Abstract: 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.

Abstract: A process is provided for strengthening a porous substrate. The process includes providing a substrate having intersecting fibers, where the intersecting fibers cooperate in the final substrate product to form an open pore network. Pathways are opened into the fibrous substrate structure, which enable a flow of gas into the or through the substrate. The substrate is positioned in a CVD (chemical vapor deposition) station, and one or more layers of a strengthening agent is deposited. The deposited layer or layers form a strong coating around fibers and fiber intersections to provide additional strength to the substrate. The strengthened substrate may then be used in wide variety of applications and fields. Advantageously, the disclosed fiber strengthening process produces a substrate having high porosity and higher strength characteristics as compared to a non-strengthened substrate.

Abstract: A porous honeycomb substrate having about 10% to about 60% by volume ceramic fiber is fabricated in a variety of material compositions. The fiber material is combined with particle-based materials to reaction-form composite structures forming a porous matrix. The porous honeycomb substrate exhibits an open pore network of porosity from the fiber component to provide high permeability for various applications such as filtration and catalytic hosting of chemical processes.

Abstract: 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.

Abstract: A fibrous ceramic material comprises a plurality of fibers having a modified aluminosilicate compositional structure (i.e., x(RO).y(Al2O3).z(SiO2) or w(MO).x(RO).y(Al2O3).z(SiO2)). The fibrous ceramic material is form by combining two or more x(RO).y(Al2O3).z(SiO2) or w(MO).x(RO).y(Al2O3).z(SiO2) 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., ?4.7×10-6/° C.).

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: The invention relates to an engine with an exhaust gas pathway extending between the engine and the atmosphere. The engine includes a manifold portion fluidically connected to an engine, a muffler portion fluidically connected to the atmosphere, a conduit portion fluidically connected between the manifold portion and the muffler portion, and a plurality of baffles operationally connected within the muffler. A substantially fibrous refractory material at least partially coats the exhaust gas pathway. Exhaust gas from the engine flowing through the exhaust gas pathway to the atmosphere flows over the substantially fibrous refractory material.

Abstract: 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.

Abstract: An exhaust gas pollution treatment device, having an inlet pipe, an outlet pipe with an exhaust path extending between the inlet pipe and the outlet pipe. A gas permeable backbone member is positioned in the exhaust path and a substantially fibrous nonwoven refractory material is disposed on the backbone.

Abstract: A simple catalytic device that is easily installed into vehicles, small engines, and industrial exhaust stacks is provided. The simple catalytic device has a ridged and stable backbone structure that withstands expected mechanical forces. In one example, the backbone is a highly gas permeable mesh or screen. A fibrous material is disposed on the backbone, with a catalytic material coating applied to the fibrous material. The catalytic device is constructed to be installable in an exhaust path, where it provides a catalytic conversion for non-particulate matter.

Abstract: A highly porous ceramic filter consisting essentially of bonded ceramic fibers forms a part of an exhaust filtration system for a gasoline two-stroke engine. The porosity of the substrate permits accumulation of particulate constituents of the exhaust stream without detracting from the engine performance due to backpressure. Embodiments of the porous ceramic filter are disposed with a catalyst to facilitate reduction of gaseous and particulate byproducts of combustion from the two-stroke engine, so that emission of harmful pollutants is minimized.

Abstract: A diesel particulate filter assembly, and methods for use of such filter assembly, including a housing having an inlet end and an outlet end, a particulate filter portion consisting essentially of mullite fibers and positioned in the housing, an array of honeycomb channels in the filter, a porous wall between adjacent channels, and an exhaust path extending through the inlet end, through the particulate filter portion and though the outlet end.

Abstract: An improved, efficient, and regenerable exhaust emission filter and filter system are provided which incorporate the use of an inorganic, non-woven fiber filter element. The filter is able to capture exhaust pollutants and particulates through the interwoven nature of the filter element and due to area enhancements applied to the filter element including microscopic enhancements. The filter has an improved life and is able to combust a greater percentage of trapped particulates due to the high temperatures the filter element can withstand. The filter element if formed from a non-woven fiber block which is machined or shaped into a filter foundation. The filter element can have a multitude of coatings and catalysts applied and can be wrapped in insulation and a casing. The improved exhaust emission filter is particularly useful for diesel engine exhausts.

Abstract: 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.