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WO2008021587A3 - An extruded porous substrate having inorganic bonds - Google Patents

An extruded porous substrate having inorganic bonds Download PDF

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Publication number
WO2008021587A3
WO2008021587A3 PCT/US2007/063935 US2007063935W WO2008021587A3 WO 2008021587 A3 WO2008021587 A3 WO 2008021587A3 US 2007063935 W US2007063935 W US 2007063935W WO 2008021587 A3 WO2008021587 A3 WO 2008021587A3
Authority
WO
WIPO (PCT)
Prior art keywords
porous substrate
fibers
additives
substrate
extruded
Prior art date
Application number
PCT/US2007/063935
Other languages
French (fr)
Other versions
WO2008021587A2 (en
Inventor
Bilal Zuberi
Robert G Lachenauer
Sunilkumar C Pillai
William M Carty
Original Assignee
Geo2 Technologies Inc
Bilal Zuberi
Robert G Lachenauer
Sunilkumar C Pillai
William M Carty
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 US11/465,754 external-priority patent/US7486962B2/en
Application filed by Geo2 Technologies Inc, Bilal Zuberi, Robert G Lachenauer, Sunilkumar C Pillai, William M Carty filed Critical Geo2 Technologies Inc
Priority to MX2009001851A priority Critical patent/MX2009001851A/en
Priority to AU2007284302A priority patent/AU2007284302B2/en
Priority to CA002660833A priority patent/CA2660833A1/en
Priority to EP07758485A priority patent/EP2051790A4/en
Priority to JP2009524713A priority patent/JP2010501451A/en
Priority to CN2007800306636A priority patent/CN101505847B/en
Publication of WO2008021587A2 publication Critical patent/WO2008021587A2/en
Publication of WO2008021587A3 publication Critical patent/WO2008021587A3/en

Links

Classifications

    • 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
    • C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
    • C04B38/0615—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances the burned-out substance being a monolitic element having approximately the same dimensions as the final article, e.g. a porous polyurethane sheet or a prepreg obtained by bonding together resin particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/02—Loose filtering material, e.g. loose fibres
    • B01D39/06—Inorganic material, e.g. asbestos fibres, glass beads or fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D24/00—Filters comprising loose filtering material, i.e. filtering material without any binder between the individual particles or fibres thereof
    • 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
    • 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
    • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
    • 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
    • C04B35/10—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 aluminium oxide
    • C04B35/111—Fine ceramics
    • 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
    • C04B35/01—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
    • C04B35/48—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 zirconium or hafnium oxides, zirconates, zircon or hafnates
    • C04B35/486—Fine ceramics
    • 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
    • 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
    • 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
    • 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
    • C04B2111/0081—Uses not provided for elsewhere in C04B2111/00 as catalysts or catalyst carriers
    • 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
    • C04B2235/3418—Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
    • 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
    • C04B2235/3427—Silicates other than clay, e.g. water glass
    • C04B2235/3463—Alumino-silicates other than clay, 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
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
    • C04B2235/422—Carbon
    • C04B2235/425—Graphite
    • 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

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Composite Materials (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Inorganic Chemistry (AREA)
  • Filtering Materials (AREA)
  • Catalysts (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Filtering Of Dispersed Particles In Gases (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)

Abstract

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.
PCT/US2007/063935 2006-08-18 2007-03-14 An extruded porous substrate having inorganic bonds WO2008021587A2 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
MX2009001851A MX2009001851A (en) 2006-08-18 2007-03-14 An extruded porous substrate having inorganic bonds.
AU2007284302A AU2007284302B2 (en) 2006-08-18 2007-03-14 An extruded porous substrate having inorganic bonds
CA002660833A CA2660833A1 (en) 2006-08-18 2007-03-14 An extruded porous substrate having inorganic bonds
EP07758485A EP2051790A4 (en) 2006-08-18 2007-03-14 An extruded porous substrate having inorganic bonds
JP2009524713A JP2010501451A (en) 2006-08-18 2007-03-14 Extruded porous substrate with inorganic bonds
CN2007800306636A CN101505847B (en) 2006-08-18 2007-03-14 An extruded porous substrate having inorganic bonds

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US11/465,754 US7486962B2 (en) 2005-11-16 2006-08-18 Extruded porous substrate having inorganic bonds
US11/465,754 2006-08-18
US11/465,758 US7578865B2 (en) 2005-11-16 2006-08-18 Method of forming a porous substrate having inorganic bonds
US11/465,758 2006-08-18

Publications (2)

Publication Number Publication Date
WO2008021587A2 WO2008021587A2 (en) 2008-02-21
WO2008021587A3 true WO2008021587A3 (en) 2008-08-28

Family

ID=39082825

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2007/063935 WO2008021587A2 (en) 2006-08-18 2007-03-14 An extruded porous substrate having inorganic bonds

Country Status (8)

Country Link
EP (1) EP2051790A4 (en)
JP (1) JP2010501451A (en)
KR (1) KR20090057392A (en)
CN (1) CN101505847B (en)
AU (1) AU2007284302B2 (en)
CA (1) CA2660833A1 (en)
MX (1) MX2009001851A (en)
WO (1) WO2008021587A2 (en)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BR112012000327B8 (en) * 2009-07-10 2023-05-16 Bio2 Tech Inc METHOD OF MANUFACTURING A SYNTHETIC BONE PROSTHESIS AND SYNTHETIC BONE PROSTHESIS
CN103228794A (en) * 2010-12-06 2013-07-31 3M创新有限公司 Microorganism concentration process and device
KR101463472B1 (en) * 2013-10-28 2014-11-20 주식회사 원익큐엔씨 Pressure control members and method for manufacturing the same, pressure control unit and vacuum deposistion apparatus containing the same
DE102015220395A1 (en) 2015-10-20 2017-04-20 Bayerische Motoren Werke Aktiengesellschaft soot sensor
CN107174883A (en) * 2017-07-24 2017-09-19 苏州宏久航空防热材料科技有限公司 One kind has top layer net distribution silicon carbide nanometer line filtration
KR102708292B1 (en) 2018-12-24 2024-09-23 엘지전자 주식회사 Robot and method for controlling thereof

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4652286A (en) * 1982-02-16 1987-03-24 Matsushita Electric Industrial Co., Ltd. Exhaust gas filter
US4761323A (en) * 1985-11-13 1988-08-02 Man Technologie Gmbh Method and article for the production of porous fiber bats
US4828785A (en) * 1986-01-27 1989-05-09 Lanxide Technology Company, Lp Inverse shape replication method of making ceramic composite articles
US5322537A (en) * 1992-04-28 1994-06-21 Matsushita Electric Industrial Co., Ltd. Exhaust gas filter and method for making the same
US6669751B1 (en) * 1999-09-29 2003-12-30 Ibiden Co., Ltd. Honeycomb filter and ceramic filter assembly
US20040231307A1 (en) * 2001-07-06 2004-11-25 Wood Thomas E. Inorganic fiber substrates for exhaust systems and methods of making same
US20050109023A1 (en) * 2002-02-05 2005-05-26 Ibiden Co., Ltd. Honeycomb filter for exhaust gas decontamination, adhesive, coating material and process for producing honeycomb filter for exhaust gas decontamination

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS58139720A (en) * 1982-02-16 1983-08-19 Matsushita Electric Ind Co Ltd Gas filter
GB2176179A (en) * 1985-06-06 1986-12-17 Morgan Materials Technology Li Porous ceramic body formed by extrusion process
JPS62114621A (en) * 1985-11-13 1987-05-26 マン　テクノロジ−　ゲ−エムベ−ハ− Production of porous fiber mat for exhaust soot filter
JPH042673A (en) * 1990-04-19 1992-01-07 Matsushita Electric Ind Co Ltd Production of high temperature-resistant material
JP2990320B2 (en) * 1992-12-08 1999-12-13 三菱重工業株式会社 Insulation material and its manufacturing method
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
JP2001252529A (en) * 2000-03-13 2001-09-18 Mitsui & Co Ltd Exhaust gas cleaning apparatus and method of manufacturing the same
US6946013B2 (en) * 2002-10-28 2005-09-20 Geo2 Technologies, Inc. Ceramic exhaust filter
US20070107395A1 (en) * 2005-11-16 2007-05-17 Bilal Zuberi Extruded porous substrate and products using the same

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4652286A (en) * 1982-02-16 1987-03-24 Matsushita Electric Industrial Co., Ltd. Exhaust gas filter
US4761323A (en) * 1985-11-13 1988-08-02 Man Technologie Gmbh Method and article for the production of porous fiber bats
US4828785A (en) * 1986-01-27 1989-05-09 Lanxide Technology Company, Lp Inverse shape replication method of making ceramic composite articles
US5322537A (en) * 1992-04-28 1994-06-21 Matsushita Electric Industrial Co., Ltd. Exhaust gas filter and method for making the same
US6669751B1 (en) * 1999-09-29 2003-12-30 Ibiden Co., Ltd. Honeycomb filter and ceramic filter assembly
US20040231307A1 (en) * 2001-07-06 2004-11-25 Wood Thomas E. Inorganic fiber substrates for exhaust systems and methods of making same
US20050109023A1 (en) * 2002-02-05 2005-05-26 Ibiden Co., Ltd. Honeycomb filter for exhaust gas decontamination, adhesive, coating material and process for producing honeycomb filter for exhaust gas decontamination

Also Published As

Publication number Publication date
AU2007284302A1 (en) 2008-02-21
EP2051790A2 (en) 2009-04-29
MX2009001851A (en) 2009-04-15
CA2660833A1 (en) 2008-02-21
JP2010501451A (en) 2010-01-21
CN101505847A (en) 2009-08-12
WO2008021587A2 (en) 2008-02-21
KR20090057392A (en) 2009-06-05
CN101505847B (en) 2011-09-07
EP2051790A4 (en) 2011-05-04
AU2007284302B2 (en) 2012-02-09

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