Patent application number | Description | Published |
20080199369 | Extruded porous substrate and products using the same - 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. | 08-21-2008 |
20080210090 | Extruded Porous Ceramic Fuel Cell Reformer Cleanup Substrate - A fuel cell reformer cleanup substrate is an extruded porous substrate of fiber-based inorganic materials. More particularly, the present invention enables an efficient fuel cell reformate cleanup filtration using a highly porous, and permeable honeycomb substrate having a washcoat that adsorbs impurities in the reformate stream upstream of a fuel cell. The porous substrate can be fabricated using an extrusion process and a number of washcoat compositions can be disposed within the porous substrate to provide adsorption of the reformate impurities. | 09-04-2008 |
20080236145 | Emission Control System using a Multi-Function Catalyzing Filter - A multi-function filter is provided for use in emission control systems, for example, on the exhaust gas from an internal combustion engine. The filter has a substrate constructed using bonded fiber structures, which cooperate to form a highly uniform open cell network, as well as to provide a uniform arrangement of pores. The substrate typically is provided as a wall-flow honeycomb structure, and in one example, is manufactured using an extrusion process. In this way, the substrate has many channel walls, each having an inlet surface and an outlet surface. The inlet surface has a uniform arrangement of pores that form a soot capture zone, where soot and other particulate matter is captured from an exhaust gas. A gas conversion catalyst is disposed inside the channel wall, where one or more pollutants in the exhaust gas are converted to less harmful substances. Because of the uniform pore structure and open cell arrangement inside the channel wall, the filter is capable of being heavily loaded with catalyst, while avoiding undue increase in backpressure to the internal combustion engine. | 10-02-2008 |
20080241014 | 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 modified aluminosilicate compositional structure (i.e., x(RO).y(Al | 10-02-2008 |
20080241032 | Catalyzing Lean NOx Filter and Method of Using Same - A NOx trapping filter is provided for use in emission control systems, for example, on the exhaust gas from an internal combustion engine. The NOx trapping filter has a substrate constructed using bonded fiber structures, which cooperate to form a highly uniform open cell network, as well as to provide a uniform arrangement of pores. The substrate typically is provided as a wall-flow honeycomb structure, and in one example, is manufactured using an extrusion process. In this way, the substrate has many channel walls, each having an inlet surface and an outlet surface. The inlet surface has a uniform arrangement of pores that form a soot capture zone, where soot and other particulate matter is captured from an exhaust gas. A NOx adsorber material is disposed in the filter to trap NOx during lean operation of the engine. A NOx conversion catalyst is also disposed inside the channel wall, where NOx and excess hydrocarbons in the exhaust gas are reacted to less harmful substances when the engine system is operated in a rich condition. Because of the uniform pore structure and open cell arrangement inside the channel wall, the filter is capable of being heavily loaded with catalyst, adsorber, while avoiding undue increase in backpressure to the internal combustion engine. | 10-02-2008 |
20080242530 | Low coefficient of thermal expansion materials including nonstoichiometric cordierite fibers and methods of manufacture - A fibrous ceramic material comprises a plurality of fibers having a R | 10-02-2008 |
20080256936 | Selective Catalytic Reduction Filter and Method of Using Same - A Selective Catalytic Reduction (SCR) filter is provided for use in emission control systems, for example, on the exhaust gas from an internal combustion engine. The SCR filter has a substrate constructed using bonded fiber structures, which cooperate to form a highly uniform open cell network, as well as to provide a uniform arrangement of pores. The substrate typically is provided as a wall-flow honeycomb structure, and in one example, is manufactured using an extrusion process. In this way, the substrate has many channel walls, each having an inlet surface and an outlet surface. The inlet surface has a uniform arrangement of pores that form a soot capture zone, where soot and other particulate matter is captured from an exhaust gas. A NOx conversion catalyst is disposed inside the channel wall, where NOx and ammonia in the exhaust gas are reacted to less harmful substances. Because of the uniform pore structure and open cell arrangement inside the channel wall, the filter is capable of being heavily loaded with catalyst, while avoiding undue increase in backpressure to the internal combustion engine. | 10-23-2008 |
20080283465 | LOW COEFFICIENT OF THERMAL EXPANSION BONDING SYSTEM FOR A HIGH POROSITY CERAMIC BODY AND METHODS OF MANUFACTURE - 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. | 11-20-2008 |
20080286179 | Method and Apparatus for an Extruded Ceramic Biosoluble Fiber Substrate - A porous ceramic substrate is disclosed that is fabricated from biosoluble ceramic fibers. Porosity and permeability of the substrate is provided by intertangled biosoluble fibers, that can be formed into a honeycomb form substrate through an extrusion process. The fibrous structure is formed from mixing biosoluble fibers with additives that include a bonding agent, and a fluid to provide an extrudable mixture. The structure is sintered at a temperature that exceeds the glass formation temperature of the bonding agent, but less than the maximum operational limits of the biosoluble fiber, to form a structure that has sufficient strength and porosity to provide for filtration and/or as a catalytic host. | 11-20-2008 |
20080292518 | Cordierite Fiber Substrate and Method for Forming the Same - 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. | 11-27-2008 |
20080292842 | Carbon Fiber Substrate and Method for Forming the Same - A porous carbon fiber substrate and method of forming the same including providing a fiber material including carbon, providing at least one extrusion aid and providing at least one bonding phase material. The fiber material, the at least one extrusion aid and the at least one bonding phase material are mixed with a fluid. The mixed fiber material, at least one extrusion aid, at least one bonding phase material and fluid are extruded into a green honeycomb substrate. The green honeycomb substrate is fired, enabling bond formation and forming a porous carbon fiber honeycomb substrate. | 11-27-2008 |
20090000260 | Fibrous Cordierite Materials - 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 | 01-01-2009 |
20090035511 | Fiber-Based Ceramic Substrate and Method of Fabricating the Same - 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. | 02-05-2009 |
20090068438 | Porous Washcoat-Bonded Fiber Substrate - 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 | 03-12-2009 |
20090092786 | Fibrous aluminum titanate substrates and methods of forming the same - 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. | 04-09-2009 |
20090136709 | Extruded Porous Substrate having Inorganic Bonds - 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. | 05-28-2009 |
20090173687 | Extruded Porous Substrate and Products Using The Same - 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. | 07-09-2009 |
20090274602 | Nonwoven Composites and Related Products and Methods - The present invention in certain embodiments is directed to a catalytic substrate suitable for use in a number of applications, including as a substrate in a catalytic converter or a particulate filter. Another aspect of the present invention is a filtering substrate suitable for use in a number of applications, including as a substrate in a particulate filter, such as a diesel particulate filter (DPF), or diesel particulate trap (DPT). The invention also provides an improved substrate for removing and/or eliminating pollutants from the exhaust of combustion engines. The catalytic substrate and filtering substrate provide, in certain embodiments, improvements in removing pollutants from an exhaust gas. The improvements include one or more of the following: faster light-off period, depth filtration of PM, less backpressure, lower probability of clogging, ability to be placed in multiple locations in the exhaust system including the manifold or the head itself, high probability of catalytic reaction, high conversion ratios of NOx, HC, and CO, a faster burnoff of PM, minimization of catalyst material use, and the like. | 11-05-2009 |
20100048374 | System and Method for Fabricating Ceramic Substrates - This invention provides a system and method for establishing proper quantities of components in the initial mixture to be used in the fabrication of a porous ceramic substrate. The components typically consist of a solvent, a bulk fiber such as mullite, an organic binder for use in extrusion of the green substrate, a glass/clay bonding phase that bonds the fibers upon high-temperature curing and a pore former that defines gaps between the particles and is vaporized out of the substrate during curing. By identifying the controllable factors related to each of the components, and adjusting the factors to vary the resulting strength and porosity of the cured substrate, an optimized strength and porosity performance can be achieved. The controlling factors for each component include its relative weight percent in the mixture. The fiber component is also controlled via fiber diameter, diameter uniformity, and fiber length-to-diameter aspect ratio. Likewise, pore former is also controlled by particle size and shape and particle density. The bonding phase may also be controlled based upon its contribution to the viscosity at sintering temperature. | 02-25-2010 |
20100150790 | Catalyzing Lean NOx Filter and Method of Using Same - A NOx trapping filter is provided for use in emission control systems, for example, on the exhaust gas from an internal combustion engine. The NOx trapping filter has a substrate constructed using bonded fiber structures, which cooperate to form a highly uniform open cell network, as well as to provide a uniform arrangement of pores. The substrate typically is provided as a wall-flow honeycomb structure, and in one example, is manufactured using an extrusion process. In this way, the substrate has many channel walls, each having an inlet surface and an outlet surface. The inlet surface has a uniform arrangement of pores that form a soot capture zone, where soot and other particulate matter is captured from an exhaust gas. A NOx adsorber material is disposed in the filter to trap NOx during lean operation of the engine. A NOx conversion catalyst is also disposed inside the channel wall, where NOx and excess hydrocarbons in the exhaust gas are reacted to less harmful substances when the engine system is operated in a rich condition. Because of the uniform pore structure and open cell arrangement inside the channel wall, the filter is capable of being heavily loaded with catalyst, adsorber, while avoiding undue increase in backpressure to the internal combustion engine. | 06-17-2010 |
20100247396 | Selective Catalytic Reduction Filter and Method of Using Same - A Selective Catalytic Reduction (SCR) filter is provided for use in emission control systems, for example, on the exhaust gas from an internal combustion engine. The SCR filter has a substrate constructed using bonded fiber structures, which cooperate to form a highly uniform open cell network, as well as to provide a uniform arrangement of pores. The substrate typically is provided as a wall-flow honeycomb structure, and in one example, is manufactured using an extrusion process. In this way, the substrate has many channel walls, each having an inlet surface and an outlet surface. The inlet surface has a uniform arrangement of pores that form a soot capture zone, where soot and other particulate matter is captured from an exhaust gas. A NOx conversion catalyst is disposed inside the channel wall, where NOx and ammonia in the exhaust gas are reacted to less harmful substances. Because of the uniform pore structure and open cell arrangement inside the channel wall, the filter is capable of being heavily loaded with catalyst, while avoiding undue increase in backpressure to the internal combustion engine. | 09-30-2010 |