From Cordierite (i.e., 2mgo.2a12o3.5sio2, Iolite) Patents (Class 264/631)
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Patent number: 8268401Abstract: A method for producing a ceramic honeycomb structure comprising applying a coating material to an outer peripheral surface of the ceramic honeycomb body to form an outer peripheral wall, the thickness of the coating material applied being determined from the outer diameter of the ceramic honeycomb body and the drying shrinkage ratio of the coating material, such that the outer diameter of the dried ceramic honeycomb structure is within a target outer size±1.4 mm.Type: GrantFiled: March 19, 2008Date of Patent: September 18, 2012Assignee: Hitachi Metals, Ltd.Inventor: Shinya Tokumaru
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Patent number: 8192667Abstract: A method of manufacturing a honeycomb structure having a plugged portion, which is faster and cheaper to manufacture, and a manufacturing apparatus thereof. A film is attached to an end face of a honeycomb structure in a state where the honeycomb structure is positioned in a table portion having a through hole into which the end face portion of the honeycomb structure is to be inserted, and the film is held in a flat state where a remaining portion of the film which is not attached to the end face is attached to the table portion. Then, holes opened so as to correspond to the openings of a part of cells are formed in the film to form the film as a mask, and a plugging material having fluidity is supplied onto the mask or onto the same plane as the mask to fill the cells with the plugging material.Type: GrantFiled: January 13, 2011Date of Patent: June 5, 2012Assignee: NGK Insulators, Ltd.Inventors: Ryuichi Shoji, Takuya Nunome, Koji Kimura, Yoshimasa Kondo, Hiroyuki Tsuji
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Patent number: 8187525Abstract: A method of forming a porous ceramic article having a narrow pore distribution includes heating a green body containing ceramic forming raw materials in a firing environment that raising the temperature of the firing environment to a peak temperature, then reducing the temperature to a hold temperature in order to form porous ceramic.Type: GrantFiled: August 27, 2008Date of Patent: May 29, 2012Assignee: Corning IncorporatedInventors: Martha Blanche Custer, Jennifer Lynn Lyon, Jianguo Wang
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Patent number: 8178019Abstract: A method for producing a ceramic honeycomb structure comprising the steps of machining end surfaces of an unsintered or sintered ceramic honeycomb structure, and ejecting a gas from a slit-like orifice moving relative to an opposing end surface without contact, thereby removing dust and/or cut pieces from end surface portions.Type: GrantFiled: September 27, 2007Date of Patent: May 15, 2012Assignee: Hitachi Metals, Ltd.Inventors: Shuhei Aramaki, Junji Komatsu
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Patent number: 8124002Abstract: An extrusion-molding machine according to the present invention comprises: a screw having a blade portion for extruding a molding material, the screw disposed in a tightly-closed space; and a die for molding an extruded molding material, wherein the space is maintained in a reduced-pressure atmosphere, and a high-hardness coat layer is formed at least on the blade portion.Type: GrantFiled: April 5, 2007Date of Patent: February 28, 2012Assignee: Ibiden Co., Ltd.Inventors: Norihiko Yamamura, Kazuya Naruse, Eiji Sumiya, Kosei Tajima
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Patent number: 8119056Abstract: The end face processing apparatus of the present invention is an end face processing apparatus for processing the cut face of a cut ceramic molded body, which comprises an air blowing outlet and an extraneous material removal member, and is configured to remove burrs remaining on the cut face from the time of cutting as well as powder adhering to the cut face and on the periphery thereof using the extraneous material removal member and air from the air blowing outlet.Type: GrantFiled: October 12, 2006Date of Patent: February 21, 2012Assignee: Ibiden Co., Ltd.Inventors: Tsuyoshi Kawai, Eiji Sumiya, Yoshiteru Ohira
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Patent number: 8110139Abstract: A honeycomb structure is manufactured by molding a pillar-shaped honeycomb molded body having a large number of cells disposed in parallel with one another in a longitudinal direction with a cell wall therebetween by extrusion-molding a raw material composition including a ceramic powder and a binder, and carrying out a firing treatment on the honeycomb molded body to manufacture a honeycomb fired body. A plurality of the honeycomb fired bodies are provided, and both end faces of each of the plurality of the honeycomb fired bodies are hold with a holding member after positioning the plurality of the honeycomb fired bodies on a predetermined position. An adhesive paste is injected into a gap between the plurality of honeycomb fired bodies held on the predetermined position. The adhesive paste is dried and solidified to form an adhesive layer.Type: GrantFiled: March 7, 2008Date of Patent: February 7, 2012Assignee: Ibiden Co., Ltd.Inventors: Kazushige Ohno, Masafumi Kunieda, Masatoshi Okuda
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Publication number: 20120028786Abstract: A method of fabricating a cordierite article from one or more steel slags such as blast furnace slag, converter slag and electric furnace slag. The cordierite article is useful for a particulate filter such as Diesel Particulate Filter.Type: ApplicationFiled: July 30, 2010Publication date: February 2, 2012Applicant: EMPIRE TECHNOLOGY DEVELOPMENT LLCInventor: Yugo Tomita
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Publication number: 20120023879Abstract: 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: ApplicationFiled: March 31, 2010Publication date: February 2, 2012Applicant: HITACHI METALS, LTD.Inventor: Shunji Okazaki
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Patent number: 8101117Abstract: The present invention provides compositions and methods for producing porous ceramic articles. The compositions and methods comprise a ceramic precursor batch comprising an organic peroxide pore forming agent where the pore forming agent is an organo-adduct of hydrogen peroxide and an organic compound or an organic peroxide of the general formula R—O—O—R?. The organic peroxide pore forming agent is stable during extrusion and other methods for forming a green body and does not decompose until the green body is dried.Type: GrantFiled: May 30, 2008Date of Patent: January 24, 2012Assignee: Corning, IncorporatedInventors: William Peter Addiego, Christopher Raymond Glose
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Patent number: 8092740Abstract: A porous material is provided, including a connected structure formed by combining silicon carbide aggregate particles with cordierite, which is a combining material in a state to hold a large number of pores, and having a porosity of 52 to 70% and a median pore diameter of 15 to 30 ?m. The porous material has a high porosity and a high strength and has a remarkably low possibility of including defective portions, such as cuts and the like which cause liquid leakage when the material is used as a filter.Type: GrantFiled: October 10, 2008Date of Patent: January 10, 2012Assignee: NGK Insulators, Ltd.Inventors: Kenji Morimoto, Katsuhiro Inoue
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Patent number: 8075829Abstract: There is provided a method for drying a honeycomb formed article 1. The method has the first step, where an unfired honeycomb formed article 1 having a plurality of cells separated by partition walls made from raw material composition containing a ceramic raw material, water, and a binder is heated and dried by microwave drying or dielectric drying, and a second step, where the honeycomb formed article 1 is dried by hot air drying, where hot air whose humidity was adjusted to have a wet-bulb temperature of 50 to 100° C. using a hot air drying apparatus 11 after the first step is passed through the cells. The method can dry a honeycomb formed article in a shorter period of time with inhibiting generation of a defect such as a deformation or breakage.Type: GrantFiled: August 7, 2009Date of Patent: December 13, 2011Assignee: NGK Insulators, Ltd.Inventors: Shuichi Takagi, Yasuhiro Horiba
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Publication number: 20110294650Abstract: 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: ApplicationFiled: May 18, 2011Publication date: December 1, 2011Inventors: Michele Fredholm, David Henry, Maxime Moreno
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Patent number: 8038759Abstract: A method of manufacturing a fibrous material includes mixing at least two cordierite precursor materials to form a mixture. One or more of the at least two cordierite precursor materials is in a form of a fiber and the mixture includes about 43% to about 51% by weight SiO2, about 36% to about 41% by weight Al2O3, and about 12% to about 16% by weight MgO. The method also includes extruding the mixture to create a fibrous body, and heat treating the fibrous body, at a temperature of about 1200° C. to about 1420° C., to form the fibrous material including about 50% to about 95% by weight cordierite. A fibrous body includes an extruded substrate having a plurality of fibers including about 50% to about 95% by weight cordierite. The extruded substrate has a coefficient of thermal expansion in at least one direction of less than about 3.8·10?6 per ° C.Type: GrantFiled: July 12, 2008Date of Patent: October 18, 2011Assignee: Geoz Technologies, Inc.Inventors: James Jenq Liu, Bilal Zuberi, Rachel A. Dahl, William M. Carty
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Publication number: 20110168141Abstract: A fuel activation catalyzer for an energy saver of an internal combustion engine is provided, which including nanometer negative ions and far infrared materials, and carrier of the nanometer negative ions material selecting from the following material's: cordierite ceramic material and/or limestone, wherein the weight of the nanometer negative ions and far infrared materials to the total weight of the nanometer negative ions and far infrared materials and the carrier is 5 wt %-30 wt %. And a manufacture method of the catalyzer for an energy saver of an internal combustion engine and an energy saver of an internal combustion engine using the catalyzer are also provided. By using the energy saver, the oil circuits and gas circuits are improved, the combustion is promoted and the heat value of the fuel is enhanced.Type: ApplicationFiled: July 13, 2007Publication date: July 14, 2011Inventors: Youping Zhou, Xiaoquan Gao, Jiequan Gao
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Patent number: 7976768Abstract: A ceramic forming batch mixture including inorganic batch materials, such as sources of alumina, titania, and silica, a pore former combination including first and second pore formers with different compositions; an organic binder; and a solvent. Also disclosed is a method for producing a ceramic article involving mixing the inorganic batch materials with the pore former combination having first and second pore formers of different composition, adding an organic binder and a solvent, forming a green body; and firing the green body. A green body having a combination of first and second pore formers with different compositions is disclosed, as are several methods for firing to produce ceramic articles such as aluminum titanate.Type: GrantFiled: May 31, 2006Date of Patent: July 12, 2011Assignee: Corning IncorporatedInventors: Michael Donavon Brady, Thomas James Deneka, Steven Bolaji Ogunwumi, Paul John Shustack, David Lambie Tennent, Patrick David Tepesch, Jianguo Wang, Christopher John Warren
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Patent number: 7960009Abstract: A porous ceramic substrate includes a first phase of microcracked cordierite ceramic material and a second phase of non-cordierite metal oxide particles dispersed in the cordierite ceramic, wherein at least a portion of the interface between the first and second phases is wetted by glass and the particles of the second phase have a size in the range of from about 0.1 to about 10 ?m.Type: GrantFiled: February 29, 2008Date of Patent: June 14, 2011Assignee: Corning IncorporatedInventors: Monika Backhaus-Ricoult, Christopher Raymond Glose
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Patent number: 7947620Abstract: A method of forming a porous mullite composition of acicular mullite grains having improved properties is described, where the mullite is formed at some time in the presence of a fluorine containing gas. For example, it has been discovered that improved properties may result from heating the mullite to a high temperature in an atmosphere selected from the group consisting of water vapor, oxygen, an inert gas or mixtures thereof or forming the mullite composition from precursors having an Al/Si ratio of at most 2.95.Type: GrantFiled: July 25, 2008Date of Patent: May 24, 2011Assignee: Dow Global Technologies LLCInventors: Chandan Saha, Aleksander Jozef Pyzik, Sten Wallin, Arthur M. Prunier, Clifford S. Todd
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Publication number: 20110115136Abstract: A method of manufacturing a honeycomb structural body includes performing a heat treatment on zeolite particles that have undergone an iron ion-exchange. The heat treatment is performed in a non-oxygenated atmosphere having a temperature within a range of approximately 500° C. through approximately 800° C. to obtain heat-treated zeolite particles. A honeycomb molded body is formed from a raw material including the heat-treated zeolite particles. The honeycomb molded body is fired to manufacture a honeycomb unit. The honeycomb structural body includes the honeycomb unit including plural cells extending from a first end face to a second end face in a longitudinal direction. The plural cells are partitioned by cell walls.Type: ApplicationFiled: September 16, 2010Publication date: May 19, 2011Applicant: IBIDEN CO., LTD.Inventors: Masafumi KUNIEDA, Yosuke Matsukawa
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Patent number: 7938876Abstract: A fibrous ceramic material comprises a plurality of fibers having a RxMg2Al4+xSi5?xO18 or RxMg2?xAl4Si5O18 compositional structure. The fibrous ceramic material is form by combining two or more RxMg2Al4+xSi5?xO18 or RxMg2?xAl4Si5O18 precursors in which at least one of the two or more RxMg2Al4+xSi5?xO18 or RxMg2?xAl4Si5O18 precursors is in fiber form. The fibrous ceramic material is shaped to form a fibrous body in which at least about 20% of all fibers therein are aligned in a substantially common direction.Type: GrantFiled: April 17, 2008Date of Patent: May 10, 2011Assignee: GE02 Technologies, Inc.Inventors: James Jenq Liu, William M. Carty, Bilal Zuberi, Sunilkumar C. Pillai
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Patent number: 7922963Abstract: A method for inspecting a honeycomb structured body of the present invention is a method for inspecting a honeycomb structured body comprising a pillar-shaped honeycomb fired body having a multitude of cells placed in parallel with one another in the longitudinal direction with a cell wall therebetween, the method comprising: measuring the shape of the honeycomb structured body in the longitudinal direction through preparing a contact measurement apparatus including a reference surface, a rail disposed perpendicularly to the reference surface, and a measurement probe including a contacting probe configured to move along the rail; contacting one end face of the honeycomb structured body with the reference surface; and moving the measurement probe in a direction nearing the reference surface to contact the contacting probe with the other end face of the honeycomb structured body.Type: GrantFiled: January 10, 2007Date of Patent: April 12, 2011Assignee: Ibiden Co., LtdInventors: Toru Idei, Norio Suzuki
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Patent number: 7919033Abstract: A method of manufacturing a honeycomb structure having a plugged portion, which is faster and cheaper to manufacture, and a manufacturing apparatus thereof. A film is attached to an end face of a honeycomb structure in a state where the honeycomb structure is positioned in a table portion having a through hole into which the end face portion of the honeycomb structure is to be inserted, and the film is held in a flat state where a remaining portion of the film which is not attached to the end face is attached to the table portion. Then, holes opened so as to correspond to the openings of a part of cells are formed in the film to form the film as a mask, and a plugging material having fluidity is supplied onto the mask or onto the same plane as the mask to fill the cells with the plugging material.Type: GrantFiled: July 17, 2008Date of Patent: April 5, 2011Assignee: NGK Insulators, Ltd.Inventors: Ryuichi Shoji, Takuya Nunome, Koji Kimura, Yoshimasa Kondo, Hiroyuki Tsuji
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Patent number: 7914728Abstract: A method for manufacturing a porous honeycomb structure, which comprises a mixing and kneading step, a forming and then drying step, and a firing and then cooling step of firing a dried honeycomb article to form a fired honeycomb article and then cooling the fired honeycomb article to prepare a porous honeycomb structure, wherein the fired honeycomb article is cooled from the firing temperature under a cooling condition of a temperature falling speed of 100° C./hr or less at least in a temperature region of 800° C. or lower.Type: GrantFiled: July 14, 2005Date of Patent: March 29, 2011Assignee: NGK Insulators, Ltd.Inventor: Tomoo Nakamura
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Patent number: 7897099Abstract: There is provided a honeycomb structure and a method for producing the honeycomb structure, capable of reducing variance in pore diameter depending on part and capable of increasing the mean pore diameter as a whole. There is provided a method for producing a cordierite honeycomb structure 1 including the step of firing a honeycomb formed body. In the firing step, a temperature rise rate from 1200° C. to 1250° C. is controlled to 40° C./hr or more, a temperature rise rate from 1250° C. to 1300° C. is controlled to 2 to 40° C./hr, and a temperature rise rate from 1300° C. to 1400° C. is controlled to 40° C./hr or more. There is further provided a honeycomb structure having a porosity of 50 to 70%, a mean pore diameter of 15 to 30 ?m, a difference in a mean pore diameter of 5 ?m or less between in the central portion and in the outer peripheral portion, a thermal expansion coefficient of 1.0×10?6/° C.Type: GrantFiled: January 7, 2005Date of Patent: March 1, 2011Assignee: NGK Insulators, Ltd.Inventors: Hiroyuki Suenobu, Yasushi Noguchi, Tomoo Nakamura
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Publication number: 20110036080Abstract: Disclosed are ceramic honeycomb articles which possess a unique microstructure characterized by porosity between 40% and 70%, and the presence of coarse pores exhibiting a depth equivalent to the thickness of the cell wall and a dimensional width, in the plane of the cell wall, exhibiting a diameter that is at least as large as the thickness of the cell wall. The articles exhibits reduced filtration efficiency coupled with low pressure drop across the filter, and a reduced regeneration need. Such ceramic articles are particularly well suited for filtration applications, such as off-road and retro-fit diesel exhaust filters or DPFs. Also disclosed is a method for manufacturing the ceramic article wherein the pore former is capable of forming coarse pores.Type: ApplicationFiled: May 29, 2009Publication date: February 17, 2011Inventors: Douglas Munroe Beall, Achim Karl-Erich Heibel, Pushkar Tandon, David John Thompson
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Patent number: 7862764Abstract: Electromagnetic (EM) drying of a plugged ware is provided that includes subjecting the ware to an axially non-uniform EM radiation field that causes more EM radiation to be dissipated in either of the plugged regions than in the unplugged region. The EM radiation field is provided by a configurable applicator system that includes a feed waveguide and a conveyor path. The feed waveguide includes configurable slots. The configurable applicator system can be set to selectively vary the amount of EM radiation dissipated by each ware along the longitudinal axis of each ware as a function of ware position along the conveying path, thereby enhancing the EM drying process.Type: GrantFiled: March 28, 2008Date of Patent: January 4, 2011Assignee: Corning IncorporatedInventors: James Anthony Feldman, Jacob George, Kevin Robert McCann, Rebecca Lynn Schulz, Gary Graham Squier, Elizabeth Marie Vileno
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Publication number: 20100326029Abstract: 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: ApplicationFiled: February 26, 2009Publication date: December 30, 2010Inventors: George Halsey Beall, Steven Alvin Tietje
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Publication number: 20100298113Abstract: The present disclosure relates to methods of making ceramic bodies using catalyzed pore formers and compositions for making the same.Type: ApplicationFiled: May 22, 2009Publication date: November 25, 2010Inventors: Philippe J. Barthe, Irene Mona Peterson, Andrew Paul Schermerhorn
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Publication number: 20100276851Abstract: The disclosure provides for a mixture suitable for extrusion and firing to form a ceramic honeycomb substrate, said mixture comprising a batch composition selected from the group consisting of a cordierite batch composition and an aluminum titanate batch composition, an optional pore former material; a binder material and water; wherein said binder is a methyl ether of cellulose binder having a count of less than 300 water-insoluble fibers per gram of binder material.Type: ApplicationFiled: April 30, 2009Publication date: November 4, 2010Inventors: Jun Hou, Susan Clair Lauderdale, Jonathan David Pesansky
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Patent number: 7789929Abstract: A method for forming a diesel particulate filter is presented. The method includes provided an extruder for receiving material to be extruded such extruder being configured to converting such material into a honeycomb structure having a lower portion and an upper portion. The lower portion has a bottom surface and a pair of vertically extending sidewalls terminating along outer edges of the bottom surface. The upper portion has a pair of opposing, pitched, sidewalls having lower edges terminating along upper edges of the vertically extending sidewalls and upper edges terminating along a common edge.Type: GrantFiled: April 4, 2007Date of Patent: September 7, 2010Assignee: Ford Global Technologies LLCInventor: James Riley
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Patent number: 7785385Abstract: In a ceramic honeycomb structure having large numbers of flow paths partitioned by porous cell walls, the cell walls have a porosity of 55-75%, with an average pore diameter Da of 10-30 ?m and a pore area ratio Sa of 10-30% on their surfaces, and the average length La of the pores at their openings and the average width Lb of the pores at depth La from the surfaces of the cell walls meet the condition of 1.1<Lb/La<5 in an arbitrary vertical cut surface of the cell walls. In the cordierite-based ceramic honeycomb structure, the ceramic contains Fe and a spinel, the amount of the spinel being 4% or less by an X-ray diffraction intensity ratio, and most of the spinel having particle sizes in a range of 0.01-5 ?m.Type: GrantFiled: August 30, 2004Date of Patent: August 31, 2010Assignee: Hitachi Metals, Ltd.Inventors: Tsunehiro Kawata, Osamu Tokudome, Hirohisa Suwabe, Kenichiro Sekiguchi, Hideya Yamane
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Patent number: 7744980Abstract: Disclosed is a honeycomb ceramic article that exhibits a primary crystalline phase of cordierite having a coefficient of thermal expansion (CTE), wherein CTE<1.5×10?7/° C. over the temperature range of about 25° C. to about 800° C.; a total porosity, P, of at least 28%, a transverse I-ratio, IT, of less than 0.92; and a pore size distribution wherein at least 60% of the total pore volume is comprised of pores having diameters between 0.5 ?m and 5.0 ?m. Also provided is a ceramic honeycomb article comprising a phase of cordierite and exhibiting a mean CTE <1.0×10?7/° C. (from 25 to 800° C.) in at least one direction, and 28%?P?33%. Methods of manufacturing ceramic articles comprising the aforementioned cordierite compositions are also disclosed.Type: GrantFiled: December 20, 2005Date of Patent: June 29, 2010Assignee: Corning IncorporatedInventors: James Albert Boorom, Lin He, Gregory Albert Merkel
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Patent number: 7736581Abstract: A method is provided for manufacturing a plugged honeycomb structure 30 including a honeycomb substrate 1 and plugging portions 15 arranged so as to form complementary checkered patterns at both end surfaces 11 and 21 of the honeycomb substrate 1. The method includes attaching a first mask film 4a to the first end surface 11 of the honeycomb substrate 1, making slurry permeation holes 3a to introduce a plugging slurry 6, attaching a second mask film 4b to the second end surface 21 of the honeycomb substrate 1, making slurry permeation holes 3b, allowing air to flow into the cells 2 so as to discharge air giving a pressure of 0.05 to 5 MPa between the first mask film 4a and the honeycomb substrate 1; and filling cell opening end portions 7 with the plugging slurry 6 to fire the resultant slurry filled substrate 20.Type: GrantFiled: December 12, 2007Date of Patent: June 15, 2010Assignee: NGK Insulators, Ltd.Inventors: Koichi Ito, Takeshi Tokunaga
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Publication number: 20100129600Abstract: Disclosed are cordierite bodies having relatively high porosity and controlled pore size. The porous cordierite bodies generally include a primary cordierite ceramic phase as defined herein. Also disclosed are methods for making and using the cordierite bodies.Type: ApplicationFiled: April 14, 2009Publication date: May 27, 2010Inventors: Yanxia Lu, Jianguo Wang, Yuming Xie
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Publication number: 20100129599Abstract: Disclosed are cordierite bodies having relatively low thermal mass with good mechanical strength. The porous cordierite bodies generally include a primary cordierite ceramic phase as defined herein. Also disclosed are methods for making and using the cordierite bodies.Type: ApplicationFiled: April 14, 2009Publication date: May 27, 2010Inventors: Yanxia Lu, Jianguo Wang, Yuming Xie
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Patent number: 7723250Abstract: A ceramic porous body including at least Si as a chemical component, the ceramic porous body being obtained by adding a porous silica powder or a porous silica-containing compound powder to a forming raw material to prepare a clay, forming the resulting ceramic clay into a specific shape, and firing the formed product. The ceramic porous body according to the present invention does not produce carbon dioxide or toxic gas during firing and allows the firing time to be reduced in comparison with the case of using a resin powder or a carbon powder as a pore-forming agent by using the porous silica powder or the porous silica-containing compound powder as the pore-forming agent during production. Moreover, a change in pore-forming characteristics or deformation of a formed product rarely occurs.Type: GrantFiled: March 24, 2005Date of Patent: May 25, 2010Assignee: NGK Insulators, Ltd.Inventors: Shinzou Hayashi, Hiroyuki Suenobu, Hirotake Yamada, Yasushi Noguchi
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Patent number: 7718113Abstract: A gas delivery substrate and method of manufacture is disclosed. A thermoplastic extrusion compound is created comprising a ceramic material and a thermoplastic resin, a green body is formed by thermoplastic extrusion of the compound, and the green body is sintered to form the gas delivery substrate. Such gas delivery substrates may be thin walled, highly porous and have secondary operations such as crimping and machining done prior to sintering.Type: GrantFiled: August 1, 2008Date of Patent: May 18, 2010Assignee: Rolls-Royce North American Technologies, Inc.Inventors: Aaron T. Crumm, Christopher J. Reilly
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Publication number: 20100117272Abstract: The present invention provides a ceramic precursor batch composition comprising inorganic ceramic-forming ingredients, a binder, an aqueous solvent and a chaotropic agent. The chaotropic agent can be urea, methylurea, ethylurea, n-butylurea, 1,3-dimethylurea, ethyleneurea, 1,1-dimethylurea, tetramethylurea, thiourea or mixtures thereof. The presence of the chaotropic agent provides a composition with a lower viscosity and/or a greater batch stiffening temperature allowing for increased rates of extrusion. Methods for producing a ceramic honeycomb body using the ceramic precursor batch composition of the present invention are also provided.Type: ApplicationFiled: November 13, 2008Publication date: May 13, 2010Inventor: MICHAEL EDWARD DEROSA
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Patent number: 7691167Abstract: A ceramic honeycomb filter comprising a sintered ceramic honeycomb body having porous partition walls defining flow paths, and plugs formed in predetermined flow paths for removing particulate matter from an exhaust gas passing through the porous partition walls, the sintered ceramic honeycomb body being formed by a cordierite-based ceramic material, at least part of the plugs comprising ceramic particles and an amorphous oxide matrix formed from colloidal oxide.Type: GrantFiled: September 29, 2004Date of Patent: April 6, 2010Assignee: Hitachi Metals, Ltd.Inventor: Shinya Tokumaru
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Patent number: 7648548Abstract: Disclosed are ceramic articles, which in one aspect are composed predominately of a cordierite having a composition close to that of Mg2Al4Si5O18. The ceramic articles possess a microstructure characterized by a unique combination of relatively high porosity and relatively narrow pore size distribution, both as measured by mercury porosimetry, that render the ceramic structure useful for ceramic filter applications requiring high thermal durability and high filtration efficiency coupled with low pressure drop along the length of the filter. Such ceramic bodies are particularly well suited for filtration applications, such as diesel exhaust filters or DPFs. Also disclosed are methods for the manufacture of the ceramic articles described herein.Type: GrantFiled: May 10, 2006Date of Patent: January 19, 2010Assignee: Corning IncorporatedInventors: Weiguo Miao, Steven Bolaji Ogunwumi, Paul John Shustack, Jianguo Wang
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Patent number: 7645427Abstract: There is provided a honeycomb structure usable in a filter for trapping/collecting particulates included in exhaust gas and in which ashes deposited inside can be removed without requiring any special mechanism or apparatus or without detaching the filter from an exhaust system. The honeycomb structure includes: a plurality of through channels 9 separated by porous partition walls 7 and extending in the axial direction of the honeycomb structure; and plugging portions 11 for plugging one end of each of predetermined through channels 9a and an opposite end of each of the rest of through channels 9b in a checkered flag pattern, alternately. In the honeycomb structure, at least one slit 15 per through channel is formed in the vicinity of the plugging portions 11 of the partition walls 7 surrounding the respective through channels 9b.Type: GrantFiled: September 23, 2003Date of Patent: January 12, 2010Assignee: NGK Insulators, Ltd.Inventors: Shogo Hirose, Toshio Yamada
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Patent number: 7618699Abstract: Substantially non-microcracked, porous, cordierite ceramic honeycomb bodies are provided. Although exhibiting moderately high thermal expansion (CTE) between 7×10?7 to 16×10?7/° C. (25-800° C.), the honeycomb bodies exhibit relatively high thermal shock parameter (TSP), such as TSR?525° C. by virtue of a high MOR/E ratio, and/or low Eratio=ERT/E1000° C. and well interconnected porosity, as witnessed by a relatively high pore connectivity factor (PCF). A method of manufacturing the honeycomb ceramic structure is also provided.Type: GrantFiled: June 28, 2007Date of Patent: November 17, 2009Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Isabelle Marie Melscoet-Chauvel, Gregory Albert Merkel, Tinghong Tao, David John Thompson
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Patent number: 7611560Abstract: There is disclosed a method of manufacturing a plugged honeycomb structure, capable of simply manufacturing a plugged honeycomb structure which can avoid a phenomenon of rapid increase of pressure losses generated by cell openings clogged with particulate matters on an inlet side.Type: GrantFiled: January 30, 2006Date of Patent: November 3, 2009Assignee: NGK Insulators, Ltd.Inventor: Yukihito Ichikawa
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Publication number: 20090267273Abstract: A process for producing a honeycomb structure includes: manufacturing a honeycomb-shaped formed article by kneading a forming raw material containing ceramic as a main component and a forming auxiliary, an additive, and a pore former to prepare kneaded clay and forming and drying the kneaded clay, calcining the honeycomb formed article to obtain a calcined article, and firing the calcined article. Upon performing a tensile load measurement of the kneaded clay or the formed article, a slope ? of the straight line through an inflection point b and an yielding point c of a graph showing a relation between the tensile load and a displacement amount is below 100% of a slope ? of the straight line through a starting point a where an elastic deformation is shown and the inflection point b.Type: ApplicationFiled: July 7, 2009Publication date: October 29, 2009Applicant: NGK INSULATORS, LTD.Inventors: Atsushi KANEDA, Shuichi ICHIKAWA
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Publication number: 20090243167Abstract: 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: ApplicationFiled: March 9, 2009Publication date: October 1, 2009Applicant: NGK INSULATORS, LTD.Inventors: Yohei ONO, Yasushi NOGUCHI
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Publication number: 20090243166Abstract: There is provided a method for manufacturing a honeycomb structure capable of inhibiting a cut due to drying or firing from generating upon manufacturing a large-sized honeycomb structure. The method for manufacturing a honeycomb structure comprises the steps of: forming kneaded clay containing 3 to 6 parts by mass of a water-absorbent resin having a water-absorption ratio of 10 to 20 times with respect to 100 parts by mass of an oxide ceramic-forming raw material into a honeycomb shape to obtain a honeycomb formed article, drying the honeycomb formed article to obtain a honeycomb dried article, and firing the honeycomb dried article to obtain a honeycomb structure having a volume of 15 to 30 liter and a porosity of 55 to 70%.Type: ApplicationFiled: March 4, 2009Publication date: October 1, 2009Applicant: NGK INSULATORS, LTD.Inventors: Yasushi NOGUCHI, Yukari NAKANE
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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: 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: 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