Christopher Malarkey

US Patent:

6368992, Apr 9, 2002

Filed:

Jun 28, 2000

Appl. No.:

09/605171

Inventors:

Douglas M. Beall - Painted Post NY
Devi Chalasani - San Diego CA
Christopher J. Malarkey - Corning NY

Assignee:

Corning Incorporated - Corning NY

International Classification:

C04B 35632

US Classification:

501 94, 501109, 501119, 264630, 264631, 264669, 419 65, 1061811, 1061821, 1061901, 1061911, 1061961, 106285, 106311

Abstract:

A binder system for use in the formation of ceramic or other powder-formed greenware comprising a binder, a solvent for the binder, a surfactant, and a component that is non-solvent with respect to the binder and solvent. The non-solvent component exhibits a lower viscosity than the solvent when containing the binder and comprises a low molecular weight oil having a 90% recovered distillation temperature range of between about 220 to 400Â C. Also disclosed is a process of forming and shaping plasticized powder mixtures and a process for forming ceramic articles utilizing the binder system.

US Patent:

6372033, Apr 16, 2002

Filed:

Feb 11, 2000

Appl. No.:

09/503625

Inventors:

Devi Chalasani - Painted Post NY
Michael Fischer - Corning NY
Christopher J. Malarkey - Corning NY
Kevin R. McCarthy - Horseheads NY
Brian E. Stutts - Horseheads NY
Michael E. Zak - Canandaigua NY

Assignee:

Corning Incorporated - Corning NY

International Classification:

C08L 8900

US Classification:

1061401, 1062033, 1061791, 106665, 106807, 106810, 10620401, 1061461, 1061572, 1061628, 106661, 1062179, 106243, 106244

Abstract:

Powder mixtures and a method of forming and shaping the mixtures. The method involves compounding the components of powder materials, binder, solvent for the binder, surfactant, and non-solvent with respect to at least the binder, the solvent, and the powder materials. The non-solvent is lower in viscosity than the binder combined with the solvent. The solvent is present in an amount that is less than the amount that would be present otherwise. The components are mixed and plasticized, and shaped to form a green body. The choice of components results in improved wet green strength in the green body. The method is especially useful for extrusion processing of aqueous binder systems such as water and cellulose ethers and hydrophobic non-solvents, to form structures such as honeycombs. In the body, the ratio, upon subsequent firing, of the isostatic strength to the A-axis strength is at least about 20% higher than in bodies made without the mixture composition of the invention. A honeycomb body having a ratio of the isostatic strength to the A-axis strength of at least about 0.

US Patent:

6375450, Apr 23, 2002

Filed:

Mar 17, 2000

Appl. No.:

09/527731

Inventors:

Nancy A. Golomb - Corning NY
Christopher J. Malarkey - Corning NY

Assignee:

Corning Incorporated - Corning NY

International Classification:

B29C 4750

US Classification:

425199, 366 87, 425205

Abstract:

An improvement in a process of making honeycomb articles, which process utilizes a co-rotating, intermeshing twin screw extrusion apparatus to mix, screen, and extrude a batch of ceramic materials through a die, the improvement which comprises the steps of separating the mixing and screening phase from the extrusion phase, by passing the batch through a first co-rotating, intermeshing twin screw extruder or a mixer extruder to mix and screen the batch, and then directly passing the mixed and screened batch through a second co-rotating, intermeshing twin screw extruder or a pumping extruder to extrude said batch through a die assembly to produce a honeycomb article.

US Patent:

6432856, Aug 13, 2002

Filed:

Jun 8, 2000

Appl. No.:

09/590106

Inventors:

Douglas M. Beall - Painted Post NY
Christopher J. Malarkey - Corning NY
Gregory A. Merkel - Big Flats NY

Assignee:

Corning Incorporated - New York NY

International Classification:

C04B 3503

US Classification:

501118, 428116, 501119, 501120, 501153, 501154

Abstract:

A sintered ceramic honeycomb article that exhibits an average linear coefficient of thermal expansion (25-800Â C. ) below about 5. 0Ã10 Â C. , a total porosity between the range of 20% to about 30%, and a pore size distribution such that at least about 86% of pores are of a pore size of less than about 2 m with the pores exhibiting a generally elongated shape oriented with their long axis in the plane of the webs, the article being made from a cordierite-forming inorganic powder batch comprising a platy talc having median particle of size less than about 2 m, at least 4% by weight of a dispersible Al O -forming source having a specific surface area in excess of 50 m /g, and one or more of the components of kaolin, calcined kaolin, silica, and corundum, each having a median particle sizes less than 5 m.

US Patent:

6455124, Sep 24, 2002

Filed:

Dec 1, 2000

Appl. No.:

09/727741

Inventors:

Douglas M. Beall - Painted Post NY
Thomas W. Brew - Corning NY
Christopher J. Malarkey - Corning NY
Mark A. Spetseris - Pine City NY

Assignee:

Corning Incorporated - Corning NY

International Classification:

B32B 312

US Classification:

428116, 264631, 264630, 264638, 264639

Abstract:

Fine circumferential skin cracking in extruded thin-walled cordierite honeycombs having channel wall thicknesses not exceeding about 0. 004 inches (100 m) but skin layers of substantially higher thickness is prevented by extruding the honeycombs under conditions that enhance cordierite crystal alignment in the skin; thin-walled honeycomb products having skins free of fine cracks that are well-matched in thermal expansion to the honeycomb cores are provided.

US Patent:

6773657, Aug 10, 2004

Filed:

Jun 17, 2002

Appl. No.:

10/174345

Inventors:

Douglas M. Beall - Painted Post NY
Christopher J. Malarkey - Corning NY
Gregory A. Merkel - Big Flats NY

Assignee:

Corning Incorporated - Corning NY

International Classification:

B28B 320

US Classification:

264628, 264631

Abstract:

A sintered ceramic that exhibits an average linear coefficient of thermal expansion (25-800Â C. ) below about 5. 0Ã10 Â C. , a total porosity between the range of 20% to about 30%. Furthermore, the sintered ceramic article exhibits a pore size distribution such that at least about 86% of pores are of a pore size of less than about 2 m. Lastly, the ceramic article exhibits an interconnected pore structure with the pores exhibiting a generally elongated shape, i. e. , the pores are predominately oriented with their long axis in the plane of the webs. This invention also relates to a method for producing a sintered cordierite ceramic article involving first compounding and plasticizing a cordierite-forming inorganic powder batch comprising a platy talc having median particle of size less than about 2 m, and preferably a talc morphology index greater than about 0. 75. The batch further comprises at least 4% by weight of the inorganic powder batch mixture of a dispersible Al O -forming source having a specific surface area in excess of 50 m /g and one or more of the components of kaolin, calcined kaolin, silica, and corundum, each having a median particle sizes less than 5 m. The plasticized powder batch thus provided is next formed into a green honeycomb by extrusion through a honeycomb extrusion die and the green honeycomb is fired to a temperature and for a time sufficient to convert the green honeycomb into a crystallized cordierite ceramic article having the aforementioned properties.

US Patent:

6800233, Oct 5, 2004

Filed:

Jan 30, 2002

Appl. No.:

10/066377

Inventors:

Nancy A. Golomb - Corning NY
Christopher J. Malarkey - Corning NY

Assignee:

Corning Incorporated - Corning NY

International Classification:

B29C 4750

US Classification:

26417711, 26417712, 26421121, 26421123

Abstract:

An improvement in a process of making honeycomb articles, which process utilizes a co-rotating, intermeshing twin screw extrusion apparatus to mix, screen, and extrude a batch of ceramic materials through a die, the improvement which comprises the steps of separating the mixing and screening phase from the extrusion phase, by passing the batch through a first co-rotating, intermeshing twin screw extruder or a mixer extruder to mix and screen the batch, and then directly passing the mixed and screened batch through a second co-rotating, intermeshing twin screw extruder or a pumping extruder to extrude said batch through a die assembly to produce a honeycomb article.

US Patent:

7780755, Aug 24, 2010

Filed:

May 31, 2007

Appl. No.:

11/807982

Inventors:

Lin He - Horseheads NY, US
Christopher John Malarkey - Corning NY, US
Jonathan David Pesansky - Corning NY, US

Assignee:

Corning Incorporated - Corning NY

International Classification:

B01D 39/06
B01D 39/14
B01D 24/00
B01D 50/00
F01N 3/10
F01N 3/08
F01N 3/00
B32B 3/12
B01J 23/00

US Classification:

55523, 55522, 55524, 428118, 422172, 422173, 422174, 422175, 422176, 422177, 422178, 422179, 422180, 60297, 502303

Abstract:

The present invention provides honeycomb ceramic articles and methods of manufacturing such articles having few or no defects in the outer skin. Methods for minimizing and/or eliminating cracks in thin-wall and ultra-thin-wall cordierite honeycomb articles are disclosed. Advantageously, the present invention prevents skin cracks from forming during the production of thin-wall and ultra-thin-wall cordierite honeycomb articles by optimizing skin properties such as porosity, thickness and pore size distribution.