Abstract: 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 SiO2, about 36% to about 41% by weight Al2O3, and about 12% to about 16% by weight MgO. The method also includes extruding the mixture to create a fibrous body, and heat treating the fibrous body, at a temperature of about 1200° C. to about 1420° C., to form the fibrous material including about 50% to about 95% by weight cordierite. A fibrous body includes an extruded substrate having a plurality of fibers including about 50% to about 95% by weight cordierite. The extruded substrate has a coefficient of thermal expansion in at least one direction of less than about 3.8·10?6 per ° C.

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: 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.

Abstract: 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 SiO2, about 36% to about 41% by weight Al2O3, and about 12% to about 16% by weight MgO. The method also includes extruding the mixture to create a fibrous body, and heat treating the fibrous body, at a temperature of about 1200° C. to about 1420° C., to form the fibrous material including about 50% to about 95% by weight cordierite. A fibrous body includes an extruded substrate having a plurality of fibers including about 50% to about 95% by weight cordierite. The extruded substrate has a coefficient of thermal expansion in at least one direction of less than about 3.8·10?6 per ° C.

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.