Geo2 Technologies, Inc.

Ge02 Technologies, Inc.

Geoz Technologies, Inc.

Bilal Zuberi

Robert G Lachenauer

William M Carty

James Jenq Liu

Sunilkumar C Pillai

Biprodas Dutta

Rachel A Dahl

Robert A DiChiara

Gordon S Alward

Jerry G Weinstein

A highly porous substrate is provided using an extrusion system. More particularly, the present invention enables the production of a highly porous substrate. Depending on the particular mixture, the present invention enables substrate porosities of about 60% to about 90%, and enables advantages at other porosities, as well. The extrusion system enables the use of a wide variety of fibers and additives, and is adaptable to a wide variety of operating environments and applications. Fibers, which have an aspect ratio greater than 1, are selected according to substrate requirements, and are typically mixed with binders, pore-formers, extrusion aids, and fluid to form a homogeneous extrudable mass. The homogeneous mass is extruded into a green substrate. The more volatile material is preferentially removed from the green substrate, which allows the fibers to form interconnected networks. As the curing process continues, fiber to fiber bonds are formed to produce a structure having a substantially open pore network. The resulting porous substrate is useful in many applications, for example, as a substrate for a filter or catalyst host, or catalytic converter.

Extruded porous substrate and products using the same

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 SiO, about 36% to about 41% by weight AlO, 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&#xb0; C. to about 1420&#xb0; 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&#xb7;10per &#xb0; C.

Fibrous cordierite materials

A process is provided for strengthening a porous substrate. The process includes providing a substrate having intersecting fibers, where the intersecting fibers cooperate in the final substrate product to form an open pore network. Pathways are opened into the fibrous substrate structure, which enable a flow of gas into the or through the substrate. The substrate is positioned in a CVD (chemical vapor deposition) station, and one or more layers of a strengthening agent is deposited. The deposited layer or layers form a strong coating around fibers and fiber intersections to provide additional strength to the substrate. The strengthened substrate may then be used in wide variety of applications and fields. Advantageously, the disclosed fiber strengthening process produces a substrate having high porosity and higher strength characteristics as compared to a non-strengthened substrate.

Method and apparatus for strengthening a porous substrate

A porous fibrous honeycomb substrate having an aluminum titanate composition and methods of producing the same are provided herein. Precursors of aluminum titanate are provided in an extrudable mixture that includes fiber materials to form a green honeycomb substrate. When cured, the precursors of aluminum titanate form an aluminum titanate composition, with the fiber materials defining the porous microstructure. Various composite structures including aluminum titanate are provided to form a porous honeycomb substrate that can be configured to be filtration media and/or a catalytic host.

Fibrous aluminum titanate substrates and methods of forming the same

A fibrous ceramic material comprises a plurality of fibers having a modified aluminosilicate compositional structure (i.e., x(RO).y(AlO).z(SiO) or w(MO).x(RO).y(AlO).z(SiO)). The fibrous ceramic material is form by combining two or more x(RO).y(AlO).z(SiO) or w(MO).x(RO).y(AlO).z(SiO) precursors in which at least one of the two or more precursors is in fiber form. The resulting fibrous ceramic material has a low coefficient of thermal expansion (i.e., &#x2266;4.7&#xd7;10-6/&#xb0; C.).

Low coefficient of thermal expansion materials including modified aluminosilicate fibers and methods of manufacture

A fibrous ceramic material comprises a plurality of fibers having a RMgAlSiOor RMgAlSiOcompositional structure. The fibrous ceramic material is form by combining two or more RMgAlSiOor RMgAlSiOprecursors in which at least one of the two or more RMgAlSiOor RMgAlSiOprecursors 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.

Low coefficient of thermal expansion materials including nonstoichiometric cordierite fibers and methods of manufacture

A method is provided for producing a highly porous substrate. More particularly, the present invention enables fibers, such as organic, inorganic, glass, ceramic, polymer, or metal fibers, to be combined with binders and additives, and extruded, to form a porous substrate. Depending on the selection of the constituents used to form an extrudable mixture, the present invention enables substrate porosities of about 60% to about 90%, and enables process advantages at other porosities, as well. The extrudable mixture may use a wide variety of fibers and additives, and is adaptable to a wide variety of operating environments and applications. Additives can be selected that form inorganic bonds between overlapping fibers in the extruded substrate that provide enhanced strength and performance of the porous substrate in a variety of applications, such as, for example, filtration and as a host for catalytic processes, such as catalytic converters.

Extruded porous substrate having inorganic bonds

A porous substrate and method of forming a porous substrate including providing a fiber material, providing at least one extrusion aid, and providing at least one washcoat precursor. The fiber material, the at least one extrusion aid and the at least one washcoat precursor are mixed to provide an extrudable batch. The extrudable batch is extruded into a green substrate. The green substrate is fired to form a porous rigid substrate and to form a washcoat at least partially coating the fiber material.

Porous washcoat-bonded fiber substrate

A porous cordierite substrate and a method of forming a porous cordierite substrate including providing a fiber that includes at least one cordierite precursor material and providing at least one organic binder material. The fiber and the organic binder material are mixed with a fluid. The mix of fiber, organic binder material and fluid is extruded into a green substrate. The green substrate is fired to enable the formation of bonds between the fibers and to form a porous cordierite fiber substrate.

Cordierite fiber substrate and method for forming the same

A porous ceramic body comprises a plurality of fibers and a bonding system bonding a portion of at least two fibers of the plurality of fibers. The plurality of fibers has a first coefficient of thermal expansion. The bonding system has a second coefficient of thermal expansion lower than the first coefficient of thermal expansion. In some embodiments, when the plurality of fibers and the bonding system are combined the resulting porous ceramic body has a third coefficient of thermal expansion which is at least about 10% less than the first coefficient of thermal expansion.

Low coefficient of thermal expansion bonding system for a high porosity ceramic body and methods of manufacture

A porous honeycomb substrate including a non-woven fibrous ceramic body is provided herein. The fibrous ceramic body is substantially composed of bonded ceramic fibers forming a rigid non-woven matrix. Washcoat and catalyst materials can be applied to at least partially coat the honeycomb channels. The porous honeycomb substrate provides an improved substrate for use in filtration applications such as exhaust particulate filtration of internal combustion engines.

Nonwoven composites and related products and methods

Low cost aluminosilicate fibers are used to form a ceramic substrate material using inorganic binders that promote the formation of stable compounds that inhibit the formation of crystal silica, or cristobalite, when the substrate is used or exposed to high operating temperatures. The aluminosilicate fibers are mixed with additives including organic and inorganic binders and a fluid to form a plastic mixture. The plastic mixture is formed into a green substrate, and subsequently cured into the ceramic substrate. The fiber-based constituents permit the formation of rigid porous structures for filtration, insulation, and high temperature processes and chemical reactions.

Fiber-based ceramic substrate and method of fabricating the same

The invention relates to an engine with an exhaust gas pathway extending between the engine and the atmosphere. The engine includes a manifold portion fluidically connected to an engine, a muffler portion fluidically connected to the atmosphere, a conduit portion fluidically connected between the manifold portion and the muffler portion, and a plurality of baffles operationally connected within the muffler. A substantially fibrous refractory material at least partially coats the exhaust gas pathway. Exhaust gas from the engine flowing through the exhaust gas pathway to the atmosphere flows over the substantially fibrous refractory material.

Catalytic fibrous exhaust system and method for catalyzing an exhaust gas

A simple catalytic device that is easily installed into vehicles, small engines, and industrial exhaust stacks is provided. The simple catalytic device has a ridged and stable backbone structure that withstands expected mechanical forces. In one example, the backbone is a highly gas permeable mesh or screen. A fibrous material is disposed on the backbone, with a catalytic material coating applied to the fibrous material. The catalytic device is constructed to be installable in an exhaust path, where it provides a catalytic conversion for non-particulate matter.

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Cambridge, MA, United States of America

Bilal Zuberi