Gregory A Merkel, 70Elmira, NY

6377729, Apr 23, 2002

Dec 22, 2000

09/747561

Gregory A. Merkel - Big Flats NY

Corning Incorporated - Corning NY

G02B 600

385 37, 385129, 385141, 385144

Negative thermal expansion materials, methods of preparation and uses therefor are disclosed. The materials are useful for negative thermal expansion substrates, such as those used for optical fiber gratings.

6391813, May 21, 2002

Dec 28, 1999

09/473376

Gregory A. Merkel - Big Flats NY

Corning Incorporated - Corning NY

C04B 35195

501119, 501 9, 501128

The invention is directed at sintered ceramic articles exhibiting a primary crystalline phase of cordierite and an analytical oxide composition, in weight percent, of 44-53% SiO , 30-38 Al O , 11-16% MgO and 0. 05 to 10% of a metal oxide. The ceramic article exhibits a coefficient of thermal expansion in at least one direction no greater than about 15. 0Ã10- Â C. over the temperature range of about 25Â C. to about 800Â C. The sum of the weight percentages of residual mullite, corundum, and spinel, as measured by X-ray diffractometry of the crushed and powdered body, is not greater than 15%. Furthermore, the invention discloses a method of producing the aforementioned ceramic body, comprising (a) selecting a raw material batch mixture for forming the cordierite ceramic body, comprising two or more compounds which serve as an alumina source, a silica source and a magnesia source, and at least one metal oxide source in an amount to result in the cordierite body comprising, on an analytical oxide basis, in weight percent, between about 0. 05-10% of the metal oxide; (b) adding an organic binder system to the inorganic mixture and forming the mixture into a green body; (c) drying the green body and thereafter firing the green body at a time and at a temperature no greater than about 1300Â C. to result in sintered ceramic body.

6413895, Jul 2, 2002

Sep 27, 2000

09/671722

Gregory A. Merkel - Big Flats NY

Corning Incorporated - Corning NY

C04B 3503

501134, 501 80, 501 81, 501135, 501136, 501152, 501154, 428116, 26417712, 55523, 55DIG 30, 60311, 95273

A structure made predominately of an NZP-type phase having the general formula R Z P Si O , where 0x8, 0y6, R is Li, Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Y, and/or lanthanides, and Z is Zr, Ti, Nb, Ta, Y, and/or lanthanidess, and optionally a sintering additive. The structure has an open porosity of at least 20% by volume, median pore diameter in micrometers of at least a value defined by the quantity [10-0. 10(% open porosity)], both as measured by mercury porosimetry, and four-point modulus of rupture as measured on a solid rod of circular cross section, of at least 300 psi. Method of making the structure involves forming a mixture of NZP-forming raw material powders that are metal oxide sources capable of reacting to form an NZP-type reaction product, and/or pre-reacted powder having the above general formula. The volumetric average of the median particle diameters of the raw material powders in the raw materials combination is at least 15 micrometers, and the particle diameters of at least 65% by volume of the totality of the raw material particles are greater than 11 micrometers. The mixture is shaped into a green structure, and fired to produce the finished structure.

6432856, Aug 13, 2002

Jun 8, 2000

09/590106

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

Corning Incorporated - New York NY

C04B 3503

501118, 428116, 501119, 501120, 501153, 501154

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.

6468325, Oct 22, 2002

Oct 5, 2000

09/680102

Willard A. Cutler - Big Flats NY
Gregory A. Merkel - Big Flats NY

Corning Incorporated - Corning NY

B01D 3920

55523, 55DIG 5, 55DIG 30, 501102, 501103, 501104

The present invention provides a method of making a ceramic filter, by forming a mixture from NZP-forming raw material powders selected from metal oxide sources capable of reacting to form a reaction product comprising an NZP-type phase having the general formula R Zr P Si O where 0y1. 0 and R is one or more of the metals Ca, Sr, and Ba, pre-reacted powder having the same general formula, and mixtures thereof; and a precursor additive selected from the group consisting of silica precursor, zirconia precursor, and mixtures thereof; shaping the mixture into a green structure; and, firing the green structure to produce a ceramic filter having an open porosity of at least 35% by volume, a median pore size of at least 8 micrometers and a permeability of at least 0. 30Ã10 m , and being suitable as a diesel particulate filter.

6506336, Jan 14, 2003

Aug 31, 2000

09/651932

Douglas M. Beall - Painted Post NY
Gregory A. Merkel - Big Flats NY

Corning Incorporated - Corning NY

B28B 320

264630, 264638, 26417712

A plasticizable raw material mixture for use in preparing a substrate having cordierite as its primary phase with a mixture of a chemical composition, percent by weight, of 11 to 17% MgO, 33 to 41% Al O and, 46 to 53% SiO , the mixture including the following (1) a platy talc having a morphology index of greater than 0. 8 and exhibiting a mean particle size of less than about 5 m; (2) an Al O forming source comprising an alumina having a mean particle size of less than about 5 m selected from the group consisting of â-alumina, transition aluminas, aluminum oxide monohydroxide, or aluminum trihydrate having; and, (3) one or more of the components of delaminated kaolin having a mean particle size of less than about 2 m, calcined kaolin exhibiting a mean particle size of less than about 2 m and a surface area of greater than about 10 m /g and/or silica having a mean particle size of less than about 5 m. , and a method of producing a green body by compounding and plasticizing a cordierite-forming raw material mixture, forming the mixture into a green ceramic body by extrusion through an extrusion die to at least partially align the raw materials in an orientation plane in such a manner that the shrinkage of the green ceramic body upon firing is anisotropic and is greater in direction perpendicular to the orientation plane than in at least one other direction in the green ceramic body.

6541407, Apr 1, 2003

May 29, 2001

09/867321

Douglas M. Beall - Painted Post NY
David L. Hickman - Big Flats NY
Gregory A. Merkel - Painted Post NY

Corning Incorporated - Corning NY

C04B 35195

501119, 501 9, 501128, 501 80, 55523, 55DIG 30, 264631

A ceramic comprising predominately a cordierite-type phase approximating the stoichiometry Mg Al Si O and having a coefficient of thermal expansion (25-800Â C. ) of greater than 4Ã10 /Â C. and less than 13Ã10 /Â C. and a permeability and a pore size distribution which satisfy the relation 2. 108 (permeability)+18. 511 (total pore volume)+0. 1863 (percentage of total pore volume comprised of pores between 4 and 40 micrometers) 24. 6. The ceramic is suitable in the fabrication of cellular, wall-flow, diesel particulate filters having a pressure drop in kPa that at an artificial carbon soot loading of 5 grams/liter and a flow rate of 26 scfm is less than 8. 9-0. 035 (number of cells per square inch)+300 (cell wall thickness in inches), a bulk filter density of at least 0. 60 g/cm and a volumetric heat capacity of at least 0. 67 J cm K as measured at 500Â C.

6562284, May 13, 2003

Dec 19, 2001

10/027993

Douglas M. Beall - Painted Post NY
Gregory A. Merkel - Painted Post NY
Brian E. Stutts - Horseheads NY

Corning Incorporated - Corning NY

C04B 35195

264631, 26417711, 26417712

This invention relates to a method of producing a honeycomb ceramic body exhibiting a predetermined radial dimension comprising producing a green ceramic honeycomb body that exhibits a radial dimension at least 9% greater than the predetermined radial dimension and a cell density of at least 500 cpsi. The method further involves shrinking the green body during firing to form a sintered honeycomb ceramic body exhibiting the final predetermined radial dimension. This invention also relates to a method of producing a ceramic body comprising the following steps: (a) compounding and plasticizing a ceramic raw material mixture and forming the plasticizable raw material mixture into a green ceramic body by extrusion through an extrusion die; (b) drying the green body and thereafter firing the green body at a time and at a temperature sufficient to sinter the ceramic body resulting in a radial shrinkage of the green ceramic body in the radial dimension due to the firing of at least 9%.