Abstract: The present invention relates to an exhaust system conduit, including a generally cylindrical outer portion and a generally cylindrical inner portion disposed within the generally cylindrical outer portion and defining a generally cylindrical fluid-flow path. The generally cylindrical inner portion further includes a substantially fibrous porous nonwoven refractory monolith and a catalyst material at least partially coating the monolith.

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 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 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 fibrous silicon carbide substrate is disclosed that is formed from a reaction between carbon fibers and silicon additives, to provide in-situ silicon carbide fibers. The fibrous structure is formed from a paper-making process of carbon or organic fibers that form a plurality of lamination members. The lamination members, each having a plurality of through holes, that when aligned in a lamination direction, form a honeycomb array of channels. The lamination members can be adapted into a wall-flow configuration for use in filtration of the exhaust of internal combustion engines.

Abstract: 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.

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: 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.

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 fibrous silicon carbide substrate is disclosed that provides porosity through an open network of pores resulting from an intertangled arrangement of silicon carbide fibers. The fibrous structure is formed from mixing carbon or organic fibers with silicon based additives, and forming a honeycomb substrate. The carbon or organic fibers are heated in an inert environment to form silicon carbide through a reaction of the carbon in the fibers and the silicon-based additives.

Abstract: A fibrous silicon carbide substrate is disclosed that provides porosity through an open network of pores resulting from an intertangled arrangement of silicon carbide fibers. The fibrous structure is formed from mixing carbon or organic fibers with silicon based additives, and forming a honeycomb substrate. The carbon or organic fibers are heated in an inert environment to form silicon carbide through a reaction of the carbon in the fibers and the silicon-based additives.

Abstract: A porous substrate produced by an extrusion process consisting essentially of bonded fibers is fabricated as a segmented substrate by joining a plurality of substrate segments with an adhesive that comprising fibers. The adhesive is bonded to fibers in the substrate segments to provide mechanical strength of the segmented substrate. The fibers in the adhesive provide a reduced elastic modulus in the adhesive layer that maintains a highly elastic structure between the segments in order to mitigate thermally induced mechanical stress when thermal gradients develop within the porous substrate during operation. The segmented porous fibrous substrate disclosed can be fabricated from a variety of materials to provide for effective filtration and as a catalytic host in various applications, including exhaust filtration of internal combustion engines.

Abstract: 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.

Abstract: A method for catalytically cleaning an exhaust gas, including receiving the exhaust gas in an inlet channel, blocking the exhaust gas in the inlet channel, diffusing the exhaust gas through a porous substantially fibrous nonwoven wall of the inlet channel, reacting the exhaust gas with at least one catalyst material to at least partially remove nitrous oxides, hydrocarbons and carbon monoxide therefrom, the at least one catalyst material being disposed on the porous wall, trapping particulate matter in the porous substantially fibrous nonwoven wall, receiving the diffused exhaust gas into an outlet channel, and transitioning the exhaust gas from the outlet channel to the atmosphere.

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: 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.