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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。
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2.发明授权公开(公告)号：US07938877B2
公开(公告)日：2011-05-10
申请号：US12104977
申请日：2008-04-17
CPC分类号： B01D39/2086 , C04B35/19 , C04B35/195 , C04B35/62245 , C04B35/62844 , C04B35/6365 , C04B35/638 , C04B35/803 , C04B38/0006 , C04B2111/00793 , C04B2111/0081 , C04B2235/3203 , C04B2235/3213 , C04B2235/3215 , C04B2235/3418 , C04B2235/442 , C04B2235/5228 , C04B2235/5268 , C04B2235/5296 , C04B2235/606 , C04B2235/9607
摘要： 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.).
摘要翻译： 纤维状陶瓷材料包括多个具有改性的硅铝酸盐组成结构的纤维（即，x（RO）y（Al 2 O 3）z（SiO 2）或w（MO）x（RO）y（Al 2 O 3） SiO 2））。 纤维状陶瓷材料是通过组合两种或多种x（RO）y（Al 2 O 3）z（SiO 2）或w（MO）x（RO）y（Al 2 O 3）z（SiO 2）前体形成的，其中至少 两种或更多种前体之一是纤维形式。 所得到的纤维状陶瓷材料的热膨胀系数（即，n1E = 4.7×10-6 /℃）。
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3.发明授权Low coefficient of thermal expansion materials including nonstoichiometric cordierite fibers and methods of manufacture 有权包括非化学计量堇青石纤维在内的低热膨胀系数和制造方法公开(公告)号：US07938876B2
公开(公告)日：2011-05-10
申请号：US12104969
申请日：2008-04-17
CPC分类号： B01D39/2086 , C04B35/195 , C04B35/62245 , C04B35/62844 , C04B35/6365 , C04B35/638 , C04B35/803 , C04B38/0006 , C04B2111/00793 , C04B2111/0081 , C04B2235/3201 , C04B2235/3206 , C04B2235/3208 , C04B2235/3262 , C04B2235/3272 , C04B2235/3287 , C04B2235/349 , C04B2235/442 , C04B2235/5224 , C04B2235/5228 , C04B2235/5232 , C04B2235/5268 , C04B2235/5296 , C04B2235/606 , C04B2235/76 , C04B2235/9607 , Y10S55/05 , Y10S55/30 , Y10S264/48
摘要： 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.
摘要翻译： 纤维状陶瓷材料包括具有RxMg2Al4 + xSi5-xO18或RxMg2-xAl4Si5O18组成结构的多根纤维。 纤维状陶瓷材料是通过组合两种或更多种RxMg2Al4 + xSi5-xO18或RxMg2-xAl4Si5O18前体形成的，其中两种或更多种RxMg2Al4 + xSi5-xO18或RxMg2-xAl4Si5O18前体中的至少一种为纤维形式。 纤维状陶瓷材料成形为形成纤维体，其中至少约20％的纤维在基本上共同的方向上排列。
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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
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 /℃
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公开(公告)号：US07858554B2
公开(公告)日：2010-12-28
申请号：US11753011
申请日：2007-05-24
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。
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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
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
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公开(公告)号：US20080178992A1
公开(公告)日：2008-07-31
申请号：US11669488
申请日：2007-01-31
IPC分类号： B32B3/12
CPC分类号： B28B1/002 , C04B28/24 , C04B35/14 , C04B35/6365 , C04B35/803 , C04B37/005 , C04B38/0019 , C04B2111/00793 , C04B2111/0081 , C04B2235/3201 , C04B2235/3206 , C04B2235/3232 , C04B2235/3272 , C04B2235/5232 , C04B2237/062 , C04B2237/38 , Y10T156/1003 , Y10T428/24149 , C04B14/4656 , C04B24/383 , C04B38/0054 , C04B38/0074 , C04B38/0645
摘要： 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.
摘要翻译： 通过基本上由粘合纤维组成的挤出方法制造的多孔基材通过将多个基材段与包含纤维的粘合剂接合而制成为分段基材。 粘合剂粘合到基片段中的纤维上以提供分段基底的机械强度。 粘合剂中的纤维在粘合剂层中提供了降低的弹性模量，其在段之间保持高度弹性的结构，以便在操作期间在多孔基材内形成热梯度时减轻热诱导的机械应力。 所公开的分段多孔纤维基材可以由各种材料制成，以提供有效的过滤和作为各种应用的催化剂主体，包括内燃机的排气过滤。
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公开(公告)号：US07901480B2
公开(公告)日：2011-03-08
申请号：US12364014
申请日：2009-02-02
CPC分类号： B01D63/066 , B01D39/2086 , B01D39/2089 , B01D46/0001 , B01D46/2418 , B01D46/2474 , B01D67/0046 , B01D2239/08 , B01D2239/10 , B01D2257/7022 , B01D2323/12 , B01D2323/18 , B01D2325/10 , B01J19/30 , B01J35/04 , B01J2219/30408 , B01J2219/30416 , B01J2219/30433 , B01J2219/30475 , B01J2219/30483 , B29C47/0028 , B29C47/12 , B29L2031/60 , B32B18/00 , C04B33/36 , C04B35/6263 , C04B35/76 , C04B35/80 , C04B35/803 , C04B35/806 , C04B35/82 , C04B38/0006 , C04B38/067 , C04B38/0675 , C04B38/068 , C04B2111/00129 , C04B2111/00793 , C04B2111/0081 , C04B2235/522 , C04B2235/5224 , C04B2235/5228 , C04B2235/5232 , C04B2235/5236 , C04B2235/524 , C04B2235/5244 , C04B2235/6021 , C04B2237/38 , C04B2237/584 , C04B2237/586 , F01N3/0222 , F01N3/0226 , F01N3/2828 , F01N3/2835 , F01N13/16 , F02M25/06 , Y10S55/05 , Y10S55/30 , Y10S264/48 , Y10T428/24149 , Y10T428/24273 , Y10T428/24992 , Y10T428/249953 , Y10T428/249967 , Y10T428/249969 , Y10T428/24997 , C04B38/0051 , C04B38/0054 , C04B38/0074
摘要： 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.
摘要翻译： 提供了一种制备高度多孔基材的方法。 更具体地，本发明使诸如有机，无机，玻璃，陶瓷，聚合物或金属纤维的纤维与粘合剂和添加剂组合并挤出以形成多孔基材。 根据用于形成可挤出混合物的组分的选择，本发明使基底孔隙率达到约60％至约90％，并且使其它孔隙率的工艺优点也得以实现。 可挤出的混合物可以使用各种各样的纤维和添加剂，并且适用于各种各样的操作环境和应用。 可以选择添加剂，其在挤出的基材中的重叠纤维之间形成无机粘合，其在多种应用中提供增强的多孔基材的强度和性能，例如过滤和作为催化过程的主体，例如催化转化器 。
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公开(公告)号：US20090173687A1
公开(公告)日：2009-07-09
申请号：US12402795
申请日：2009-03-12
CPC分类号： B01D63/066 , B01D39/2086 , B01D39/2089 , B01D46/0001 , B01D46/2418 , B01D46/2474 , B01D67/0046 , B01D2239/08 , B01D2239/10 , B01D2257/7022 , B01D2323/12 , B01D2323/18 , B01D2325/10 , B01J19/30 , B01J35/04 , B01J2219/30408 , B01J2219/30416 , B01J2219/30433 , B01J2219/30475 , B01J2219/30483 , B29C47/0028 , B29C47/12 , B29L2031/60 , B32B18/00 , C04B33/36 , C04B35/6263 , C04B35/76 , C04B35/80 , C04B35/803 , C04B35/806 , C04B35/82 , C04B38/0006 , C04B38/067 , C04B38/0675 , C04B38/068 , C04B2111/00129 , C04B2111/00793 , C04B2111/0081 , C04B2235/522 , C04B2235/5224 , C04B2235/5228 , C04B2235/5232 , C04B2235/5236 , C04B2235/524 , C04B2235/5244 , C04B2235/6021 , C04B2237/38 , C04B2237/584 , C04B2237/586 , F01N3/0222 , F01N3/0226 , F01N3/2828 , F01N3/2835 , F01N13/16 , F02M25/06 , Y10S55/05 , Y10S55/30 , Y10S264/48 , Y10T428/24149 , Y10T428/24273 , Y10T428/24992 , Y10T428/249953 , Y10T428/249967 , Y10T428/249969 , Y10T428/24997 , C04B38/0051 , C04B38/0054 , C04B38/0074
摘要： 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. As the curing process continues, fiber to fiber bonds are formed to produce a structure having a substantially open pore network. The resulting porous substrate is useful in many applications, for example, as a substrate for a filter or catalyst host, or catalytic converter.
摘要翻译： 使用挤出系统提供高度多孔的基材。 更具体地说，本发明能够生产高度多孔的基材。 根据特定的混合物，本发明使得基底孔隙率为约60％至约90％，并且还能够在其它孔隙率方面发挥优势。 挤出系统能够使用各种纤维和添加剂，并且适用于各种各样的操作环境和应用。 具有大于1的长径比的纤维根据基底要求进行选择，并且通常与粘合剂，成孔剂，挤出助剂和流体混合以形成均匀的可挤出物料。 将均匀的物料挤出成绿色基材。 优选从绿色衬底移除更易挥发的材料，这允许纤维形成互连的网络。 随着固化过程的继续，形成纤维与纤维结合以产生具有基本上开孔网络的结构。 所得到的多孔基材在许多应用中是有用的，例如作为过滤器或催化剂载体或催化转化器的底物。
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10.发明申请Low coefficient of thermal expansion materials including nonstoichiometric cordierite fibers and methods of manufacture 有权包括非化学计量堇青石纤维在内的低热膨胀系数和制造方法公开(公告)号：US20080242530A1
公开(公告)日：2008-10-02
申请号：US12104969
申请日：2008-04-17
IPC分类号： C04B35/03
CPC分类号： B01D39/2086 , C04B35/195 , C04B35/62245 , C04B35/62844 , C04B35/6365 , C04B35/638 , C04B35/803 , C04B38/0006 , C04B2111/00793 , C04B2111/0081 , C04B2235/3201 , C04B2235/3206 , C04B2235/3208 , C04B2235/3262 , C04B2235/3272 , C04B2235/3287 , C04B2235/349 , C04B2235/442 , C04B2235/5224 , C04B2235/5228 , C04B2235/5232 , C04B2235/5268 , C04B2235/5296 , C04B2235/606 , C04B2235/76 , C04B2235/9607 , Y10S55/05 , Y10S55/30 , Y10S264/48
摘要： 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.
摘要翻译： 一种纤维状陶瓷材料包括多个具有R x 2 M 2 H 2 Al 4+ x 5 Si 5-x
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