公开(公告)号：US20100048374A1

公开(公告)日：2010-02-25

申请号：US12473562

申请日：2009-05-28

申请人： James Jenq Liu ,  Bilal Zuberi ,  William M. Carty ,  Rachel A. Dahl ,  Jerry C. Weinstein ,  Sunilkumar C. Pillai ,  Timothy Gordon ,  James Marshall

发明人： James Jenq Liu ,  Bilal Zuberi ,  William M. Carty ,  Rachel A. Dahl ,  Jerry C. Weinstein ,  Sunilkumar C. Pillai ,  Timothy Gordon ,  James Marshall

IPC分类号： C03C10/14

CPC分类号： B01D39/2089 ,  B01D46/0001 ,  B01D46/2418 ,  B01D46/2448 ,  B01D2046/2433 ,  B01D2239/10 ,  B01D2257/7022 ,  F01N2330/06 ,  F02M25/06

摘要： 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. Likewise, pore former is also controlled by particle size and shape and particle density. The bonding phase may also be controlled based upon its contribution to the viscosity at sintering temperature.

摘要翻译： 本发明提供了一种用于在用于制造多孔陶瓷衬底的初始混合物中建立适量的组分的系统和方法。 组分通常由溶剂，诸如莫来石的本体纤维，用于挤出生坯基材的有机粘合剂，在高温固化时粘合纤维的玻璃/粘土粘合相和定孔之间的间隙的成孔剂组成 在固化期间颗粒被蒸发出基底。 通过确定与每个部件相关的可控因素，并且调整因素以改变固化的基材的所得强度和孔隙率，可以实现优化的强度和孔隙率性能。 每个组分的控制因素包括混合物中的相对重量百分数。 纤维组分也通过纤维直径，直径均匀性和纤维长度与直径的比例进行控制。 同样，成孔剂也由颗粒尺寸和形状和颗粒密度控制。 结合阶段也可以基于其对烧结温度下的粘度的贡献来控制。

公开(公告)号：US20080292518A1

公开(公告)日：2008-11-27

申请号：US11753011

申请日：2007-05-24

申请人： James Jeng Liu ,  Bilal Zuberi ,  Jerry G. Weinstein ,  Rachel A. Dahl

发明人： James Jeng Liu ,  Bilal Zuberi ,  Jerry G. Weinstein ,  Rachel A. Dahl

IPC分类号： B01D46/04 ,  B28B1/00

CPC分类号： C04B35/195 ,  B01D2279/30 ,  C04B35/803 ,  C04B38/0006 ,  C04B2103/0072 ,  C04B2103/0074 ,  C04B2111/00793 ,  C04B2111/0081 ,  C04B2111/2084 ,  C04B2111/346 ,  C04B2235/5228 ,  C04B2235/5232 ,  C04B38/068

摘要： 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.

摘要翻译： 多孔堇青石基质和形成多孔堇青石基质的方法，包括提供包含至少一种堇青石前体材料并提供至少一种有机粘合剂材料的纤维。 纤维和有机粘合剂材料与流体混合。 将纤维，有机粘合剂材料和流体的混合物挤出成绿色底物。 烧成绿色基底以能够在纤维之间形成结合并形成多孔堇青石纤维基材。

公开(公告)号：US08038759B2

公开(公告)日：2011-10-18

申请号：US12172217

申请日：2008-07-12

申请人： James Jenq Liu ,  Bilal Zuberi ,  Rachel A. Dahl ,  William M. Carty

发明人： James Jenq Liu ,  Bilal Zuberi ,  Rachel A. Dahl ,  William M. Carty

IPC分类号： B01D39/20 ,  B01D46/00 ,  C04B35/03

CPC分类号： B01D46/2429 ,  B01D46/2425 ,  B01D46/244 ,  B01D46/2444 ,  B01D46/2448 ,  B01D2046/2433 ,  B01D2046/2496 ,  B01D2279/30 ,  C04B35/195 ,  C04B35/62245 ,  C04B35/62675 ,  C04B35/6316 ,  C04B35/803 ,  C04B2235/3206 ,  C04B2235/3418 ,  C04B2235/349 ,  C04B2235/5228 ,  C04B2235/6021 ,  C04B2235/656 ,  C04B2235/6567 ,  C04B2235/96 ,  C04B2235/9607 ,  Y10S55/05 ,  Y10S55/30 ,  Y10S264/48

摘要： 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.

摘要翻译： 制造纤维材料的方法包括混合至少两种堇青石前体材料以形成混合物。 所述至少两种堇青石前体材料中的一种或多种是纤维形式，并且所述混合物包含约43％至约51％重量的SiO 2，约36％至约41％的Al 2 O 3和约12％至约 16％（重量）MgO。 该方法还包括挤出混合物以产生纤维体，并在约1200℃至约1420℃的温度下热处理纤维体，以形成纤维材料，包括约50％至约95％的 重量堇青石。 纤维体包括具有包含约50重量％至约95重量％的堇青石的多根纤维的挤出基材。 挤出的基材的至少一个方向的热膨胀系数小于约3.8×10 -6 /℃

公开(公告)号：US07858554B2

公开(公告)日：2010-12-28

申请号：US11753011

申请日：2007-05-24

申请人： James Jenq Liu ,  Bilal Zuberi ,  Jerry G. Weinstein ,  Rachel A. Dahl ,  William M. Carty

发明人： James Jenq Liu ,  Bilal Zuberi ,  Jerry G. Weinstein ,  Rachel A. Dahl ,  William M. Carty

IPC分类号： B01J23/00 ,  B01J21/00 ,  B01J20/00 ,  C04B38/00 ,  C04B35/00

CPC分类号： C04B35/195 ,  B01D2279/30 ,  C04B35/803 ,  C04B38/0006 ,  C04B2103/0072 ,  C04B2103/0074 ,  C04B2111/00793 ,  C04B2111/0081 ,  C04B2111/2084 ,  C04B2111/346 ,  C04B2235/5228 ,  C04B2235/5232 ,  C04B38/068

摘要： 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.

摘要翻译： 多孔堇青石基质和形成多孔堇青石基质的方法，包括提供包含至少一种堇青石前体材料并提供至少一种有机粘合剂材料的纤维。 纤维和有机粘合剂材料与流体混合。 将纤维，有机粘合剂材料和流体的混合物挤出成绿色底物。 烧成绿色基底以能够在纤维之间形成结合并形成多孔堇青石纤维基材。

公开(公告)号：US20090000260A1

公开(公告)日：2009-01-01

申请号：US12172217

申请日：2008-07-12

申请人： James Jenq Liu ,  Bilal Zuberi ,  Rachel A. Dahl ,  William M. Carty

发明人： James Jenq Liu ,  Bilal Zuberi ,  Rachel A. Dahl ,  William M. Carty

IPC分类号： B01D39/20 ,  C04B35/03 ,  C04B38/00

CPC分类号： B01D46/2429 ,  B01D46/2425 ,  B01D46/244 ,  B01D46/2444 ,  B01D46/2448 ,  B01D2046/2433 ,  B01D2046/2496 ,  B01D2279/30 ,  C04B35/195 ,  C04B35/62245 ,  C04B35/62675 ,  C04B35/6316 ,  C04B35/803 ,  C04B2235/3206 ,  C04B2235/3418 ,  C04B2235/349 ,  C04B2235/5228 ,  C04B2235/6021 ,  C04B2235/656 ,  C04B2235/6567 ,  C04B2235/96 ,  C04B2235/9607 ,  Y10S55/05 ,  Y10S55/30 ,  Y10S264/48

摘要： 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.

摘要翻译： 制造纤维材料的方法包括混合至少两种堇青石前体材料以形成混合物。 所述至少两种堇青石前体材料中的一种或多种是纤维形式，并且所述混合物包含约43％至约51％重量的SiO 2，约36％至约41％的Al 2 O 3和约12％至约 16％（重量）MgO。 该方法还包括挤出混合物以产生纤维体，并在约1200℃至约1420℃的温度下热处理纤维体，以形成纤维材料，包括约50％至约95％的 重量堇青石。 纤维体包括具有包含约50重量％至约95重量％的堇青石的多根纤维的挤出基材。 挤出的基材在至少一个方向上具有小于约3.8.10-6 /℃的热膨胀系数