From Cordierite (i.e., 2mgo.2a12o3.5sio2, Iolite) Patents (Class 264/631)
  • Patent number: 11866380
    Abstract: A method of fabricating a coating includes providing a ceramic matrix composite that includes SiC fibers disposed in a SiC matrix, depositing a base slurry on the ceramic matrix composite, wherein the base slurry contains powders of a metal oxide, at least one of silicon carbide, silicon nitride, or free silicon, and barium-magnesium-aluminosilicate in a first carrier fluid, drying the deposited base slurry to produce a base green layer, depositing a transition slurry on the base green layer, wherein the transition slurry contains powders of a metal oxide, at least one of silicon carbide, silicon nitride, or free silicon, at least one of zirconium carbide, zirconium nitride, or zirconium oxide, and barium-magnesium-aluminosilicate in a second carrier fluid, drying the deposited transition slurry to produce a transition green layer, and forming a consolidated coating on the ceramic matrix composite by heating the base green layer and the at least one transition green layer to cause chemical reactions that conv
    Type: Grant
    Filed: August 9, 2019
    Date of Patent: January 9, 2024
    Assignee: RTX CORPORATION
    Inventors: Imelda P. Smyth, Sarah A. Frith
  • Patent number: 11505503
    Abstract: Batch mixtures comprising alumina trihydrate for forming ceramic honeycomb bodies comprised of cordierite and methods of manufacturing honeycomb bodies from such batch mixtures are provided.
    Type: Grant
    Filed: April 15, 2020
    Date of Patent: November 22, 2022
    Assignee: Corning Incorporated
    Inventors: Marcia Kim Hansen, Michael James Lehman, Elizabeth Marie Vileno
  • Patent number: 11280243
    Abstract: A catalyst substrate may include a ceramic base body including first and second ends, the second end being opposite to the first end, and the ceramic base body being provided with a plurality of cells each extending between the first and second ends; and a plurality of metal particles or metal fragments introduced into one or more internal spaces of one or more selected cells in the plurality of cells. Each of the plurality of metal particles or metal fragments has a size equal to or less than an opening width of the cell. The plurality of metal particles or metal fragments is configured to generate heat in accordance with varying magnetic field.
    Type: Grant
    Filed: April 16, 2019
    Date of Patent: March 22, 2022
    Assignees: NGK Insulators, Ltd., Faurecia Systemes D'Echappement
    Inventors: Yukio Miyairi, Masaaki Masuda, Jean-Paul Brunel
  • Patent number: 11136272
    Abstract: The present disclosure is related to a method of producing a fired ceramic article. The method may include: heating a ceramic green body in a kiln, and controlling oxygen concentration in the kiln such that the oxygen concentration swings during the heating of the ceramic green body.
    Type: Grant
    Filed: November 20, 2018
    Date of Patent: October 5, 2021
    Assignee: NGK Insulators, Ltd.
    Inventors: Daniel Yukichi Kitaguchi, Takeshi Tokunaga
  • Patent number: 10352211
    Abstract: An exhaust gas purification filter collects PM contained in and purifies exhaust gas emitted from a gasoline direct injection engine. The exhaust gas purification filter has a honeycomb structural body which has a plurality of cells, partition walls and plug members. Each of the cells is surrounded by the partition walls. An opening section of one end of each of the cells is plugged by a plug member. The plug members satisfies a relationship of L/D?50 and L?3, where L is an average length (mm) of the plug members and D is an average pore size mm of the plug members. The honeycomb structural body and the plug members are made of cordierite. The cordierite contains silica, talc, kaolin, alumina and/or aluminum hydroxide, etc.
    Type: Grant
    Filed: January 27, 2015
    Date of Patent: July 16, 2019
    Assignee: DENSO CORPORATION
    Inventor: Mikio Ishihara
  • Patent number: 10022715
    Abstract: The manufacturing method of the honeycomb structure includes a raw material preparing step of adding the powder of porous silica as the inorganic pore former to a forming raw material and kneading the forming raw material to prepare the kneaded forming raw material, an extruding step of extruding the obtained forming raw material to form a honeycomb formed body, and a firing step of firing the extruded honeycomb formed body to form a honeycomb structure containing a cordierite component, and an amount of oil to be absorbed by the porous silica to be added to the forming raw material is in a range of 50 to 190 ml/100 g, and a BET specific surface area of the porous silica is in a range of 340 to 690 m2/g.
    Type: Grant
    Filed: February 16, 2017
    Date of Patent: July 17, 2018
    Assignee: NGK Insulators, Ltd.
    Inventor: Kosuke Nobiki
  • Patent number: 9480388
    Abstract: A drying duct and a household appliance having the same. The household appliance includes a main body, a drying space placed in the main body and including an air suction hole and an air drain hole, a drying duct including at least one inside-air suction hole communicating with the air drain hole, an inside-air discharge hole communicating with the air suction hole, and an outside-air suction hole and an outside-air discharge hole communicating with the outside of the drying space, and at least one dehumidifying agent placed in the drying duct. The drying duct includes an inside-air suction path into which air inside of the drying space is suctioned, an outside-air suction path into which air outside of the drying space is suctioned, and an inside/outside air movement path communicating with the inside-air suction path and the outside-air suction path.
    Type: Grant
    Filed: June 20, 2011
    Date of Patent: November 1, 2016
    Assignee: SAMSUNG ELECTRONICS CO., LTD.
    Inventors: Seung Gee Hong, Woo Jin Shin, Jae Man Joo, Young Hwan Ko
  • Patent number: 9054502
    Abstract: A ceramic insulator for surrounding an electrode of an ignition device, such as a corona igniter or spark plug, is provided. The insulator is formed of a ceramic material including alumina in an amount of 28 to 38 wt. %, silica in an amount of 57 to 67 wt. %, and calcium oxide in an amount of 3 to 7 wt. %, based on the total weight of the ceramic material. The ceramic insulator is typically formed by firing a mixture of Kaolin, calcium carbonate, and silica, wherein the calcium carbonate acts as a flux during firing. The ceramic material has a relative permittivity of about 5.5 to 6.5 and thus improves the electrical efficiency of the ignition device. The ceramic material is also capable of withstanding temperatures of 900 to 1000° C. and has excellent thermal shock resistance, making it suitable for use in internal combustion engines.
    Type: Grant
    Filed: August 6, 2014
    Date of Patent: June 9, 2015
    Assignee: Federal-Mogul Ignition Company
    Inventor: William J. Walker, Jr.
  • Patent number: 9028741
    Abstract: A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and a 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, applying sealant composition including aluminum hydroxide particles, talc particles, kaolin particles, water and organic binder to either end of each through-hole of the body in the longitudinal direction such that the honeycomb structure of the body has each through-hole sealed at one end, and sintering the body made of the raw material paste and having the honeycomb structure sealed by the sealant composition such that a ceramic body having the honeycomb structure is formed.
    Type: Grant
    Filed: April 30, 2013
    Date of Patent: May 12, 2015
    Assignee: Ibiden Co., Ltd.
    Inventor: Kazunori Yamayose
  • Patent number: 9005517
    Abstract: A method for making a cordierite filter article, including: firing an extruded green body batch composition according to: a first temperature ramping from ambient temperature up to a first soaking temperature; a first soaking at a temperature of at least 1255° C. for at least 2 hours; a second temperature ramping from the first soak temperature down to a second soak temperature; and a second soaking at a temperature of at least 1250° C. and at least 5° C. below the first soaking temperature, as defined herein.
    Type: Grant
    Filed: May 16, 2012
    Date of Patent: April 14, 2015
    Assignee: Corning Incorporated
    Inventors: David J Bronfenbrenner, Lisa Larae Hepburn, Sriram Rangarajan Iyer, Lev Lvovitch Kuandykov, Dell Joseph St Julien, Elizabeth Ann White
  • Patent number: 8999224
    Abstract: A porous ceramic honeycomb article includes a primary cordierite phase and an intercrystalline glass phase. In an as-fired condition, the porous ceramic honeycomb article exhibits microcrack parameter Nb3?0.06 and an as-fired E500° C./E25° C. ratio ?0.99. The article exhibits a coated microcrack parameter Nb3?0.14 and a coated E500° C./E25° C. ratio ?1.06 after the porous ceramic honeycomb article has been washcoated and calcined at a temperature of 550° C. After the article is exposed to a thermal treatment at a temperature ?800° C. following washcoating and calcining, at least a first portion of the porous ceramic honeycomb article has a first treated microcrack parameter Nb3?0.18, and a first treated mean coefficient of thermal expansion of not more than 12×10?7/° C. over a temperature range of 25° C. to 800° C. Methods of forming the porous ceramic honeycomb article are also disclosed.
    Type: Grant
    Filed: November 30, 2010
    Date of Patent: April 7, 2015
    Assignee: Corning Incorporated
    Inventors: Douglas Munroe Beall, Gregory Albert Merkel, Martin Joseph Murtagh
  • Patent number: 8974721
    Abstract: A method of making ceramic bodies includes systematically orienting the bodies during firing relative to a temperature gradient in a kiln. The systematic orientation of the bodies relative to the temperature gradient can allow for an average deviation of a measured shape of the ceramic bodies from a predetermined target contour shape to be less than what they would be if the bodies were oriented randomly relative to the temperature gradient.
    Type: Grant
    Filed: August 1, 2012
    Date of Patent: March 10, 2015
    Assignee: Corning Incorporated
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodbourn, David Robertson Treacy, Jr., Casey Allen Volino
  • Patent number: 8974723
    Abstract: 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: Grant
    Filed: February 9, 2009
    Date of Patent: March 10, 2015
    Assignee: NGK Insulators, Ltd.
    Inventors: Yasushi Noguchi, Takehiko Watanabe, Takeshi Tokunaga, Yukari Nakane
  • Patent number: 8974722
    Abstract: A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and a 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 partitions formed between the through-holes, immersing each of end portions of the body in the longitudinal direction into a sealant slurry heated at a temperature in the range of from 50° C. to 100° C. such that the sealant slurry infiltrates into the through-holes at one of the end portions of the body and seals either end of each of the through-holes of the body, and sintering the body having the honeycomb structure such that a ceramic body having the honeycomb structure is formed.
    Type: Grant
    Filed: April 30, 2013
    Date of Patent: March 10, 2015
    Assignee: Ibiden Co., Ltd.
    Inventor: Kazunori Yamayose
  • Publication number: 20150028528
    Abstract: A method for firing a green honeycomb ceramic body including heating the green honeycomb ceramic body from room temperature to a first temperature of less than or equal to about 350° C. with at least one heating rate of greater than or equal to about 80° C./hr. The green honeycomb ceramic body may be heated from the first temperature to a second temperature of greater than or equal to about 800° C. at a heating rate of greater than or equal to about 90° C./hr. The green honeycomb ceramic body may be heated from the second temperature to a third temperature of greater than or equal to about 1000° C. The green honeycomb ceramic body may include aluminum raw materials for forming an aluminum titanate ceramic body.
    Type: Application
    Filed: July 26, 2013
    Publication date: January 29, 2015
    Applicant: CORNING INCORPORATED
    Inventors: David Jack Bronfenbrenner, Luan Trong Nguyen, Elizabeth Marie Vileno
  • Publication number: 20150028527
    Abstract: A method for firing a green honeycomb ceramic body including heating the green honeycomb ceramic body from room temperature to a first temperature of about 300° C. The green honeycomb ceramic body is then heated from the first temperature to a second temperature of greater than or equal to about 800° C. at a heating rate of greater than or equal to about 90° C./hr. The green honeycomb ceramic body may have a diameter of from greater than or equal to about 4.0 inches to less than or equal to about 9.0 inches, and it may include a carbon-based pore former in a concentration of from greater than or equal to about 10% to less than or equal to about 45% by weight.
    Type: Application
    Filed: July 26, 2013
    Publication date: January 29, 2015
    Applicant: CORNING INCORPORATED
    Inventors: David Jack Bronfenbrenner, Sriram Rangarajan Iyer
  • Patent number: 8926875
    Abstract: The invention is directed to a method for managing pore size distribution in honeycomb substrates by using two or more pore forming agents in the batch ingredients. In particular, the invention is particularly useful in managing pore size distribution in cordierite and aluminum titanate honeycomb substrates in the face of particle size variations in the pore forming agents and other materials used to make such substrates.
    Type: Grant
    Filed: August 27, 2009
    Date of Patent: January 6, 2015
    Assignee: Corning Incorporated
    Inventors: Mark Allen Spetseris, Balaji Venkatesan Swarnamani, Conor J Walsh, Gregory N Yourkievitz
  • Patent number: 8926891
    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: Grant
    Filed: April 27, 2011
    Date of Patent: January 6, 2015
    Assignee: Sumitomo Chemical Company, Limited
    Inventor: Kousuke Uoe
  • Publication number: 20140370232
    Abstract: There is disclosed a porous material containing aggregates; and a composite binding material which binds the aggregates to one another in a state where pores are formed and in which mullite particles that are reinforcing particles are dispersed in cordierite that is a binding material, and a content of metal silicon is smaller than 15 mass %. Preferably, to a total mass of the aggregates, the composite binding material and the metal silicon, a lower limit value of a content of the composite binding material is 12 mass %, and an upper limit value of the content of the composite binding material is 50 mass %. Preferably, to the total mass, a lower limit value of a content of the mullite particles is 0.5 mass %, and an upper limit value of the content of the mullite particles is 15 mass %. A porous material having a high thermal shock resistance is provided.
    Type: Application
    Filed: September 4, 2014
    Publication date: December 18, 2014
    Inventors: Yunie IZUMI, Yoshimasa KOBAYASHI
  • 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
  • Patent number: 8894917
    Abstract: Methods of making a porous cordierite ceramic honeycomb article are provided. In example methods, a batch composition includes a quantity of non-crosslinked pore former provided as a superaddition of about 20% or less of a dry weight of a quantity of inorganic components. Batch compositions are also provided that include a quantity of clay and other substantially nonfibrous inorganic components sufficient to yield an article including cordierite. Example batch compositions can include clay having a median particle size of about 7 ?m or less and/or provided in an amount that is 10% or less of the dry weight of the quantity of inorganic components.
    Type: Grant
    Filed: May 19, 2009
    Date of Patent: November 25, 2014
    Assignee: Corning Incorporated
    Inventor: William Peter Addiego
  • 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
  • Publication number: 20140290195
    Abstract: There is disclosed a porous material which has an improved thermal shock resistance. The porous material contains aggregates and a composite binder. The composite binder includes glass as a binder and mullite particles as reinforcing particles, and the mullite particles are dispersed in the glass. The aggregates are connected to each other by the composite binder in a state where pores are formed in the porous material. Preferably, a lower limit of a percentage of a content of the composite binder to a total mass of the aggregates and composite binder is 12 mass %, and an upper limit of the percentage of the content of the composite binder to the total mass of the aggregates and composite binder is 50 mass %. Preferably, the glass contains MgO, Al2O3 and SiO2 and further contains at least one selected from a group consisting of Na2O, K2O and CaO.
    Type: Application
    Filed: March 4, 2014
    Publication date: October 2, 2014
    Applicant: NGK Insulators, Ltd.
    Inventors: Yunie IZUMI, Yoshimasa KOBAYASHI
  • Publication number: 20140290196
    Abstract: Provided is a technique to manufacture a honeycomb structure reducing a width of dimensional difference generated during firing between an end part and a central part and having excellent thermal shock resistance, and the method includes: a honeycomb formed body preparing step of extruding a kneaded material including a cordierite forming raw material A, to prepare a formed body; a plugged honeycomb formed body preparing step of filling cell openings thereof with a plugging material which includes a forming raw material containing a cordierite forming raw material B and resin balloon of 1.0 to 15 mass % and has a difference in firing shrinkage rate of ?1.0 to +2.0% from the formed body, to prepare a plugged formed body; and a honeycomb structure preparing step of firing the prepared plugged formed body, to prepare a honeycomb structure provided with porous plugged portions.
    Type: Application
    Filed: March 27, 2014
    Publication date: October 2, 2014
    Applicant: NGK Insulators, Ltd.
    Inventors: Yusuke TSUCHIYA, Hiroyuki SUENOBU, Masaki HOURA, Yuichi HAMAZAKI
  • 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
  • Patent number: 8808601
    Abstract: Honeycomb ceramic wall flow filters exhibiting reduced plug depth variability, produced by introducing flowable ceramic plugging cements into the ends of selected channels in the honeycombs and wherein the ceramic plugging cements consist of shear-conditioned mixtures exhibiting reduced viscosity differentials.
    Type: Grant
    Filed: April 29, 2009
    Date of Patent: August 19, 2014
    Assignee: Corning Incorporated
    Inventors: Michael C Brown, Luiz Eduardo Ferri, Ralph Henry Hagg, Robert Daniel Parker
  • 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: 8741210
    Abstract: Porous spodumene-cordierite honeycomb bodies of high strength but low volumetric density, useful for the manufacture of close-coupled engine exhaust converters, gasoline engine particulate exhaust filters, and NOx integrated engine exhaust filters, are provided through the reactive sintering of batches comprising sources of magnesia, alumina and silica together with a lithia source, such as a spodumene or petalite ore.
    Type: Grant
    Filed: February 15, 2013
    Date of Patent: June 3, 2014
    Assignee: Corning Incorporated
    Inventors: Gregory Albert Merkel, Cameron Wayne Tanner
  • 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
  • Publication number: 20140113106
    Abstract: A honeycomb structure mainly composed of cordierite and obtained by forming and firing a forming material containing a layered clay mineral whose layer charge (X) is 0.2<X?2 in addition to the cordierite forming material and an organic binder. A total amount of at least one element selected from a group consisting of sodium, potassium, and calcium contained in the layered clay mineral is set to 0.5% by mass or less in terms of oxide with respect to a total with the cordierite forming material, and a content ratio of the organic binder is set to 5 parts by mass or less with respect to 100 parts by mass in total of the cordierite forming material and the layered clay mineral.
    Type: Application
    Filed: December 23, 2013
    Publication date: April 24, 2014
    Applicant: NGK INSULATORS, LTD.
    Inventors: Takahiro TOMITA, Shinji KAWASAKI
  • Patent number: 8691361
    Abstract: A ceramic honeycomb structure having a large number of flow paths defined by porous cell walls having porosity of 45-68% and an average pore size of 15-35 ?m, the volume of pores having diameters of more than 50 ?m being more than 10% and 25% or less of the total pore volume, the volume of pores having diameters of 100 ?m or more being 1-8% of the total pore volume, the volume of pores having diameters of less than 10 ?m being 3-10% of the total pore volume, and the pores having a pore size distribution deviation ? [=log(D20)?log(D80)] of 0.45 or less, wherein D20 represents a pore size (?m) at a pore volume corresponding to 20% of the total pore volume, and D80 represents a pore size (?m) at a pore volume corresponding to 80% of the total pore volume, in a curve showing the relation between a pore size and a cumulative pore volume obtained by accumulating a pore volume from the maximum pore size to a particular pore size, and D80<D20.
    Type: Grant
    Filed: March 18, 2009
    Date of Patent: April 8, 2014
    Assignee: Hitachi Metals, Ltd.
    Inventors: Shunji Okazaki, Toshitaka Ishizawa
  • 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.
  • Patent number: 8663545
    Abstract: There are provided a honeycomb structure and a method of manufacturing the structure, capable of preventing or reducing generation of CO2 or harmful gas during firing to thereby prevent or inhibit pollution and global warming, and capable of obtaining a honeycomb structure having few defects such as cracks and maintaining high strength and low thermal expansion. In a method of manufacturing a honeycomb structure, in which a forming material containing a cordierite forming material and an organic binder is kneaded and formed to prepare a honeycomb-shaped formed article (honeycomb formed article), and the prepared honeycomb formed article is fired to obtain a honeycomb-shaped structure (honeycomb structure) mainly composed of cordierite: the forming material containing a layered clay mineral whose layer charge (X) is 0.
    Type: Grant
    Filed: November 19, 2004
    Date of Patent: March 4, 2014
    Assignee: NGK Insulators, Ltd.
    Inventors: Takahiro Tomita, Shinji Kawasaki
  • Patent number: 8591800
    Abstract: A method of manufacturing a cordierite-based honeycomb structure, comprising: adding an alumina source material, a silica source material and a magnesia source material to obtain a cordierite forming material; obtaining a clay by use of the resultant cordierite forming material; extruding the resultant clay into a honeycomb shape to obtain a formed honeycomb body; drying the resultant formed honeycomb body to obtain a dried honeycomb body; and firing the resultant dried honeycomb body to manufacture the cordierite-based honeycomb structure, wherein a first alumina source material having a degree of circularity of 0.70 or more and an average particle diameter of 1 to 10 ?m is added as at least the alumina source material in an amount of 10 mass % or more with respect to the total mass of the cordierite forming material to obtain the cordierite forming material.
    Type: Grant
    Filed: September 22, 2005
    Date of Patent: November 26, 2013
    Assignee: NGK Insulators, Ltd.
    Inventors: Yasushi Noguchi, Hiroyuki Suenobu
  • Publication number: 20130269303
    Abstract: The present invention provides a green molded body capable of easily controlling the porosity of a honeycomb structure. One aspect of the present invention is a green molded body composed of a honeycomb-shaped cylindrical body 70 with a plurality of through holes 70a being formed approximately in parallel with each other, wherein the cylindrical body 70 comprises a ceramic raw material powder and a fluorine source, and wherein the ceramic raw material powder is the one for forming at least one of an aluminum titanate-based ceramics and a cordierite-based ceramics by sintering.
    Type: Application
    Filed: December 13, 2011
    Publication date: October 17, 2013
    Applicant: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventors: Kousuke Uoe, Osamu Yamanishi
  • Publication number: 20130255207
    Abstract: There is disclosed a honeycomb structure which has an excellent collecting performance of a particulate matter and in which a pressure loss during flowing of a fluid through the honeycomb structure is low. The honeycomb structure includes a honeycomb base material having porous partition walls with which a plurality of cells are formed to become through channels of a fluid, a value of a ratio of an average open frontal area diameter of pores which are open in the surfaces of the partition walls to an average pore diameter of the pores formed in the partition walls is from 0.05 to 0.45, the partition walls have a single layer structure, and preferably, an open frontal area diameter of each of the pores which are open in the surfaces of the partition walls is from 0.5 to 10 ?m.
    Type: Application
    Filed: March 21, 2013
    Publication date: October 3, 2013
    Applicant: NGK INSULATORS, LTD.
    Inventors: Yunie IZUMI, Yoshimasa KOBAYASHI
  • Patent number: 8529826
    Abstract: There is provided a manufacturing method of a honeycomb structure, comprising: forming kneaded clay containing a cordierite forming raw material formed by mixing talc having an average particle diameter of 0.1 to 40 ?m, kaolin having an average particle diameter of 0.1 to 20 ?m, an alumina source raw material having an average particle diameter of 0.05 to 10 ?m, and a silica having an average particle diameter of 0.1 to 20 ?m, a binder, a surface active agent, water, and a hygroscopic resin having an average particle diameter of two to 200 ?m after water absorption and a water absorption magnification of two to 100 magnifications into honeycomb shape to fabricate a honeycomb formed body; and firing the honeycomb formed body to obtain a honeycomb structure whose porosity is less than 40%.
    Type: Grant
    Filed: March 9, 2009
    Date of Patent: September 10, 2013
    Assignee: NGK Insulators, Ltd.
    Inventors: Yohei Ono, Yasushi Noguchi
  • 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
  • Patent number: 8497009
    Abstract: A honeycomb structure 10 of the present invention is provided with porous partition walls 12 made of a ceramic material containing cordierite as a main crystal phase and separating and forming a plurality of cells 14 functioning as fluid passages. The partition walls 12 contain sodium at 0.08 to 0.15 mass % in terms of sodium oxide. A honeycomb structure having a large average pore size can be provided.
    Type: Grant
    Filed: September 14, 2009
    Date of Patent: July 30, 2013
    Assignee: NGK Insulators, Ltd.
    Inventors: Yasushi Noguchi, Yukari Nakane
  • 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
  • Publication number: 20130111862
    Abstract: Disclosed are ceramic bodies comprised of composite cordierite aluminum magnesium titanate ceramic compositions and methods for the manufacture of same.
    Type: Application
    Filed: November 14, 2012
    Publication date: May 9, 2013
    Inventors: Adriane Marie Divens-Dutcher, Patrick David Tepesch, Elizabeth Marie Vileno
  • Publication number: 20130106031
    Abstract: A method of manufacturing a particulate filter includes plugging at least some of the channels of a green cellular ceramic body on a first end with a green plugging material that includes a liquid vehicle to form a partially plugged green cellular ceramic body, firing the partially plugged green cellular ceramic body to form a partially plugged ceramic article, and plugging at least some of the channels on a second end of the partially plugged ceramic article with a plugging material that sets at a temperature of less than 1000° C.
    Type: Application
    Filed: October 31, 2011
    Publication date: May 2, 2013
    Inventors: Thorsten Rolf Boger, Todd Parrish St Clair, Patrick David Tepesch, Brian Paul Usiak
  • Patent number: 8398797
    Abstract: A method for producing a cordierite-based ceramic honeycomb filter comprising the steps of introducing a plugging material of a cordierite-forming material into predetermined flow paths of a sintered, cordierite-based ceramic honeycomb having an outer diameter of 150 mm or more, and drying and sintering the resultant plugs, the sintering step comprising a temperature-elevating process, a temperature-keeping process and a temperature-lowering process, and the temperature-elevating process having a temperature-elevating speed of 70-500° C./hr from 800° C. to the highest keeping temperature.
    Type: Grant
    Filed: September 28, 2007
    Date of Patent: March 19, 2013
    Assignee: Hitachi Metals, Ltd.
    Inventor: Shunji Okazaki
  • Publication number: 20130055694
    Abstract: A ceramic honeycomb structure suitable for particulate filters, having an inlet face and an outlet face, comprising a plurality of inlet cells and a plurality of outlet cells extending through the structure from the inlet face to the outlet face, the inlet cells being open at the inlet face and closed where adjoining the outlet face, and the outlet cells being open at the outlet face and closed where adjoining the inlet face. The inlet and/or outlet cells are quadrangular in cross-section and are arranged in an alternating pattern; the outlet cells may have a cross-sectional area generally smaller than that of inlet cells and no point of a given inlet cell is closer to an adjacent inlet cell than to an adjacent outlet cell. A process for preparing the ceramic honeycomb structure is also disclosed.
    Type: Application
    Filed: March 25, 2011
    Publication date: March 7, 2013
    Applicant: IMERYS
    Inventors: Thierry Salmona, Carl De Poncins
  • Publication number: 20130049269
    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: April 27, 2011
    Publication date: February 28, 2013
    Applicant: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventor: Kousuke Uoe
  • Patent number: 8377836
    Abstract: The present disclosure relates to methods of making ceramic bodies using catalyzed pore formers and compositions for making the same.
    Type: Grant
    Filed: May 22, 2009
    Date of Patent: February 19, 2013
    Assignee: Corning Incorporated
    Inventors: Philippe J Barthe, Irene Mona Peterson, Andrew Paul Schermerhorn
  • Patent number: 8377370
    Abstract: Disclosed are high-porosity cordierite honeycomb substrates having fine pore size, narrow pore size distribution, little or no microcracking, and a high thermal shock resistance. The porous ceramic honeycomb substrates generally include a primary cordierite ceramic phase as defined herein. Also disclosed are methods for making and using the cordierite substrates.
    Type: Grant
    Filed: March 5, 2010
    Date of Patent: February 19, 2013
    Assignee: Corning Incorporated
    Inventor: Gregory Albert Merkel