Abstract: The present invention relates to an electrolyte structure coated on at least one surface with a roughened interfacial nano-crystalline layer. Another aspect of the present invention is a solid oxide fuel cell which includes a positive air electrode, a negative fuel electrode, an electrolyte structure interposed between the positive air electrode and negative fuel electrode, and a roughened interfacial nano-crystalline layer interposed between the electrolyte structure and at least one of the positive air electrode and negative fuel electrode. The present invention also relates to methods of making the coated electrolyte and solid oxide fuel cell.

Abstract: Zeolite/alumina composite, and a method for making, the composite for use as a catalyst substrate or catalyst carrier and comprising zeolite having a silica/alumina ratio of greater than 300 and gamma alumina having a specific surface area of greater than 100 m2/g. The zeolite/alumina composite exhibits a modulus of rupture of at least 750 psi. Additionally, the invention is also directed at a three catalyst (TWC) system for use in the removal of hydrocarbons, carbon monoxide and oxides of nitrogen from waste gas, the TWC system comprising the following components: (1) a zeolite/alumina composite catalyst support exhibiting a modulus of rupture of at least 750 psi and having a zeolite with a silica/zeolite ratio of at least 300 and the alumina comprising a gamma alumina having a specific surface area of greater than 100 m2/g; and, (2) a noble metal catalyst impregnated on the catalyst support, the noble metal selected from the group consisting of platinum, rhodium, iridium and palladium.

Abstract: Improved batch uniformity delivered to the discharge slots of an extrusion die is obtained by providing a stressor component of reduced cross-sectional area from the feedholes which suddenly increases the linear flow velocity due to its reduced cross-sectional area, and then just as suddenly restores the original flow conditions as it exits the stressor component into a larger diameter channel. A rapid change in particle alignment, due to the cross-sectional flow change, produces a shearing influence on the batch, and functions to produce a more uniform flow as it enters the discharge slot sections of the extrusion die.

Abstract: A gravity-flow cyst-reducing water filtration device, comprising a removable high surface area cyst-reducing filtration member that provides at least 99.95% removal of 3-4 &mgr;m particles when tested in accordance with NSF standard 53, Drinking Water Treatment Units—Health Effects (September 1997). The cyst-reducing filtration member is adapted for connection to a bottom rim of a filtration cartridge sleeve of a water filter carafe, the cartridge sleeve being integral with a bottom surface of an untreated water reservoir of the water filter carafe. The cartridge sleeve further comprises an air vent hole that is located proximate to a top rim of the cartridge sleeve, wherein the cartridge sleeve further contains a filtration cartridge that is filled with an ion-exchange resin and carbon granules.

Abstract: Disclosed is a method of manufacturing a catalytic converter for purifying exhaust gases from an internal combustion engine wherein the converter exhibits a monolithic ceramic substrate surrounded by a supporting mat. The method generally includes the steps of: Forming a catalytic converter utilizing a compressive closing method generally involves wrapping the substrate in a sufficient amount of supporting mat material and inserting the wrapped substrate into generally cylindrical metal container, compressively closing the container around the wrapped substrate sufficiently to provide a gas tight seal and to hold the imparted compressive stress. The present invention further discloses an improvement involving compressively closing the container around the wrapped substrate by resizing the container over substantially the entire portion of its length which is occupied by the wrapped substrate to a predetermined metal shell/container outside diameter OD.

Abstract: 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% SiO2, 30-38 Al2O3, 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 15.0×10−7° C. over the temperature range of about 25° C. to about 800° 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%.

Abstract: A process for making a honeycomb article having longitudinal channels extending from one face to a second face supporting a uniform coating of activated carbon on the channel walls, the process comprising the step of providing a solid heat-activated oxidant within the channels and heating the article to release the oxidant and uniformly activate the carbon coating.

Abstract: A binder system for use in the formation of ceramic or other powder-formed greenware comprising a binder, a solvent for the binder, a surfactant, and a component that is non-solvent with respect to the binder and solvent. The non-solvent component exhibits a lower viscosity than the solvent when containing the binder and comprises a low molecular weight oil having a 90% recovered distillation temperature range of between about 220 to 400° C. Also disclosed is a process of forming and shaping plasticized powder mixtures and a process for forming ceramic articles utilizing the binder system.

Abstract: Ceramic honeycombs incorporating cell walls of a sintered alumina material providing controlled pore size distribution in combination with high BET surface area and flexural (MOR) strength are formed by the extrusion, drying and firing of plasticized alumina powder batches containing major proportions of anhydrous, high-surface-area gamma alumina powders dispersed with selected acids; low combined drying and firing shrinkages provide strong, crack-free bodies of high surface area and strength.

Abstract: A sensor for measuring the non-methane HC concentration of gas sample, e.g., automotive exhaust gas, the sensor comprises a sensor base, capable of producing a output signal representative of the exothermic effect of the hydrocarbon species in the gas sample. The sensor base has disposed on, and integral with, its surface, a porous selective oxidation catalyst layer comprising capable of selectively oxidizing a combination of CO+H2+alkene species in the gas sample and leaving unoxidized the alkane and aromatic hydrocarbons. The sensor base further includes a first supported resistance temperature device which has disposed thereon a total oxidation catalyst layer capable of oxidizing the remaining alkane and aromatic hydrocarbon species in the gas sample, and a non-catalyzed second resistance temperature device.

Abstract: An extrusion die for forming a cellular honeycomb structure having a finned protrusion extending from at least one cell wall of the honeycomb structure. The extrusion die is a composite extrusion die that comprises a primary extrusion die body having an inlet face and an outlet face, and at least a first insert member that is secured into a first intersection formed by a pair of intersecting slots at the outlet face of the primary extrusion die body. More preferably, a plurality of insert members are secured into a plurality of intersections, each intersection being formed by a pair of intersecting slots and each of the intersections being defined by four pegs/pins at the outlet face of the primary extrusion die body.

Abstract: A binder system for use in the formation of ceramic or other powder-formed greenware comprising a binder, a solvent for the binder, a surfactant, and a component that is non-solvent with respect to the binder and solvent. The non-solvent component exhibits a lower viscosity than the solvent when containing the binder and comprises at least a portion of an organic liquid having a 90% recovered distillation temperature of no greater than about 225° C. and more preferably less than 220° C. Also disclosed is a process of forming and shaping plasticized powder mixtures and a process for forming ceramic articles utilizing the binder system.

Abstract: A method for forming an extrusion die for producing honeycomb structures having hexagonal shaped cells is disclosed. A plurality of at least three plates are straight cut across the surface portion of each plate with desired angles to produce hexagonal shaped pins. The pins from each of the three plates are successively bonded to a die body or laminated carrier plate, with such orientation and positioning as to produce a die face with hexagonally shaped discharge slots.

Abstract: Honeycomb extrusion dies for the extrusion of honeycomb ceramics of high cell density and reduced cell wall thickness are machined from fully consolidated powder metallurgy (P/M) stainless steels, providing dies with reduced feed hole roughness, improved feed hole straightness, and superior discharge slot finish, with the result that significantly enhanced extrusion performance and higher quality honeycomb extrusions are realized.

Abstract: A powder-formed cellular honeycomb body of novel tapered, curved and/or very high cell density configuration is provided through a reforming procedure wherein a precursor honeycomb shaped from a plasticized powder batch material is filled with a compatible plastic filler, reshaped at a temperature at which the plastic deformation characteristics of the honeycomb and filler are matched, and then solidified after removal of the filler to fix the final configuration of the body.

Abstract: A catalytic converter for purifying exhaust gases from an internal combustion engine includes a monolithic ceramic substrate having a peripheral surface encircled by a non-intumescent supporting mat material. A metal shell comprising a wider portion which is adjacent to and encloses the mat material and the substrate. The metal shell further comprises a narrower portion, preferably triangularly shaped, that overlaps and is attached to the outer surface of the wider metal shell portion. The wider and narrower metal shell portions combine to exert a compressive force on the wrapped substrate.

Abstract: A preform for a z-flow honeycomb filter is formed by a pressing process wherein a batch charge is shaped in a press into a preform of finished plug-and-channel configuration, the shaped preform comprising opposing overlapping arrays of closed-end inlet and outlet channels wherein the end closures consist of bridging segments of batch material connected in continuous (seamless) or uninterrupted fashion with the adjoining channel walls.

Abstract: These sealing glass frits are a class of frits that seal in the intermediate temperature range of 600°-800° C. The frits are based on high strain point/high CTE alkali-zinc-silicate glass compositions. The sealing frits are useful in planar solid oxide fuel cells (SOFC).

Abstract: A water filtering carafe comprising a raw water reservoir, a filtered water reservoir, and a gravity-flow cyst reduction water filter cartridge for filtering raw water passing from the raw into the filtered water reservoir, the carafe including a mounting receptacle for the filter cartridge which forms a cyst-blocking water seal as the filter is mounted therein, such that the combination of the water seal and water filter cartridge provides at least a 99.95% reduction in particles of 3-4 microns diameter in a charge of raw water passing from the raw water reservoir into the filtered water reservoir.

Abstract: A honeycomb article has longitudinal channels extending from one face to a second face. A portion of the honeycomb is removed by cutting away a helical slot that depthwise extends from the outer surface of the honeycomb through a majority of the channels and lengthwise extends along the honeycomb channel axis commencing at or near the first face and toward the second face. The helical slot traverses a minimum of one rotation around the honeycomb axis. The honeycomb article can be used in a number of applications including heat exchange, thermal mixing, physical mixing, chemical stripping, and chemical reactions of one or more workstreams entering from one face, or entering in a countercurrent mode from both faces.