Abstract: A fibrous ceramic material comprises a plurality of fibers having a RxMg2Al4+xSi5?xO18 or RxMg2?xAl4Si5O18 compositional structure. The fibrous ceramic material is form by combining two or more RxMg2Al4+xSi5?xO18 or RxMg2?xAl4Si5O18 precursors in which at least one of the two or more RxMg2Al4+xSi5?xO18 or RxMg2?xAl4Si5O18 precursors 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.