating temperatures. Also provided is a method and an apparatus for cleaning an exhaust gas by removing solid particles predominantly containing carbon from the exhaust gas with the honeycomb filter.Type: GrantFiled: August 20, 2004Date of Patent: June 23, 2009Assignee: Ohcera Co., Ltd.Inventors: Tsutomu Fukuda, Masahiro Fukuda, Masaaki Fukuda, Toshinobu Yoko, Masahide Takahashi
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Patent number: 7550190Abstract: Core-skin bonding is improved between honeycomb and composite face sheets by applying a polyamide and/or rubber-containing adhesive to the edge of the honeycomb prior to bonding. Edge coating of honeycomb with a polyamide and/or rubber-containing adhesive is useful in further increasing the bond strength between honeycomb and prepreg face sheets, especially when the matrix resin of the prepreg is designed to adhere the prepreg to the honeycomb without the use of a separate structural adhesive.Type: GrantFiled: May 11, 2006Date of Patent: June 23, 2009Assignee: Hexcel CorporationInventors: Yen-Seine Wang, Robert Morrison, Clark Smith
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Publication number: 20090146350Abstract: A process for producing a honeycomb structure includes: a mixing step where forming raw materials including a ceramic raw material are mixed to obtain a forming blended material, a kneading step where the forming blended material is kneaded to obtain kneaded clay, a forming step where the kneaded clay is formed into a honeycomb shape to obtain a honeycomb formed article, and a firing step where the honeycomb formed article is fired to obtain a honeycomb structure. The ceramic raw material is a cordierite forming raw material, and a magnetic powder contained in the kneaded clay is at a ratio of 400 ppm or less with respect to solid content conversion mass of the whole kneaded clay. There is provided a honeycomb structure capable of improving trapping efficiency, in particular, initial trapping efficiency by reducing the number of coarse pores in the partition walls.Type: ApplicationFiled: February 9, 2009Publication date: June 11, 2009Applicant: NGK INSULATORS, LTD.Inventors: Yasushi NOGUCHI, Takehiko WATANABE, Takeshi TOKUNAGA, Yukari NAKANE
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Publication number: 20090140471Abstract: A method of manufacturing a honeycomb structure is disclosed wherein a green honeycomb body having a first contour is differentially altered such that the green honeycomb body has a second contour which is wider at a first end than at a second end. In one aspect, the altering is accomplished by removing a part of the green honeycomb body, such as with a removal tool. In another aspect, the altering is accomplished by exposing different regions of the honeycomb body to different drying environments.Type: ApplicationFiled: November 21, 2008Publication date: June 4, 2009Inventors: Tonia Havewala Fletcher, Thomas George Havens, Christopher John Malarkey
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Publication number: 20090139208Abstract: The invention relates to a process for manufacturing a porous silicon carbide structure of the honeycomb type, said process being characterized in that it comprises the following steps: forming of a paste from a mixture of silicon carbide grains, the diameter d50 of which is between 5 ?m and 300 ?m, of an organic binder and of an inorganic pore former, in the form of particles based on silica, the overall porosity of said particles being greater than 70%; forming of a honeycomb-shaped green plastic monolith; drying of said monolith; and firing of the monolith at a temperature greater than 2100° C. The structure obtained by the process may be used as catalytic support in an exhaust line of a diesel or petrol engine or as particulate filter in an exhaust line of a diesel engine.Type: ApplicationFiled: July 19, 2006Publication date: June 4, 2009Inventors: Daniel Urffer, Carine Barataud-Dien
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Patent number: 7537634Abstract: A method for manufacturing a plugged honeycomb structure includes the steps of: applying a predetermined amount of the plugging slurry on a face of an end face sealing member, one end face of the masked honeycomb structure is pressed against the face to which the plugging slurry was applied of the end face sealing member to fill the plugging slurry in the predetermined cells on the one end face side, and drying at least the plugging slurry at a portion in contact with the face of the end face sealing member in a state that the face of the end face sealing member is pressed against the one end face of the masked honeycomb structure. The method can manufacture simply at a low cost a plugged honeycomb structure with reduced accumulation of deposit on an end face when the honeycomb structure is used as a filter or the like.Type: GrantFiled: March 15, 2006Date of Patent: May 26, 2009Assignee: NGK Insulators, Ltd.Inventors: Tatsuhiko Hatano, Masahiro Masuda, Yukihito Ichikawa
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Publication number: 20090130378Abstract: A honeycomb structure includes a ceramic block including a plurality of honeycomb fired bodies, a first adhesive layer, and a second adhesive layer. The plurality of honeycomb fired bodies includes center-portion honeycomb fired bodies located at a center portion in a cross-section perpendicular to the longitudinal direction and peripheral honeycomb fired bodies surrounding the center-portion honeycomb fired bodies. The first adhesive layer is interposed between the center-portion honeycomb fired bodies to connect the center-portion honeycomb fired bodies. The second adhesive layer is interposed between each of the center-portion honeycomb fired bodies and each of the peripheral honeycomb fired bodies and between the peripheral honeycomb fired bodies. An adhesive strength ? between the center-portion honeycomb fired bodies bonded via the first adhesive layer is higher than an adhesive strength ? between honeycomb fired bodies bonded via the second adhesive layer.Type: ApplicationFiled: October 14, 2008Publication date: May 21, 2009Applicant: IBIDEN CO., LTD.Inventors: Masaki IMAEDA, Hiroki SATO
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Publication number: 20090130381Abstract: Disclosed are washcoated ceramic honeycomb filters. The ceramic filters exhibit a relatively high level of washcoat loading while exhibiting minimized levels of backpressure. Also disclosed are methods for manufacturing the washcoated ceramic honeycomb filters. The method comprises providing an cell geometry derived from a predetermined level of washcoat loading to be applied to the ceramic honeycomb article.Type: ApplicationFiled: November 19, 2008Publication date: May 21, 2009Inventors: Eric Jean Paul Francois, Guillaume Guzman, Maxime Moreno, Christopher Michel Remy
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Publication number: 20090113863Abstract: Disclosed are cement compositions for applying to honeycomb substrates. The cement compositions contain an inorganic powder batch composition; a binder; a liquid vehicle; and an elastic modulus reducing additive. The elastic modulus reducing additive can contain a ceramic fiber or a monohydrated alumina. The cement compositions are well suited for forming ceramic diesel particulate wall flow filters. Also disclosed herein are end plugged wall flow filters that include the disclosed cement compositions and methods for the manufacture thereof.Type: ApplicationFiled: November 4, 2008Publication date: May 7, 2009Inventors: Yanxia Lu, Isabelle Marie Melscoet-Chauvel
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Patent number: 7524450Abstract: There is provided a method for manufacturing a silicon carbide based honeycomb structure, the method using, as a part of a starting material, a recycled raw material recycled from a recovered material generated in a process for manufacturing the silicon carbide based honeycomb structure and derived from a starting material for a silicon carbide based honeycomb structure; wherein the recycled raw material is pulverized to have an average particle size of 10 to 300 ?m. According to the present invention, structure defects such as voids or coarse particles, which have been problems upon manufacturing a silicon carbide based honeycomb structure, are hardly formed, and a silicon carbide based honeycomb structure having excellent strength and uniform heat conductivity can be obtained. In addition, since a once kneaded material is used as a part of a starting material, the time for kneading can be shortened.Type: GrantFiled: September 29, 2004Date of Patent: April 28, 2009Assignee: NGK Insulators, Ltd.Inventors: Masashi Marada, Shuichi Ichikawa, Aiko Otsuka, Atsushi Kaneda, Yasushi Noguchi
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Patent number: 7520918Abstract: A method and system for detecting defects in a plugged honeycomb structure includes forming a sheet of light having a first color across a first end face of the honeycomb structure, generating a first reflected signal from the sheet of light at a location corresponding to a cell containing a defect in the honeycomb structure, illuminating the first end face with an incident light beam having a second color, generating a second reflected signal from the incident light beam, and capturing an image of the first and second reflected signals. After being detected, the defective cells may then be marked or repaired without relocating the plugged honeycomb structure. Apparatus and methods for marking or repairing the defective cell(s) are described.Type: GrantFiled: December 16, 2005Date of Patent: April 21, 2009Assignee: Corning IncorporatedInventor: Leon Robert Zoeller, III
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Patent number: 7520911Abstract: A porous cordierite ceramic honeycomb article with increased mechanical strength and thermal shock resistance. The porous cordierite ceramic honeycomb article has MA<2220, or MT>2660 wherein MA=3645(IA)?106(CTE)+19(d90)+17(% porosity), MT=4711(IT)+116(CTE)?26(d90)?28(% porosity), and a CTE?9×10?7/° C. in at least one direction. A method of manufacturing is also disclosed wherein the inorganic raw material mixture contains talc, an alumina-forming source, a silica-forming source, and 0-18 wt. % of a kaolin or calcined kaolin containing not more than 8 wt. % of a fine kaolin source having a median particle diameter of less than 7 ?m, wherein the fired porous ceramic cordierite honeycomb article has a porosity<54% . Alternatively, if greater than 8 wt. % of the fine kaolin source is used, then a slow ramp rate is utilized from 1200° C. to 1300° C. of not more than 20° C./hr.Type: GrantFiled: November 30, 2005Date of Patent: April 21, 2009Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Gregory Albert Merkel, David John Thompson
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Publication number: 20090098333Abstract: A honeycomb structure includes honeycomb fired bodies having cell walls extending along the longitudinal direction to define a plurality of cells, and an outer wall at the outermost peripheral face. The fired bodies are connected at the outer wall by an adhesive layer. The cell wall has a thickness of at least about 0.15 mm and at most about 0.30 mm. A thickness of a border wall is at least about 5 times greater and at most about 20 times greater than the thickness of the cell wall. The border wall includes the adhesive layer, and first and second outer walls which are connected to each other. The catalyst permeation preventive region is provided in the outer wall or between the outer wall and the adhesive layer. The catalyst permeation preventive region includes at least one of a water repellent material, a cation exchanger and water absorbing material.Type: ApplicationFiled: September 19, 2008Publication date: April 16, 2009Applicant: IBIDEN CO., LTD.Inventors: Masafumi KUNIEDA, Mari KITAJIMA
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Publication number: 20090096138Abstract: A method for manufacturing a honeycomb seal by powder-metallurgical injection molding is described wherein, during the powder-metallurgical injection molding; mixing a metal powder and/or a ceramic powder with at least one binding agent to produce a homogeneous mass; subsequently fabricating a molded article for the honeycomb seal having honeycomb-structured cells from the homogeneous mass by injection molding; subsequently performing a debindering process on the molded article; and, subsequently thereto, compacting the molded article via a sintering process to form the honeycomb seal having the desired geometric properties. Prior to the sintering process, partially filling at least some of the cells of the molded article in each case with at least one hollow body, subsequently sintering the molded article together with the hollow bodies that have been introduced into the cells.Type: ApplicationFiled: March 29, 2007Publication date: April 16, 2009Inventor: Reinhold Meier
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Patent number: 7517379Abstract: A method of blocking partial cells at the periphery of diesel filters is disclosed. The method comprises plugging the partial cells with a suitable plugging material. In one embodiment, a line of plugging material is applied to either or both of the end faces of the diesel filter along an outermost row of partial cells to block same. In another embodiment, the outermost wall the diesel filter is first beveled to form a beveled edge and uniquely off-set the partial cells. Then the beveled edge has applied thereto a plugging material, such as a line or bead. A honeycomb structure having reduced number of unplugged partial cells at the periphery is also disclosed.Type: GrantFiled: December 16, 2005Date of Patent: April 14, 2009Assignee: Corning IncorporatedInventor: Charles Mitchel Sorensen, Jr.
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Publication number: 20090092786Abstract: A porous fibrous honeycomb substrate having an aluminum titanate composition and methods of producing the same are provided herein. Precursors of aluminum titanate are provided in an extrudable mixture that includes fiber materials to form a green honeycomb substrate. When cured, the precursors of aluminum titanate form an aluminum titanate composition, with the fiber materials defining the porous microstructure. Various composite structures including aluminum titanate are provided to form a porous honeycomb substrate that can be configured to be filtration media and/or a catalytic host.Type: ApplicationFiled: October 31, 2008Publication date: April 9, 2009Applicant: GEO2 Technologies, Inc.Inventors: James Jenq Liu, Bilal Zuberi, William M. Carty
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Patent number: 7513921Abstract: An exhaust gas filter apparatus includes a particulate filter for collecting a particulate from an exhaust gas. The exhaust gas filter also includes a electromagnetic radiation resonator to heat a portion of the particulate to ignite the particulate and regenerate the particulate filter.Type: GrantFiled: October 24, 2005Date of Patent: April 7, 2009Assignee: HRL Laboratories, LLCInventors: Amanda C. Phelps, Kevin W. Kirby, Daniel Gregoire
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Patent number: 7504057Abstract: In a method of manufacturing an exhaust gas purifying filter that captures and purifies particulates involved in an exhaust gas emitted from an internal combustion engine, a honeycomb mold body of a desired length is firstly made by an extrusion molding step. In a sealing and enlarging step, tapered front parts of a multi-taper jig are inserted into the corresponding openings of the cells. The multi-taper jig is then oscillatory moved in a direction perpendicular to a longitudinal length of the ceramic mold body while heating the partition walls forming the cells, so that the opening of one cell is closed and sealed completely and the opening of the adjacent cell is enlarged in area. Finally, the honeycomb mold body is burned.Type: GrantFiled: February 27, 2006Date of Patent: March 17, 2009Assignee: Denso CorporationInventors: Satoshi Ishikawa, Mikio Ishihara, Kazuhide Sato
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Publication number: 20090057963Abstract: A method for fabricating ceramic honeycomb structural bodies that includes conveying at least one green honeycomb structural body of a first type and at least one green honeycomb structural body of a second type through a kiln in a manner which reduces cracking or fissures in the fired objects.Type: ApplicationFiled: August 27, 2008Publication date: March 5, 2009Inventors: Yuk Fung Chan, Gregory Paul Dillon, Tudor Constantin Gheorghiu, Mahesh Chandra Mathur, Adedoyin Ademola Oyelaran, David Robert Potts
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Device and process for producing a device for the catalytic generation of hydrogen from hydrocarbons
Patent number: 7494517Abstract: A device for the catalytic generation of hydrogen from hydrocarbons includes a catalytic converter having feed and distribution channels for starting materials and discharge and collection manifolds for products. The feed and distribution channels and the discharge and collection manifolds are formed from a plurality of identically structured channels. Inlet channels for supplying and distributing starting materials and outlet channels for collecting and discharging products are defined by, in each case, inversely arranged closed and open channel ends. The inlet and outlet channels extend substantially across the entire catalytic converter and are provided in an alternately intermeshing arrangement.Type: GrantFiled: April 15, 2005Date of Patent: February 24, 2009Assignee: NuCellSys GmbHInventors: Johanna Bass, Roland Cwik, Tomas Stefanovski -
Publication number: 20090041635Abstract: A device for treating fluids, such as automotive exhaust gases is provided, as well as a method of manufacturing such a device. The invention provides a honeycomb structure, a matrix of ceramic walls that defines a plurality of parallel, fluid-conducting cells oriented along an axis, arranged in a stacked or discontinuous configuration between an inlet and outlet, where adjacent layers of honeycomb structure are separated by layers of air spaces. Each matrix layer has opposing faces that defines the inlets and outlets of the cells, and a peripheral portion or peripheral region including an outer skin. The peripheral portions or peripheral regions of adjacent stacked ceramic layers are mutually contiguous to prevent fluid flowing through the stacked ceramic layers from leaking between said outer skins.Type: ApplicationFiled: August 10, 2007Publication date: February 12, 2009Inventors: George E. Berkey, Keith L. House
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Patent number: 7488367Abstract: A honeycomb filter includes partition walls forming a plurality of cells extending in one direction, and plugging sections alternately plugging the cells at the ends of the honeycomb filter, the partition walls being formed of a porous base material having a porosity of 45 to 70%. When the average pore size of the base material measured by mercury porosimetry is (A) ?m and the average pore size of the base material measured by a bubble point method is (B) ?m, the average pore size differential rate expressed by “{(A?B)/B}*100” is 35% or less, and the maximum pore size of the base material measured by the bubble point method is 150 ?m or less.Type: GrantFiled: September 21, 2005Date of Patent: February 10, 2009Assignee: NGK Insulators, Ltd.Inventors: Yoshiyuki Kasai, Toshihiro Hirakawa
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Patent number: 7488368Abstract: The ceramic honeycomb structure has a plurality of cells partitioned by porous partition walls and extending through the structure in an axial direction, one end portion of a predetermined cell is plugged with a plugging portion constituted of a plugging material with which the cell is filled, and the other end portion of a remaining cell is plugged with the plugging portion on a side opposite to the end portion of the predetermined cell. In the ceramic honeycomb structure, a sectional numerical aperture of the plugging portion in the vicinity of the partition wall is smaller than that of the plugging portion in the vicinity of a central axis, and a difference between the sectional numerical apertures is 10% or more.Type: GrantFiled: October 19, 2005Date of Patent: February 10, 2009Assignee: NGK Insulators, Ltd.Inventors: Toshio Yamada, Tatsuhiko Hatano
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Patent number: 7485170Abstract: Disclosed are ceramic honeycomb articles, which are composed predominately of a crystalline phase cordierite composition. The ceramic honeycomb articles possess a microstructure characterized by a unique combination of relatively high porosity between 42% and 56%, and relatively narrow pore size distribution wherein less than 15% of the total porosity has a pore diameter less than 10 ?m, less than 20% of the total porosity has a pore diameter greater than 30 ?m, and dbreadth?1.50 wherein dbreadth=(d90?d10)/d50. The articles exhibits high thermal durability and high filtration efficiency coupled with low pressure drop across the filter. Such ceramic articles are particularly well suited for filtration applications, such as diesel exhaust filters or DPFs. Also disclosed is a method for manufacturing the ceramic article wherein the pore former is preferably potato starch having a median particle diameter greater than 40 ?m.Type: GrantFiled: November 30, 2005Date of Patent: February 3, 2009Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Thomas Richard Chapman, Weiguo Miao, Jianguo Wang
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Patent number: 7485594Abstract: A porous mullite composition is made by forming a mixture of one or more precursor compounds having the elements present in mullite (e.g., clay, alumina, silica) and a property enhancing compound. The property enhancing compound is a compound having an element selected from the group consisting of Mg, Ca, Fe, Na, K, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, B, Y, Sc, La and combination thereof. The mixture is shaped and to form a porous green shape which is heated under an atmosphere having a fluorine containing gas to a temperature sufficient to form a mullite composition comprised substantially of acicular mullite grains that are essentially chemically bound.Type: GrantFiled: May 1, 2007Date of Patent: February 3, 2009Assignee: Dow Global Technologies, Inc.Inventors: Chandan Saha, Sharon Allen, Chan Han, Robert T. Nilsson, Arthur R. Prunier, Jr., Aleksander J. Pyzik, Sten A. Wallin, Robin Ziebarth, Timothy J. Gallagher
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Publication number: 20090014925Abstract: A method for manufacturing a porous ceramic structure which comprises: mixing a ceramic material, a foamed resin and, if necessary, a forming auxiliary; forming the mixture; and then firing the thus formed body, wherein: a resin of an outer shell of the foamed resin is constituted of a copolymer containing 60 wt % or more of acrylonitrile and 40 wt % or less of methyl methacrylate.Type: ApplicationFiled: January 11, 2005Publication date: January 15, 2009Applicant: NGK Insulators, Ltd.Inventors: Yasushi Noguchi, Kyoko Makino, Shuuji Ueda
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Publication number: 20090011176Abstract: A tubular honeycomb structure 1 comprising partition walls 2 which define and form a plurality of cells 3 each functioning as a fluid passage extending from one end face 4 of honeycomb structure to other end face 5, wherein the areas of the sections of the individual cells 3 (cell sections) normal to the flow direction A of fluid are so made as to be approximately equal to each other over a given range of the center of each cell and its vicinity in the fluid flow direction A and to gradually decrease or gradually increase at each cell end of at least one end face 4 of honeycomb structure in the fluid flow direction A. This honeycomb structure can reduce the incoming loss and outgoing loss of a fluid such as exhaust gas or the like and can show a lower pressure loss.Type: ApplicationFiled: August 9, 2007Publication date: January 8, 2009Applicant: NGK INSULATORS, LTD.Inventor: Yukihito Ichikawa
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Publication number: 20090008830Abstract: A method for producing a ceramic honeycomb filter having large numbers of flow paths partitioned by cell walls, the flow paths having plugs at positions separate from an end surface of the honeycomb filter, comprising the steps of introducing a base-forming material into the flow paths on one end surface side, charging a plug-forming material into flow paths to be provided with plugs from the other end surface side, and sintering it.Type: ApplicationFiled: January 29, 2007Publication date: January 8, 2009Applicant: HITACHI METALS, LTD.Inventors: Shunji Okazaki, Yasuhiko Ohtsubo
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Patent number: 7473392Abstract: Disclosed is a sintered ceramic article that exhibits a primary crystalline phase of cordierite having an analytical oxide composition, expressed in weight percent on an oxide basis, of 49-53% SiO2, 33-38% Al2O3, 12-16% MgO and which exhibits a coefficient of thermal expansion equal to or more negative than ?0.6×10?7/° C. over the temperature range of about 25° C. to about 800° C. Also disclosed is a method for producing a ceramic article comprising the aforementioned cordierite.Type: GrantFiled: October 3, 2007Date of Patent: January 6, 2009Assignee: Corning IncorporatedInventor: Raja Rao Wusirika
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Patent number: 7468156Abstract: There is provided a method for manufacturing a porous ceramic structure, including: firing a formed body containing ceramic particles and a combustible powder functioning as a pore former, and burning off the combustible powder to obtain the porous ceramic structure. The combustible powder has an exothermic rate of 0 to 35 ?V·min./mg, which is obtained from a differential thermal analysis. The method for manufacturing a porous ceramic structure can inhibit a crack from being generated during firing even without slowing down the temperature rise rate at the combustion range of the pore former or without lowering an oxygen content in the firing atmosphere.Type: GrantFiled: July 31, 2006Date of Patent: December 23, 2008Assignee: NGK Insulators, Ltd.Inventors: Yasushi Noguchi, Hiroyuki Suenobu, Takehiko Watanabe
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Publication number: 20080295470Abstract: A honeycomb filter includes a pillar-shaped honeycomb structure integrally formed, first and second lamination members, a metal casing containing the honeycomb structure and the lamination member, and first and second end members connected to first and second end portions of the casing, respectively to secure the honeycomb structure and the lamination member. The honeycomb structure includes a wall portion defining through holes which extend substantially along a longitudinal direction of the honeycomb structure, each of the through holes being sealed at either one end portion. Each of the lamination members has aligned through holes extending substantially along the longitudinal direction. The honeycomb structure and lamination members include inorganic fibers oriented substantially perpendicular to the longitudinal direction.Type: ApplicationFiled: May 29, 2008Publication date: December 4, 2008Applicant: IBIDEN CO., LTD.Inventors: Kazutake OGYU, Yusuke KONDO
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Publication number: 20080289307Abstract: A honeycomb structure includes a plurality of cells, an inorganic fiber, and an inorganic matter. The plurality of cells are disposed substantially in parallel with one another in a longitudinal direction with a cell wall therebetween. The inorganic matter forms a fixed portion in which said inorganic fibers are fixed to one another, part of the fixed portion having a fissure.Type: ApplicationFiled: May 20, 2008Publication date: November 27, 2008Applicant: IBIDEN CO., LTD.Inventors: Kazutake OGYU, Yusuke Kondo
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Publication number: 20080284067Abstract: A material for a silicon carbide fired body is manufactured by wet mixing at least a silicon carbide powder and an iron compound powder. A honeycomb structure is manufactured by molding a raw material composition containing the material for a silicon carbide fired body and an additive to manufacture a honeycomb molded body which has cell walls extending along a longitudinal direction of the honeycomb molded body to define a plurality of cells extending along the longitudinal direction. The honeycomb molded body is degreased to manufacture a honeycomb degreased body. The honeycomb degreased body is fired to manufacture a honeycomb structure including a honeycomb fired body.Type: ApplicationFiled: May 8, 2008Publication date: November 20, 2008Applicant: IBIDEN CO., LTD.Inventors: Kazuya NARUSE, Kosei Tajima
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Publication number: 20080286179Abstract: A porous ceramic substrate is disclosed that is fabricated from biosoluble ceramic fibers. Porosity and permeability of the substrate is provided by intertangled biosoluble fibers, that can be formed into a honeycomb form substrate through an extrusion process. The fibrous structure is formed from mixing biosoluble fibers with additives that include a bonding agent, and a fluid to provide an extrudable mixture. The structure is sintered at a temperature that exceeds the glass formation temperature of the bonding agent, but less than the maximum operational limits of the biosoluble fiber, to form a structure that has sufficient strength and porosity to provide for filtration and/or as a catalytic host.Type: ApplicationFiled: May 14, 2007Publication date: November 20, 2008Applicant: GEO2 TECHNOLOGIES, INC.Inventors: James Jeng Liu, Bilal Zuberi
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Patent number: 7449427Abstract: The honeycomb structured body of the present invention is a honeycomb structured body in which a plurality of porous ceramic members are combined with one another through an adhesive layer, each of the porous ceramic members having a plurality of cells which are allowed to penetrate in a longitudinal direction with a wall portion therebetween and either one end of which is sealed, with a catalyst supporting layer being adhered to the wall portion, wherein an average pore diameter of the porous ceramic member is larger than an average particle diameter of particles constituting the catalyst supporting layer, and when a pore diameter distribution of the porous ceramic member and a particle diameter distribution of particles constituting the catalyst supporting layer are drawn with the pore diameter and the particle diameter being on the same axis, a pore volume in an overlapped area of both the distributions is about 10% or less to the entire pore volume of the porous ceramic member.Type: GrantFiled: September 12, 2006Date of Patent: November 11, 2008Assignee: Ibiden Co., LtdInventors: Kazushige Ohno, Hiroki Sato, Masayuki Hayashi, Kazutake Ogyu
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Patent number: 7445745Abstract: A method for fabricating a ceramic article which includes providing a batch comprising components of (i) a mixture of inorganic raw materials comprising talc, alumina, and silica; (ii) a binder comprising a water-soluble organic binder and a fibrous silicate mineral having a high aspect ratio in combination with a large surface area that is highly charged and has a strong interaction with a polar solvent, and is further characterized by a median particle size of 1-2 microns; and (iii) a polar solvent; mixing the batch components to form a homogenous and plasticized mass; shaping the plasticized mass into a green body wherein the green body has improved strength in a temperature region between 300°-900° C. to resist cracking during subsequent sintering; and, sintering the green body by heating to a temperature and for a time to initiate and sufficiently achieve conversion of the green body into a fired ceramic article.Type: GrantFiled: August 3, 2004Date of Patent: November 4, 2008Assignee: Corning IncorporatedInventor: Irene M. Peterson
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Publication number: 20080265095Abstract: An energy absorbing apparatus and system for leading edge structures includes an impact member, such as a “bird-band”, of a plastically deformable material of a predetermined configuration positioned with the structure in an area of the leading edge of the structure to absorb energy of an impact of a projectile with the leading edge of the structure, and to redistribute the energy of the impact to the structure, and can break up the projectile, and can increase the impact area. The structure can have one or more sheet members, such as a single sheet, or an inner face sheet and an outer face sheet with a core positioned between the inner face sheet and the outer face sheet. One or more impact members of the plastically deformable material can be positioned with one or more of the single sheet, the inner face sheet, the outer face sheet or the core.Type: ApplicationFiled: April 24, 2007Publication date: October 30, 2008Inventors: Timothy J. Lee, Jason L. Firko, Jonathan W. Gabrys