Geo2 Technologies, Inc.

Ge02 Technologies, Inc.

Sunilkumar C Pillai

Bilal Zuberi

William M Carty

Robert G Lachenauer

James Jenq Liu

Biprodas Dutta

Roger Maddalena

Dominique (deceased) Janssen

Jose Simoes

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 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

Method of forming a porous substrate having inorganic bonds

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North Billerica, MA, United States of America

Sunilkumar C Pillai