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 |
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 |
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 |
20080269042 | CONTROLLED DISTRIBUTION OF CHEMISTRY IN CERAMIC SYSTEMS - A method of the controlling the chemical and physical characteristics of a body formed from a powder precursor, including measuring a predetermined amount of a first particulate precursor material, wherein the first particulate precursor material defines a plurality of respective generally spherical first phase particles, adhering second phase particles to the respective first phase particles to define composite particles, forming the composite particles into a green body, and heating the green body to yield a fired body. The second phase particles adhered to the first phase particles are substantially uniformly distributed and a respective first phase particle defines a first particle diameter that is at least about 10 times larger than the second phase diameter defined by a respective second phase particle. The composite particles define a predetermined composition. | 10-30-2008 |
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 |
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 |
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 |
20130192309 | SELECTIVE GLASS BATCHING METHODS FOR IMPROVING MELTING EFFICIENCY AND REDUCING GROSS SEGREGATION OF GLASS BATCH COMPONENTS - A method of increasing efficiency in glass batch melting by controlling the reaction paths of batch constituents as they melt, preventing early formation, flow, segregation and pooling of low-viscosity liquids. The glass batch raw material components are separated into first and second portions with different respective compositions, resulting in first and second respective compositions having first and second respective reaction paths. The respective portions are combined with remaining raw materials to define a mixture which is then introduced into the melter and reacted to yield a homogeneous glass melt. The first composition has a first melting temperature having a first reaction path resulting in a first liquid having sufficient viscosity to minimize flowing. The second composition has a second melting temperature and the first liquid fluxes the second composition to yield a molten glass composition. | 08-01-2013 |