公开(公告)号：US20210395896A1

公开(公告)日：2021-12-23

申请号：US17279374

申请日：2019-09-20

Applicant: CORNING INCORPORATED

Inventor： Thomas William Brew ,  Dennis Michael Brown ,  Brian James Miller ,  Obiefuna Chukwuemeka Okafor

IPC: C23C28/04 ,  C23C16/36 ,  C23C16/02 ,  B21C25/02

Abstract: Methods of applying an inorganic material to a metal substrate that includes a metallic material having an austenite transformation temperature. The method includes depositing inorganic particles onto a surface of the metal substrate. In some embodiments, methods may include depositing inorganic particles at a deposition temperature that does not cause the metallic material to exceed the austenite transformation temperature. The inorganic particles deposited onto the surface of the metal substrate may form an abrasion-resistant coating on the surface of the metal substrate. The difference between the coefficient of thermal expansion of the metallic material and the coefficient of thermal expansion of the abrasion-resistant coating may be 10×10−6/degrees C. or less.

公开(公告)号：US20210370216A1

公开(公告)日：2021-12-02

申请号：US17405726

申请日：2021-08-18

Applicant: CORNING INCORPORATED

Inventor： Douglas Munroe Beall ,  Dana Craig Bookbinder ,  Thomas William Brew ,  Kenneth Richard Miller

IPC: B01D46/24 ,  B28B3/26 ,  B01D46/00

Abstract: A method and extrusion die to form a laminar integral skin of a honeycomb structure is provided. The method includes extruding a ceramic precursor batch through a die with feedholes in entry side and slots in exit face of the die to form the honeycomb structure. In a region on the periphery of the die configured to form the cell matrix, a series of concentric slots around the matrix in the exit face of the die are configured to feed skin onto the matrix. Ring sections between concentric slots are angled away from the center and a mask is disposed on top of the periphery producing a channel for extruded skin to meet and bond to extruded matrix. Optionally, slots in the skin-forming ring sections enhance knitting between laminar skin layers.

公开(公告)号：US10603814B2

公开(公告)日：2020-03-31

申请号：US16077122

申请日：2017-02-13

Applicant: Corning Incorporated

Inventor： Slater Kent Atkins ,  Thomas William Brew ,  Darin Wayne Felty ,  Tushar Gulati ,  Min Shen ,  Mark Allen Spetseris ,  Eric Lee Thompson

IPC: B29C48/11 ,  B28B3/26 ,  B29C48/30 ,  B28B3/20

Abstract: A honeycomb extrusion die assembly (10) comprising a honeycomb extrusion die (701) and a forming plate (800) to block batch flow to at least a portion of a skin forming region. The honeycomb extrusion die (701) comprising a step cut discharge surface (758, 760) in the skin forming region and at least some slots (722) each with a divot (312) spaced toward a discharge surface (710) from a feedhole-slot intersection and a wide portion at the discharge surface (710) extending into the die body to the divot (312) to strengthen a peripheral region of a honeycomb extrudate in a reinforcement region, and a bulk nominal section corresponding to a bulk region of the honeycomb body.

公开(公告)号：US12110597B2

公开(公告)日：2024-10-08

申请号：US17279374

申请日：2019-09-20

Applicant: CORNING INCORPORATED

Inventor： Thomas William Brew ,  Dennis Michael Brown ,  Brian James Miller ,  Obiefuna Chukwuemeka Okafor

IPC: C23C28/04 ,  B21C25/02 ,  C23C16/02 ,  C23C16/36

CPC classification number: C23C28/044 ,  B21C25/025 ,  C23C16/0272 ,  C23C16/36 ,  C23C28/042

Abstract: Methods of applying an inorganic material to a metal substrate that includes a metallic material having an austenite transformation temperature. The method includes depositing inorganic particles onto a surface of the metal substrate. In some embodiments, methods may include depositing inorganic particles at a deposition temperature that does not cause the metallic material to exceed the austenite transformation temperature. The inorganic particles deposited onto the surface of the metal substrate may form an abrasion-resistant coating on the surface of the metal substrate. The difference between the coefficient of thermal expansion of the metallic material and the coefficient of thermal expansion of the abrasion-resistant coating may be 10×10−6/degrees C. or less.

公开(公告)号：US20230398716A1

公开(公告)日：2023-12-14

申请号：US18032085

申请日：2021-11-22

Applicant: CORNING INCORPORATED

Inventor： Thomas William Brew ,  Keith Norman Bubb ,  Ryan Joseph Grohsmeyer ,  Michael James Lehman ,  Kenneth Charles Sariego ,  Min Shen

IPC: B28B3/26

CPC classification number: B28B3/269 ,  B28B2003/203

Abstract: An extrusion die (16) including a plurality of pins (38) having side surfaces defining an intersecting array of slots (30) extending axially into the die (16) from a discharge face (34) of the die (16). A plurality of feedholes (28) extend axially from an inlet face (32) of the die (16) opposite to the discharge face (34). The feedholes (28) connect with the slots (30) at intersections (35) within the die (16) to create a flow path from the inlet face (32) to the discharge face (34). A first coating (42) is on at least a portion of the feedholes (28) in a first zone (46) extending over a first axial length of the flow path. A second coating (44) that is different than the first coating (42) is on at least a portion of the side surfaces (37) of the pins (38) in a second zone (48) extending over a second axial length of the flow path. Methods of fabricating an extrusion die (16) and manufacturing a ceramic article (100), such as a honeycomb body, are also disclosed.

公开(公告)号：US11697873B2

公开(公告)日：2023-07-11

申请号：US17414569

申请日：2019-12-13

Applicant: CORNING INCORPORATED

Inventor： Thomas William Brew ,  Yuehao Li ,  Min Shen

IPC: C23C16/04 ,  C23C16/34 ,  C23C16/36 ,  C23C16/455

CPC classification number: C23C16/045 ,  C23C16/34 ,  C23C16/36 ,  C23C16/45502 ,  C23C16/45565

Abstract: Methods of depositing an inorganic material on an extrusion die including positioning an extrusion die within a vapor deposition chamber, positioning an impedance disk over a face of the extrusion die, the impedance disk having a plurality of through holes and the face of the extrusion die having a plurality of slots defined by a plurality of extrusion die pins, and flowing one or more deposition gases through the plurality of through holes and into the plurality of slots to deposit inorganic particles on side walls of the plurality of pins. The total impedance to the flow of the deposition gases across the impedance disk and the extrusion die may be equal to a disk impedance of the impedance disk plus a die impedance of the extrusion die, and the disk impedance may be at least 40% of the total impedance to the flow of the deposition gases.

公开(公告)号：US11642813B2

公开(公告)日：2023-05-09

申请号：US17405726

申请日：2021-08-18

Applicant: CORNING INCORPORATED

Inventor： Douglas Munroe Beall ,  Dana Craig Bookbinder ,  Thomas William Brew ,  Kenneth Richard Miller

IPC: B28B3/26 ,  B01D46/00 ,  B01D46/24

CPC classification number: B28B3/269 ,  B01D46/0001 ,  B01D46/001 ,  B01D46/247 ,  B01D46/2418 ,  B01D46/2429 ,  B01D46/2444 ,  B01D46/2462 ,  B01D46/2474 ,  B01D46/2476 ,  B01D46/2482 ,  B01D46/2492 ,  B01D46/24493 ,  B01D46/24494

Abstract: A method and extrusion die to form a laminar integral skin of a honeycomb structure is provided. The method includes extruding a ceramic precursor batch through a die with feedholes in entry side and slots in exit face of the die to form the honeycomb structure. In a region on the periphery of the die configured to form the cell matrix, a series of concentric slots around the matrix in the exit face of the die are configured to feed skin onto the matrix. Ring sections between concentric slots are angled away from the center and a mask is disposed on top of the periphery producing a channel for extruded skin to meet and bond to extruded matrix. Optionally, slots in the skin-forming ring sections enhance knitting between laminar skin layers.

公开(公告)号：US11117083B2

公开(公告)日：2021-09-14

申请号：US15755910

申请日：2016-08-24

Applicant: Corning Incorporated

Inventor： Douglas Munroe Beall ,  Dana Craig Bookbinder ,  Thomas William Brew ,  Kenneth Richard Miller

IPC: B01D46/00 ,  B01D46/24 ,  B28B3/26

Abstract: A method to form a laminar integral skin of a honeycomb structure is provided. The method includes extruding a ceramic precursor batch through a die with feedholes in entry side and slots in exit face of the die to form the honeycomb structure. In a region on the periphery of the die configured to form the cell matrix, a series of concentric slots around the matrix in the exit face of the die are configured to feed skin onto the matrix. Ring sections between concentric slots are angled away from the center and a mask is disposed on top of the periphery producing a channel for extruded skin to meet and bond to extruded matrix. Optionally, slots in the skin-forming ring sections enhance knitting between laminar skin layers. The die and honeycomb body having uniform integral skin are also provided.

公开(公告)号：US20200238568A1

公开(公告)日：2020-07-30

申请号：US16776830

申请日：2020-01-30

Applicant: CORNING INCORPORATED

Inventor： James Joseph Bernas ,  Thomas William Brew ,  Jason Nelson Brown ,  Steven John Kremer ,  Kenneth Charles Sariego

IPC: B28B3/20 ,  B28B3/26 ,  B01J35/04 ,  B01D46/24

Abstract: Ceramic honeycomb extrusion apparatus and a method of extruding a honeycomb body are disclosed. The honeycomb extrusion apparatus and method utilize a homogenizer plate comprising through holes and a screen support plate comprising screen support plate openings and aligned with the through holes.

公开(公告)号：US20190030753A1

公开(公告)日：2019-01-31

申请号：US16077122

申请日：2017-02-13

Applicant: Corning Incorporated

Inventor： Slater Kent Atkins ,  Thomas William Brew ,  Darin Wayne Felty ,  Tushar Gulati ,  Min Shen ,  Mark Allen Spetseris ,  Eric Lee Thompson

IPC: B28B3/26

Abstract: A honeycomb extrusion die assembly (10) comprising a honeycomb extrusion die (701) and a forming plate (800) to block batch flow to at least a portion of a skin forming region. The honeycomb extrusion die (701) comprising a step cut discharge surface (758, 760) in the skin forming region and at least some slots (722) each with a divot (312) spaced toward a discharge surface (710) from a feedhole-slot intersection and a wide portion at the discharge surface (710) extending into the die body to the divot (312) to strengthen a peripheral region of a honeycomb extrudate in a reinforcement region, and a bulk nominal section corresponding to a bulk region of the honeycomb body.