Abstract: The present invention is directed towards a ceramic nanocomposite comprising a nanostructured carbon component inside a ceramic host. The ceramic nanocomposite may further comprise vapor grown carbon fibers. Such nanostructured carbon materials impart both structural and thermal barrier enhancements to the ceramic host. The present invention is also directed towards a method of making these ceramic nanocomposites and for methods of using them in various applications.

Abstract: A porous calcium phosphate ceramic comprising a support portion having pores, and ring-shaped portions formed in the pores, the ring-shaped portions having pluralities of fine pores so that they have a network structure. A method for producing a porous calcium phosphate ceramic comprising stirring a slurry containing coarse calcium phosphate particles, fine calcium phosphate particles, a nonionic surfactant and a water-soluble high-molecular compound to foam the slurry; gelling the foamed slurry; and then drying the resultant get to obtain a sintered porous calcium phosphate ceramic; the nonionic surfactant being malamide and/or polyoxyethylene lauryl ether.

Abstract: According to a producing method including; preparing a foaming slurry by agitating and blending a dispersion medium containing hollow glass or ceramic particles having an average particle diameter of 1 ?m or more, a dispersant and a foaming agent to foam; obtaining a dried body by dropping the foaming slurry in liquid nitrogen, followed by freeze drying in a vacuum; and sintering the dried body to obtain a spherical porous body having open pores interconnected over an entirety, a porous body that is highly communicative, has sufficient mechanical strength and is suitable as a cell culture carrier for microcarrier culture can be provided.

Abstract: A ceramic powder having a perovskite structure is manufactured by synthesizing a ceramic powder by a dry synthesis process and then heat-treating the synthesized ceramic powder in a solution. The dry synthesis method includes a solid phase synthesis method, an oxalate method, a citric acid method and a gas phase synthesis method.

Abstract: A method of preparing spherical pellets from a slurry comprising a ceramic powder, a solvent, and any desired additives, by means of a drop-generating orifice to which said slurry is fed is described, wherein the drops are released from said orifice by means of a relative flow of a liquid medium which is a poor solvent for the solvent of the slurry, formed into spherical bodies in said liquid medium by means of the action of surface tension, and thereafter treated for consolidation. More specifically, the present invention relates to the preparation of pellets of a catalyst or catalyst support material, suitable for use in high temperature conditions.

Abstract: A method of making a catalyst comprising mixing a metal oxide precursor and a pore former to form a metal oxide precursor mixture and calcining the metal oxide precursor mixture in the presence of a flowing gas having a flow rate to form the catalyst comprising metal oxide. The catalyst comprises a first distribution of pores having a median pore diameter of 10 to 50 angstroms and a second distribution of pores having a median pore diameter of 1 to 500 angstroms. The median pore diameter of the second distribution of pores is inversely related to the flow rate of the gas.

Abstract: A homogeneous bulky porous ceramic material is provided, the average pore diameter D50 of which is less than 4 ?m and the closed porosity of which is less than 2 ?m, and having a bubble point that matches the pore diameter measured on the material. A hollow fiber based on the material and a module employing such fibers together with a paste constituting a precursor for the material and including a pore-forming agent are also provided.

Abstract: An alumina sintered body having communicating pores of 400–1100 ? in average pore diameter and 4–16% in porosity and being obtainable by mixing first alumina particles 1 having a particle diameter of 0.2–0.7 ?m and a sphericity of 0.7–1.0 as an aggregate and second alumina particles having a particle diameter of 0.01–0.1 ?m as a pore forming material to embed a plurality of the second alumina particles 2 in the spaces between the first alumina particles 1, and sintering the mixture at a temperature of 1200–1400° C. The alumina sintered body can be used for a part for various gas permeable industrial materials inclusive of protective film for gas sensors, and the like.

Abstract: The present invention provides a method for making a microporous ceramic material and includes the steps of (a) preparing a starting material for firing comprising a nonoxide ceramic precursor containing silicon as an essential component; (b) heating the starting material for firing in an atmosphere containing at least 1 mol % of hydrogen so as to form microporous ceramic product; and (c) cooling the microporous ceramic product.

Abstract: The invention describes an article and method comprising a refractory article having an outer surface covered by an insulating coating over which a protective glaze is applied. The method includes applying a suspension of an insulating coating to a refractory piece, drying the suspension, applying a glaze slip over the coating, and drying the slip to form a protective glaze. In one embodiment, the article comprises a carbon-bonded alumina-graphite nozzle, an insulating coating containing hollow microspheres, and a protective glaze formed from a fusible frit. The invention is described as improving wetting to the refractory piece, reducing delamination of the glaze and insulating coating from the piece, and reducing oxidation of the piece.

Abstract: A block copolymer, preferably a block copolymer such as poly(isoprene-block-ethylene oxide), PI-b-PEO, is used as a structure directing agent for a polymer derived ceramic (PDC) precursor, preferably a silazane, most preferably a silazane commercially known as Ceraset. The PDC precursor is preferably polymerized after mixing with the block copolymer to form a nanostructured composite material. Through further heating steps, the nanostructured composite material can be transformed into a nanostructured non-oxide ceramic material, preferably a high temperature SiCN or SiC material.

Abstract: A ceramic porous body is provided which uses a binder made of a glass that has excellent acid resistance and alkali resistance and which can be used for a long period of time as a filtration filter. The ceramic porous body is formed from ceramic particles that are bonded using a glass binder comprising 5 to 20 mol % of a plurality of metal oxides, selected from the group consisting of Li2O, Na2O, K2O, MgO, CaO, SrO and BaO and containing at least two alkali metal oxides selected from the group consisting of Li2O, Na2O and K2O as an essential component, at least 3 mol % of at least one of ZrO2 and TiO2 as a total amount, and SiO2 and incidental impurities as the balance.

Abstract: The invention provides porous silicon nitride ceramics that having uniform, fine closed pores and a manufacturing method thereof. Metal Si powder is mixed with a sintering additive, followed by thermal treatment, which is a pre-process for forming a specific grain boundary phase. Two-stage thermal treatment is thereafter performed by microwave heating at a temperature of 1000° C. or more. The metal Si powder is thereafter subjected to a nitriding reaction from its surface, the metal Si is thereafter diffused to nitride formed on the outer shell thereof such that porous silicon nitride ceramics having uniform, fine closed pores can be produced. Having a high ratio of closed pores and being superior in electrical/mechanical characteristics, the porous silicon nitride ceramics can display excellent characteristics if used, for example, for an electronic circuit board that requires an anti-hygroscopicity, a low dielectric constant, a low dielectric loss, and mechanical strength.

Abstract: Microporous ceramic materials used in structural materials, high-temperature filters, electrode materials or preform materials for infiltration by homogeneously mixing and molding a ceramic precursor powder polymer. The powder is saturated by introducing fluid to a pressure vessel. The fluid is super saturated by adjusting pressure in the vessel. Micropores are formed in the molded bodies by evolving the fluid from the molded bodies by heating and hardening the molded bodies. The hardened molded bodies are heated to pyrolysis. Pore characteristics (e.g., pore size and pore size distribution) suitable to target materials are controlled by adjusting pressure at a non-critical state without requiring additional processes or devices.

Abstract: A thermochemically stable oxidic thermal insulating material presenting phase stability, which can be used advantageously as a thermal insulating layer on parts subjected to high thermal stress, such as turbine blades or such like. The thermal insulating material can be processed by plasma spraying and consists preferably of a magnetoplumbite phase whose preferred composition is MMeAl11O19, where M is La or Nd and where Me is chosen from among zinc, the alkaline earth metals, transition metals, and rare earths, preferably from magnesium, zinc, cobalt, manganese, iron, nickel and chromium.

Abstract: A large, high density foam glass tile which can be used as a facade on both exterior and interior building walls. The foam glass tile can also be used with other materials to form a panel or a composite. The present invention may be used on the critical surfaces of buildings at high risk for terrorist attacks, in combination with cement, steel or other high strength building materials. The present invention may also be used in surfaces of typical buildings. The present invention has the advantage of absorbing a substantial portion of a shock wave caused by an explosion. The present invention also has the advantage of being more resistant to earthquakes.

Abstract: An aluminum titanate-based ceramic body having a composition a formula comprising a(Al2O3.TiO2)+b(CaO.Al2O3.2SiO2)+c(SrO.Al2O3.2SiO2)+d(BaO.Al2O3.2SiO2)+e(3Al2O3.2SiO2)+f(Al2O3)+g (SiO2)+h(Fe2O3.TiO2)+i(MgO.2TiO2), wherein a, b, c, d, e, f, g, h, and i are weight fractions of each component such that (a+b+c+d+e+f+g+h+i)=1, wherein 0.5<a?0.95; 0?b?0.5; 0?c?0.5; 0?d?0.5; 0<e?0.5; 0?f?0.5; 0?g?0.1; 0?h?0.3; 0?i?0.3; b+d>0.01. A method of forming the ceramic body is provided. The ceramic body is useful in automotive emissions control systems, such as diesel exhaust filtration.

Abstract: There is provided macrostructures of porous inorganic material which can have controlled size, shape, and/or porosity and a process for preparing the macrostructures. The macrostructures comprise a three-dimension network of particles of porous inorganic materials. The process for preparing the macrostructures involves forming an admixture containing a porous organic ion exchanger and a synthesis mixture capable of forming a porous inorganic material and then converting the synthesis mixture to a solid porous inorganic material. After formation of the composite material, the porous organic ion exchanger can be removed from the composite material to obtain the macrostructures, either before or after the porous inorganic material is hydrothermally treated with a structure directing agent to convert at least a portion of such porous inorganic material to a crystalline molecular sieve composition. The resulting macrostructure is composed of particles of the crystalline molecular sieve composition.

Abstract: A porous grog with a body composition of water, clay and combustible material. Further, an earthenware water purification filter utilizing the porous grog in the body composition of the filter. A water purification system incorporating said filter, said water purification system capable of removing about 99% of all particles not less than 1.0 micron is size.

Abstract: The present invention provides a method for making a microporous ceramic material and includes the steps of (a) preparing a starting material for firing comprising a nonoxide ceramic precursor containing silicon as an essential component; (b) heating the starting material for firing in an atmosphere containing at least 1 mol % of hydrogen so as to form microporous ceramic product; and (c) cooling the microporous ceramic product.

Abstract: A method for forming a region of low dielectric constant nanoporous material is disclosed. In one embodiment, the present method includes the step of preparing a microemulsion. The method of the present embodiment then recites applying the microemulsion to a surface above which it is desired to form a region of low dielectric constant nanoporous material. Next, the present method recites subjecting the microemulsion, which has been applied to the surface, to a thermal process such that the region of low dielectric constant nanoporous material is formed above the surface.

Abstract: A metal oxide catalyst precursor composition comprises a pore former and a catalyst reagent.

Abstract: Provided is a catalyst formulation which exhibits extended catalyst life. The formulation comprises a mixture of a ceramic foam material uniformly interspersed between the solid catalyst particles, with the volume percent of ceramic material in the mixture preferably ranging from 20 to 60 volume %. The catalyst formulation is particularly applicable to solid catalyst particles comprised of a phosphoric acid impregnated substrate, and is particularly useful for processes such as catalytic hydrocarbon condensation processes.

Abstract: A brick additive and methods for using the brick additive are disclosed. The additive may include an internal porosity. The internal porosity may display an intra-granular internal porosity in which at least some of the pores are interconnected via an open network of pore spaces. In some embodiments, the additive is capable of maintaining its internal porosity after undergoing thermal modification via calcination, for example. In addition, brick additives of the present invention may display a large surface area.

Abstract: Macroporous ceramics were produced using the droplets of an emulsion as the templates around which the ceramic is deposited through a sol-gel process. Subsequent aging, drying and calcination yields a ceramic with pores in the range of 0.1 to several micrometers which have been left behind by the droplets. The unique deformability of the droplets prevents cracking and pulverization during processing and allows one to obtain porosities in excess of 74%. By starting with a monodisperse emulsion (produced through a repeated fractionation procedure) pores with a uniform and controllable size have been obtained. Self-assembly of these droplets into a colloidal crystal leads to ceramics which contain ordered arrays of pores. A wide range of porosities is obtainable with the advantages of low-temperature sol-gel processing, with a high degree of control and low cost.

Abstract: Mesoporous hexagonal, cubic, lamellar, wormhole, or cellular foam aluminosilicates, gallosilicates and titanosilicates derived from protozeolitic seeds using an ionic structure directing agent are described. The silicon and aluminum, gallium or titanium centers in the structures are stable so that the framework of the structure does not collapse when heated in the presence of water or water vapor (steam). The steam stable compositions can be used as catalysts for hydrocarbon conversions, including the fluidized bed catalytic cracking and the hydrocracking of petroleum oils, and other reactions of organic compounds.

Abstract: The present invention relates to compositions comprising the reaction product of amorphous silica or ultra-fine silica and one or more bases. The present invention also relates to materials and method involving the use of such products. In particular, the present invention i.a. relates to new mineral wool products, e.g. products comprising man-made vitreous fibres (such as glass fibres, slag fibres, stone fibres and rock fibres) or perlite, having included therein a binder component which comprises amorphous silica and aklali metal organosiliconates, e.g. potassium methyl siliconate. An important feature of such products is the preparation of the binder systems under vigorous mixing. Such products provide good fire, heat and sound insulating properties. The present invention also provides to a method for removing odorous substances from a gas where materials prepared from ultra-fine silica, water, and one or more components enabling porosity-conferring binding of the material, e.g. a base or bases.

Abstract: A cordierite ceramic body having (i) a pore size distribution and a porosity which satisfy the relationship 10.2474/[(d50)2(pore fraction)]+0.0366183(d90)?0.00040119(d90)2+0.468815(1/pore fraction)2+0.0297715(d50)+1.61639(d50?d10)/d50?3.65, and (ii) a CTE (25°-800° C.) of ?15×10?7/° C., wherein the cordierite ceramic body is produced from a moldable mixture comprising cordierite-forming raw materials including (a) a fine talc having a median particle diameter, as measured by laser diffraction, of less than 10 micrometers, and a B.E.T. specific surface area of greater than 5 m2/g, and (b) a pore former. The cordierite ceramic body is suitable in the fabrication of cellular, wall-flow diesel particulate filters having a low pressure drop, high filtration efficiency and improved strength.

Abstract: The invention is directed at a mullite-aluminum titanate porous diesel particulate filter constituting a porous ceramic body containing, expressed in terms of weight percent of the total body, of 60-90%, preferably 70-80%, most preferably 70% iron-aluminum titanate solid solution having a stoichiometry of Al2(1?x)Fe2xTiO5, where x is 0-0.1, and 10-40%, preferably 20-30%, most preferably 30% mullite (3Al2O3.2SiO2), and consists essentially, expressed in terms of weigh percent on the oxide basis, of 3 to 15% SiO2, 55 to 65% Al2O3, 22 to 40% TiO2, and 0 to 10% Fe2O3, and being useful for filtration of diesel exhaust. The inventive diesel particulate filter exhibits high interconnected open porosity and large median pore size, in combination with high permeability when fired to a temperature of between 1650° to 1700° C., along with high thermal shock resistance and good filtration capability.

Abstract: Porous hexagonal, cubic, lamellar, wormhole, or cellular foam aluminosilicates, gallosilicates and titanosilicates derived from protozeolitic seeds or zeolite fragments using an organic porogen directing agent are described. The porous aluminosilicates optionally also can contain zeolite crystals depending upon the aging of the protozeolitic seeds. The silicon and aluminum, gallium or titanium centers in the structures are stable so that the framework of the structure does not collapse when heated in the presence of water or water vapor (steam). The steam stable compositions can be used as catalysts for hydrocarbon conversions, including the fluidized bed catalytic cracking and the hydrocracking of petroleum oils, and other reactions of organic compounds.

Abstract: The invention is intended to introduce cells easily into a ceramics for in vivo use. Also, the invention provides a ceramics for in vivo use which has a good affinity to a living body and no harmful action on a living body. The invention relates to a porous ceramics having many almost globular pores and made of a component comprising a calcium phosphate type. These pores are brought into contact and communicated with each other to thereby exhibit permeability. The permeability was designed to be 150 centidarcy or more and 8000 centidarcy or less.

Abstract: A ceramic material, includes SiO2 and Na2O and/or K2O. The material is characterized by a porosity of over 60% and by pores, more than 70% of which have a pore size ranging between 0.1 and 15 &mgr;m. The ceramic material can be used as filtering material, for water storage and as adsorbent material.

Abstract: A process for preparing a silicate porous product, which comprises a step of forming a clay mineral into a dispersion by means of a dispersant, a step of removing gases dissolved in the dispersion, a step of freezing the dispersion and drying it in its frozen state under reduced pressure, and a step of firing the dried product obtained by the drying.

Abstract: A ceramic composite material, for example, a ceramic molded body or a layer obtained by pyrolysis of a starting mixture, containing at least one polymer precursor material and at least one filler, which has an average particle size of less than 200 nm. Such a composite material may be used, for example, for producing fibers, filters, catalyst support materials, ceramic sheathed-element glow plugs, metal-containing reactive composite materials, porous protective shells for sensors, ceramic or partially ceramic coatings or microstructured ceramic components.

Abstract: A thermal insulation molding having a density of 150-500 kg/m3, includes a thermal insulation material, containing 5%-75% by weight of pyrogenic silica (HDK), 5%-50% by weight of electric-arc silica, 5%-50% by weight of opacifier, wherein the electric-arc silica has a bulk density of <200 kg/m3, a carbon content of <0.1% by weight, an alkali metal oxide content of <0.2% by weight, an alkaline-earth metal oxide content of <0.3% by weight, an SO3 content of <0.05% by weight and a specific surface area of >30 m2/g.

Abstract: The invention relates to a method for producing a monolithic, porous, ceramic shaped body and to the shaped bodies produced according to this method. Said shaped body is used predominantly as a support material for porous, inorganic and/or organic membranes for the flow filtration of liquids and gases. The aim of the invention is to provide a method for producing a shaped body consisting substantially of TiO2 with an open porosity >10%, an average pore size of between 1 and 50 &mgr;m and a mechanical stability >20 N/mm2. To achieve this, a first TiO2-powder fraction is pre-sintered at temperatures >1200° C.

Abstract: A honeycomb structure made of a silicon carbide-based porous body and having a number of through-holes extending in the axial direction, separated by partition walls. The strength and Young's modulus of the silicon carbide-based porous body satisfy the following relation: Strength (MPa)/Young's modulus (GPa)≧1.1. The honeycomb structure contains refractory particles such as silicon carbide particles and the like and yet can be produced at a relatively low firing temperature at a low cost, has a high strength and a high thermal shock resistance, and can be suitably used, for example, as a filter for purification of automobile exhaust gas by a treatment such as plugging of through-channel at its inlet or outlet, or as a catalyst carrier, even under a high SV condition.

Abstract: Mesoporous hexagonal, cubic, lamellar, wormhole, or cellular foam aluminosilicates, gallosilicates and titanosilicates derived from protozeolitic seeds using an ionic structure directing agent are described. The silicon and aluminum, gallium or titanium centers in the structures are stable so that the framework of the structure does not collapse when heated in the presence of water or water vapor (steam). The steam stable compositions can be used as catalysts for hydrocarbon conversions, including the fluidized bed catalytic cracking and the hydrocracking of petroleum oils, and other reactions of organic compounds.

Abstract: Porous ceramics are described, which are produced by a) mixing an aqueous solution of a suitable ionotropically orientable polyanion, either with oxides, hydroxides or hydrated oxides, which are present in the form of a sol, of the metals Al, Zr, Ti and Nb, or with finely crystalline oxides, hydroxides or hydrated oxides, which are present in suspension, of these metals, or with finely crystalline tricalcium phosphate or apatite which are present in suspension, b) bringing the mixed sol obtained as in a) or the suspension obtained as in a) into contact with a solution of a salt of a di- or trivalent metal cation in order to produce an ionotropic gel body, c) compacting the gel body by introducing it into electrolyte solutions which further enhance the syneresis of the polyelectrolyte which was originally formed, d) washing the gel body with water and subsequently impregnating it with a readily volatile, water-miscible solvent, e) freeing the anhydrous gel body or gel bodies obtained as in d) from the

Abstract: Powder of a metal serving as a precursor for ceramics (1) and a sintering additive are mixed with each other and heat-treated by microwave heating thereby nitriding or oxidizing the metallic powder from the surface thereof and diffusing the metal with a nitride or an oxide formed on the shell of the metal for obtaining porous ceramics (1) having homogeneous and fine closed pores (1a). The porous ceramics (1) according to the present invention, having the closed pores (1a) homogeneously diffusing at a high ratio, exhibits excellent characteristics when applied to an electronic circuit board or the like requiring moisture absorption resistance, low permittivity and low dielectric loss as well as mechanical strength.

Abstract: A process for the preparation of bulk foams which comprises contacting ceramic foam particles with a hydrophobic material to form impregnated and/or coated ceramic foam particles with hydrophobic properties. The impregnated and/or coated ceramic foam particulate material is mixed with a ceramic binding material with or without an organic binder in an aqueous composition solution to form a castable and pressable mixture. The castable and pressable mixture is cast, and optionally pressed, in a mold to form a wet green body, which is in turn dried to form a dried green body, and is then fired and sintered to form a bulk shape foam article.

Abstract: A porous ceramics body for in vivo or in vitro 1use in which a number of pores are closely distributed in three dimensional directions, adjoining pores thereof being partitioned by wall portions with respective communication ports to bring said adjoining pores into communication with each other such that a series of connected spherical pores are formed therewithin, said porous ceramics body being made of a sintered calcium phosphate body, characterized in that, within said sintered calcium phosphate body, pores each having a diameter of 5 microns (&mgr;m) or more account for 80% or more of all the pores in terms of volume whereas pores having a diameter of less than 5 microns (&mgr;m) account for less than 20% of all the pores in terms of volume as subjected to a mercury porosimeter measurement.

Abstract: A method of making a molecularly imprinted porous structure makes use of a surfactant analog of the molecule to be imprinted that has the imprint molecule portion serving as the surfactant headgroup. The surfactant analog is allowed to self-assemble in a mixture to create at least one supramolecular structure having exposed imprint groups. The imprinted porous structure is formed by adding reactive monomers to the mixture and allowing the monomers to polymerize, with the supramolecular structure serving as a template. The resulting solid structure has a shape that is complementary to the shape of the supramolecular structure and has cavities that are the mirror image of the imprint group. Similarly, molecularly imprinted particles may be made by using the surfactant to create a water-in-oil microemulsion wherein the imprint groups are exposed to the water phase.

Abstract: A porous sintered body in which the leaching amounts of heavy metals are small and having high availability contains 0.5-15 weight % of B2O3, preferably contains 20-60 weight % of Al2O3, 18-60 weight % of SiO2, 1-12 weight % of the sum of Na2O, K2O, Li2O, and P2O5, 1-30 weight % of the sum of CaO, SrO, BaO, and MgO, and 0.5-15 weight % of B2O3.

Abstract: The present invention relates to microporous ceramic materials, and the production method thereof, which can be suitably used in various structural materials, high-temperature filters, electrode materials, preform materials for infiltration, etc., wherein said method comprises the steps of: producing molded bodies by homogeneously mixing a starting material of polymer ceramic precursor powder, and then forming the same; saturating the same by introducing fluid of a non-critical state to said molded bodies in a pressure vessel; super-saturating the fluid of a non-critical state saturated to molded bodies by adjusting pressure in said pressure vessel; forming micropores in said molded bodies by evolving said fluid of a non-critical state from said molded bodies by heating said molded bodies; hardening said molded bodies having micropores; and carrying out pyrolysis by heating said hardened molded bodies. Accordingly, the present invention allows easy control of pore characteristics (e.g.

Abstract: Mesoporous hexagonal, cubic or wormhole aluminosilicates derived from zeolite seeds using an ionic structure directing agent are described. The aluminum in the structures is stable so that the framework of the structures does not collapse when heated in the presence of water or water vapor (steam). The steam stable aluminosilicates can be used as acid catalysts for hydrocarbon conversions, including the fluidized bed catalytic cracking and the hydrocracking of petroleum oils, and other cracking of organic compounds.

Abstract: The present invention relates to new mesoporous inorganic solids in the form of primary and/or secondary inorganic particles of D10≧1 &mgr;m and D50≧3 &mgr;m, preferably from D10≧2 &mgr;m and D50≧10 &mgr;m the size of which can go up to 10 mm, wherein the microporous volume (pores of size less than or equal to 2 &mgr;m) represents at most 10% of the total porous volume up to 300 nm.

Abstract: A porous ceramic fiber insulating material and method of making a material having a combination of silica (SiO2) and alumina (Al2O3) fibers, and boron-containing powders is the topic of the new invention. The insulative material is composed of about 60 wt % to about 80 wt % silica fibers, about 20 wt % to about 40 wt % alumina fibers, and about 0.1 wt % to about 1.0 wt % boron-containing powders. A specific boron-containing powder used for this invention is boron carbide powder which provide boron-containing by-products, which aid in fusion and sintering of the silica and alumina fibers. The material is produced by forming an aqueous slurry, blending and chopping the fibers via a shear mixer, orienting the fibers in the in-plane direction, draining water from the fibers, pressing the fibers into a billet, heating the fibers to remove residual water, and firing the billet to fuse the fibers of the material. After sintering, bulk density of the new insulation material ranges from 6 to 20 lb/ft3.

Abstract: A hybrid insulation material comprises of porous ceramic substrate material impregnated with nanoporous material and method of making the same is the topic of this invention. The porous substrate material has bulk density ranging from 6 to 20 lb/ft3 and is composed of about 60 to 80 wt % silica (SiO2) 20 to 40 wt % alumina (Al2O3) fibers, and with about 0.1 to 1.0 wt % boron-containing constituent as the sintering agent. The nanoporous material has density ranging from 1.0 to 10 lb/ft3 and is either fully or partially impregnated into the substrate to block the pores, resulting in substantial reduction in conduction via radiation and convention. The nanoporous material used to impregnate the fiber substrate is preferably formed from a precursor of alkoxysilane, alcohol, water, and an acid or base catalyst for silica aerogels, and from a precursor of aluminum alkoxide, alcohol, water, and an acid or base catalyst for alumina aerogels.

Abstract: A ceramic comprising predominately a cordierite-type phase approximating the stoichiometry Mg2Al4Si5O18 and having a coefficient of thermal expansion (25-800° C.) of greater than 4×10?7/° C. and less than 13×10?7/° C. and a permeability and a pore size distribution which satisfy the relation 2.108 (permeability)+18.511 (total pore volume)+0.1863 (percentage of total pore volume comprised of pores between 4 and 40 micrometers)>24.6. The ceramic is suitable in the fabrication of cellular, wall-flow, diesel particulate filters having a pressure drop in kPa that at an artificial carbon soot loading of 5 grams/liter and a flow rate of 26 scfm is less than 8.9-0.035 (number of cells per square inch)+300 (cell wall thickness in inches), a bulk filter density of at least 0.60 g/cm3 and a volumetric heat capacity of at least 0.67 J cm?3 K?1 as measured at 500° C.