WO2007061457A3 - System for extruding a porous substrate - Google Patents

System for extruding a porous substrate Download PDF

Info

Publication number
WO2007061457A3
WO2007061457A3 PCT/US2006/028530 US2006028530W WO2007061457A3 WO 2007061457 A3 WO2007061457 A3 WO 2007061457A3 US 2006028530 W US2006028530 W US 2006028530W WO 2007061457 A3 WO2007061457 A3 WO 2007061457A3
Authority
WO
WIPO (PCT)
Prior art keywords
fibers
porous substrate
substrate
extruded
mixed
Prior art date
Application number
PCT/US2006/028530
Other languages
French (fr)
Other versions
WO2007061457A2 (en
Inventor
Bilal Zuberi
Robert G Lachenauer
Sunilkumar C Pillai
Original Assignee
Geo2 Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US11/323,430 external-priority patent/US20070111878A1/en
Application filed by Geo2 Technologies Inc filed Critical Geo2 Technologies Inc
Priority to JP2008541148A priority Critical patent/JP2009515808A/en
Priority to EP06788219A priority patent/EP1951637A4/en
Priority to BRPI0618693-9A priority patent/BRPI0618693A2/en
Priority to AU2006317688A priority patent/AU2006317688A1/en
Priority to DE202006017357U priority patent/DE202006017357U1/en
Priority to DE202006017355U priority patent/DE202006017355U1/en
Priority to CA002629180A priority patent/CA2629180A1/en
Publication of WO2007061457A2 publication Critical patent/WO2007061457A2/en
Publication of WO2007061457A3 publication Critical patent/WO2007061457A3/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/20—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2068—Other inorganic materials, e.g. ceramics
    • B01D39/2082—Other inorganic materials, e.g. ceramics the material being filamentary or fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
    • B01J37/0018—Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
    • B28B3/26—Extrusion dies
    • B28B3/2636—Extrusion dies using means for co-extruding different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/40—Mixing specially adapted for preparing mixtures containing fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/40—Mixing specially adapted for preparing mixtures containing fibres
    • B28C5/404—Pre-treatment of fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/11—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/10—Clay
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/36—Reinforced clay-wares
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
    • C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62625—Wet mixtures
    • C04B35/6263—Wet mixtures characterised by their solids loadings, i.e. the percentage of solids
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/6303—Inorganic additives
    • C04B35/6316—Binders based on silicon compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0006—Honeycomb structures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/007—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores
    • C04B38/0074—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores expressed as porosity percentage
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/07—Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal
    • E04C5/073—Discrete reinforcing elements, e.g. fibres
    • E04C5/076—Specially adapted packagings therefor, e.g. for dosing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F01N3/0222—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
    • B28B2003/203—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded for multi-channelled structures, e.g. honeycomb structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/60—Multitubular or multicompartmented articles, e.g. honeycomb
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00793—Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5216—Inorganic
    • C04B2235/522—Oxidic
    • C04B2235/5228—Silica and alumina, including aluminosilicates, e.g. mullite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5296—Constituents or additives characterised by their shapes with a defined aspect ratio, e.g. indicating sphericity
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/602—Making the green bodies or pre-forms by moulding
    • C04B2235/6021—Extrusion moulding
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/75—Products with a concentration gradient
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/34—Oxidic
    • C04B2237/341—Silica or silicates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/38—Fiber or whisker reinforced
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/58—Forming a gradient in composition or in properties across the laminate or the joined articles
    • C04B2237/586—Forming a gradient in composition or in properties across the laminate or the joined articles by joining layers or articles of the same composition but having different densities

Abstract

An extrudable mixture is provided for producing a highly porous substrate wherein fibers, such as organic, inorganic, glass, ceramic or metal fibers, are mixed into a mass that when extruded and cured forms a highly porous substrate. Depending on the particular mixture the present invention enables substrate porosities of about 60% to 90%. The extrudable mixture may use a wide variety of fibers and additives and is adaptable to a wide variety of operating environments. Fibers, which have an aspect ratio greater than 1, are mixed with binders, pore-formers, extrusion aids and fluid to form a homogeneous mass which is extruded into a green substrate. The more volatile material is removed from the green substrate allowing the fibers to interconnect. As curing continues, fiber to fiber bonds form to produce a structure having a substantially open pore network. The resulting porous substrate forms a filter, catalyst host or catalytic converter.
PCT/US2006/028530 2005-11-16 2006-07-21 System for extruding a porous substrate WO2007061457A2 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
JP2008541148A JP2009515808A (en) 2005-11-16 2006-07-21 System for extruding porous carriers
EP06788219A EP1951637A4 (en) 2005-11-16 2006-07-21 System for extruding a porous substrate
BRPI0618693-9A BRPI0618693A2 (en) 2005-11-16 2006-07-21 porous substrate
AU2006317688A AU2006317688A1 (en) 2005-11-16 2006-07-21 System for extruding a porous substrate
DE202006017357U DE202006017357U1 (en) 2005-11-16 2006-07-21 Extrudable mixture for producing highly porous substrate for filtration devices (e.g. oil/air filters) or catalytic converters, comprises ceramic material consisting elongated fibers, binder material, and fluid, which are homogeneous mass
DE202006017355U DE202006017355U1 (en) 2005-11-16 2006-07-21 Porous substrate having high porosity useful for e.g. filter comprises structure formed of bonded ceramic fibers produced by mixing ceramic fiber with additives and fluid; extruding the mixture into green substrate followed by curing
CA002629180A CA2629180A1 (en) 2005-11-16 2006-07-21 System for extruding a porous substrate

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
US73723705P 2005-11-16 2005-11-16
US60/737,237 2005-11-16
US11/323,430 US20070111878A1 (en) 2005-11-16 2005-12-30 Extrudable mixture for forming a porous block
US11/322,777 2005-12-30
US11/323,430 2005-12-30
US11/323,429 US20070107395A1 (en) 2005-11-16 2005-12-30 Extruded porous substrate and products using the same
US11/323,429 2005-12-30
US11/322,777 US20070152364A1 (en) 2005-11-16 2005-12-30 Process for extruding a porous substrate

Publications (2)

Publication Number Publication Date
WO2007061457A2 WO2007061457A2 (en) 2007-05-31
WO2007061457A3 true WO2007061457A3 (en) 2007-11-01

Family

ID=38067677

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2006/028530 WO2007061457A2 (en) 2005-11-16 2006-07-21 System for extruding a porous substrate

Country Status (8)

Country Link
EP (1) EP1951637A4 (en)
JP (1) JP2009515808A (en)
KR (1) KR20080068114A (en)
AU (1) AU2006317688A1 (en)
BR (1) BRPI0618693A2 (en)
CA (1) CA2629180A1 (en)
DE (2) DE202006017357U1 (en)
WO (1) WO2007061457A2 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9168471B2 (en) 2010-11-22 2015-10-27 Irema-Filter Gmbh Air filter medium combining two mechanisms of action

Families Citing this family (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7858554B2 (en) * 2007-05-24 2010-12-28 Geo2 Technologies, Inc. Cordierite fiber substrate and method for forming the same
DE102006014236A1 (en) 2006-03-28 2007-10-04 Irema-Filter Gmbh Fleece material used as a pleated air filter in a motor vehicle comprises thinner fibers homogeneously incorporated into thicker fibers
WO2008126306A1 (en) * 2007-03-30 2008-10-23 Ibiden Co., Ltd. Catalyst support
US7781372B2 (en) * 2007-07-31 2010-08-24 GE02 Technologies, Inc. Fiber-based ceramic substrate and method of fabricating the same
WO2008146350A1 (en) * 2007-05-25 2008-12-04 Ibiden Co., Ltd. Honeycomb structure and process for producing honeycomb structure
US8894917B2 (en) 2008-05-30 2014-11-25 Corning Incorporated High porosity cordierite honeycomb articles
US8871676B2 (en) 2008-09-18 2014-10-28 Dow Global Technologies Llc Method for making porous acicular mullite-containing composites
CN102652890A (en) * 2011-03-02 2012-09-05 尚安亭 Glass fiber aluminium filter plate and preparation method
KR101311273B1 (en) 2012-05-08 2013-09-25 고려대학교 산학협력단 Method for producing porous tubular scaffolds and porous tubular scaffolds manufactured thereby
DE102013008402A1 (en) 2013-05-16 2014-11-20 Irema-Filter Gmbh Nonwoven fabric and process for producing the same
KR101692268B1 (en) * 2015-09-22 2017-01-04 주식회사 지테크섬유 Manufacturing method of continuously porous body
JP6695712B2 (en) * 2016-03-11 2020-05-20 日本特殊陶業株式会社 Fiber reinforced porous body
US10029949B2 (en) * 2016-10-24 2018-07-24 The Boeing Company Precursor material for additive manufacturing of low-density, high-porosity ceramic parts and methods of producing the same
CN108327072B (en) * 2018-01-24 2019-04-02 浙江大学 A kind of building material production system strengthened based on carbon dioxide step mineralising
DE102019200180A1 (en) 2018-07-25 2020-01-30 Audi Ag Filter element for a particle filter, exhaust gas particle filter, method for producing a filter element and use of a coating material
CN111205100B (en) * 2020-03-02 2022-06-07 西北工业大学 Method for in-situ growth of silicon carbide nanowire by non-catalytic precursor impregnation pyrolysis method
DE102020116821A1 (en) 2020-06-25 2021-12-30 Bayerische Motoren Werke Aktiengesellschaft Component as well as motor vehicle
CN111807852B (en) * 2020-07-16 2022-10-04 北京中材人工晶体研究院有限公司 Method for preparing high-porosity porous ceramic material
CN112476776A (en) * 2020-11-26 2021-03-12 丁小巧 Fiber concrete preparation system of processing
CN113198332A (en) * 2021-04-08 2021-08-03 华南理工大学 MXene-nanofiber composite membrane and preparation method and application thereof
WO2023203577A1 (en) * 2022-04-20 2023-10-26 Prerna Goradia Regenerable smart materials for selective removal of pollutants from water and waste water

Citations (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4047965A (en) * 1976-05-04 1977-09-13 Minnesota Mining And Manufacturing Company Non-frangible alumina-silica fibers
US4053011A (en) * 1975-09-22 1977-10-11 E. I. Du Pont De Nemours And Company Process for reinforcing aluminum alloy
US4329162A (en) * 1980-07-03 1982-05-11 Corning Glass Works Diesel particulate trap
US4420316A (en) * 1982-02-22 1983-12-13 Corning Glass Works Filter apparatus and method of making it
US5053092A (en) * 1988-03-21 1991-10-01 Corning Incorporated Method for producing a sinterable extruded laminated article
US5126431A (en) * 1989-12-29 1992-06-30 Phillips Petroleum Company Production and recovery of poly(arylene sulfide ketone) and poly(arylene sulfide diketone) resins
US5338253A (en) * 1990-12-16 1994-08-16 Behr Gmbh & Co. Filter for an air-conditioning or heating system for a motor vehicle
US5518833A (en) * 1994-05-24 1996-05-21 Eagle-Picher Industries, Inc. Nonwoven electrode construction
US5623013A (en) * 1994-12-16 1997-04-22 Ube Industries, Ltd. Xonotlite-reinforced organic polymer composition
US5662731A (en) * 1992-08-11 1997-09-02 E. Khashoggi Industries Compositions for manufacturing fiber-reinforced, starch-bound articles having a foamed cellular matrix
US5681373A (en) * 1995-03-13 1997-10-28 Air Products And Chemicals, Inc. Planar solid-state membrane module
US5900207A (en) * 1996-02-08 1999-05-04 Rutgers, The State University Old Queens Solid freeform fabrication methods
US6238618B1 (en) * 1998-10-01 2001-05-29 Corning Incorporated Production of porous mullite bodies
US20030127393A1 (en) * 2001-06-22 2003-07-10 Frederick Tepper Nanosize electropositive fibrous adsorbent
US20040194505A1 (en) * 2003-04-01 2004-10-07 Ji Wang Method of making a photonic crystal preform
US20040231307A1 (en) * 2001-07-06 2004-11-25 Wood Thomas E. Inorganic fiber substrates for exhaust systems and methods of making same
US6860917B2 (en) * 2001-12-04 2005-03-01 Fleetguard, Inc. Melt-spun ceramic fiber filter and method
US20050049362A1 (en) * 2003-08-26 2005-03-03 Buckley Paul W. Methods of preparing a polymeric material composite

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS586222A (en) * 1981-07-03 1983-01-13 Nippon Denso Co Ltd Manufacture of honeycomb filter
DE3444407A1 (en) * 1984-12-05 1986-06-05 Didier-Werke Ag, 6200 Wiesbaden CERAMIC MOLDED PART WITH GRADIENT-SHAPED POROSITY AND THE USE THEREOF FOR THE PRODUCTION OF COMPOSITE MOLDED PARTS
JPH0645510B2 (en) * 1989-02-03 1994-06-15 イソライト工業株式会社 Inorganic oxide artificial fiber honeycomb structure and method for manufacturing the same
JPH05270943A (en) * 1992-03-27 1993-10-19 Nippon Soken Inc Fiber-reinforced porous body
JPH05285929A (en) * 1992-04-09 1993-11-02 Takeda Chem Ind Ltd Method for drying hollow molded article
JP2614809B2 (en) * 1993-03-26 1997-05-28 ニチアス株式会社 Manufacturing method of heat-resistant low specific gravity fibrous molding
JP2000109380A (en) * 1998-10-01 2000-04-18 Nichiha Corp Lightweight inorganic board
JP2000226275A (en) * 1999-02-08 2000-08-15 Nichias Corp Porous inorganic material and its production
US6365092B1 (en) * 1999-06-23 2002-04-02 Abb Lummus Global, Inc. Method for producing a sintered porous body
US7459110B2 (en) * 2003-12-04 2008-12-02 Ceramtec Ag Porous fiber-ceramic composite

Patent Citations (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4053011A (en) * 1975-09-22 1977-10-11 E. I. Du Pont De Nemours And Company Process for reinforcing aluminum alloy
US4047965A (en) * 1976-05-04 1977-09-13 Minnesota Mining And Manufacturing Company Non-frangible alumina-silica fibers
US4329162A (en) * 1980-07-03 1982-05-11 Corning Glass Works Diesel particulate trap
US4420316A (en) * 1982-02-22 1983-12-13 Corning Glass Works Filter apparatus and method of making it
US5053092A (en) * 1988-03-21 1991-10-01 Corning Incorporated Method for producing a sinterable extruded laminated article
US5126431A (en) * 1989-12-29 1992-06-30 Phillips Petroleum Company Production and recovery of poly(arylene sulfide ketone) and poly(arylene sulfide diketone) resins
US5338253A (en) * 1990-12-16 1994-08-16 Behr Gmbh & Co. Filter for an air-conditioning or heating system for a motor vehicle
US5662731A (en) * 1992-08-11 1997-09-02 E. Khashoggi Industries Compositions for manufacturing fiber-reinforced, starch-bound articles having a foamed cellular matrix
US5518833A (en) * 1994-05-24 1996-05-21 Eagle-Picher Industries, Inc. Nonwoven electrode construction
US5623013A (en) * 1994-12-16 1997-04-22 Ube Industries, Ltd. Xonotlite-reinforced organic polymer composition
US5681373A (en) * 1995-03-13 1997-10-28 Air Products And Chemicals, Inc. Planar solid-state membrane module
US5900207A (en) * 1996-02-08 1999-05-04 Rutgers, The State University Old Queens Solid freeform fabrication methods
US6238618B1 (en) * 1998-10-01 2001-05-29 Corning Incorporated Production of porous mullite bodies
US20030127393A1 (en) * 2001-06-22 2003-07-10 Frederick Tepper Nanosize electropositive fibrous adsorbent
US20040231307A1 (en) * 2001-07-06 2004-11-25 Wood Thomas E. Inorganic fiber substrates for exhaust systems and methods of making same
US6860917B2 (en) * 2001-12-04 2005-03-01 Fleetguard, Inc. Melt-spun ceramic fiber filter and method
US20040194505A1 (en) * 2003-04-01 2004-10-07 Ji Wang Method of making a photonic crystal preform
US20050049362A1 (en) * 2003-08-26 2005-03-03 Buckley Paul W. Methods of preparing a polymeric material composite

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9168471B2 (en) 2010-11-22 2015-10-27 Irema-Filter Gmbh Air filter medium combining two mechanisms of action

Also Published As

Publication number Publication date
WO2007061457A2 (en) 2007-05-31
KR20080068114A (en) 2008-07-22
DE202006017357U1 (en) 2007-04-26
CA2629180A1 (en) 2007-05-31
EP1951637A2 (en) 2008-08-06
AU2006317688A1 (en) 2007-05-31
JP2009515808A (en) 2009-04-16
EP1951637A4 (en) 2009-10-28
BRPI0618693A2 (en) 2011-09-06
DE202006017355U1 (en) 2007-04-05

Similar Documents

Publication Publication Date Title
WO2007061457A3 (en) System for extruding a porous substrate
TW200728367A (en) An extruded porous substrate and products using the same
WO2010051292A3 (en) Fibrous aluminum titanate substrates and methods of forming the same
JP2009515808A5 (en)
CN103702960A (en) Process for producing cemented and skinned ceramic honeycomb structures
JP2007525612A (en) Cordierite filter with reduced pressure loss
EP1493724A4 (en) Porous material and method for production thereof
PL1663515T3 (en) Porous ceramic filters with catalyst coatings
JP2006513127A5 (en)
WO2007008288A3 (en) Layered composition and processes for preparing and using the composition
EP3120916A3 (en) Ceramic honeycomb structure and its production method
DE602005027173D1 (en) HONEY WAVE STRUCTURE AND METHOD OF MANUFACTURE
WO2007126603A3 (en) Reactive binders for porous wall-flow filters
WO2008085571A3 (en) Carbon black monolith, carbon black monolith catalyst, methods for making same, and uses thereof
WO2008060504A3 (en) Filters with controlled submicron porosity
WO2008021064A3 (en) Polymer-coated inorganic membrane for separating aromatic and alphatic compounds
TW200642760A (en) Layered composition and processes for preparing and using the composition
TW200614569A (en) Organic/inorganic composite porous film and electrochemical device prepared thereby
WO2009070218A3 (en) Fine porosity low-microcracked ceramic honeycombs and methods thereof
DE602005004428D1 (en) PROCESS FOR PREPARING A COMPOSITION AND NANOCOMPOSITE THEREFOR
WO2009060836A1 (en) Cellulose porous membrane
WO2008021587A3 (en) An extruded porous substrate having inorganic bonds
JP2008037722A (en) Method of manufacturing honeycomb structure
ATE232511T1 (en) CORDIERITE STRUCTURES
WO2009039019A3 (en) A catalyst composition useful in the catalytic reduction of sulfur compound contained in a gas stream and a method of making and using such composition

Legal Events

Date Code Title Description
WWE Wipo information: entry into national phase

Ref document number: 200680037343.9

Country of ref document: CN

WWE Wipo information: entry into national phase

Ref document number: 2008541148

Country of ref document: JP

121 Ep: the epo has been informed by wipo that ep was designated in this application
DPE1 Request for preliminary examination filed after expiration of 19th month from priority date (pct application filed from 20040101)
ENP Entry into the national phase

Ref document number: 2629180

Country of ref document: CA

WWE Wipo information: entry into national phase

Ref document number: 2006317688

Country of ref document: AU

WWE Wipo information: entry into national phase

Ref document number: 2419/CHENP/2008

Country of ref document: IN

WWE Wipo information: entry into national phase

Ref document number: MX/a/2008/006387

Country of ref document: MX

NENP Non-entry into the national phase

Ref country code: DE

WWE Wipo information: entry into national phase

Ref document number: 2006788219

Country of ref document: EP

ENP Entry into the national phase

Ref document number: 2006317688

Country of ref document: AU

Date of ref document: 20060721

Kind code of ref document: A

WWE Wipo information: entry into national phase

Ref document number: 1020087014038

Country of ref document: KR

DPE1 Request for preliminary examination filed after expiration of 19th month from priority date (pct application filed from 20040101)
ENP Entry into the national phase

Ref document number: PI0618693

Country of ref document: BR

Kind code of ref document: A2

Effective date: 20080516