Patent ID: 7862641
Filing Date: 2011-01-04
Classification: B01D,B01J,B29C,B29L,B32B,C04B,F01N,F02M,Y10S,Y10T

Abstract:
1. A porous honeycomb substrate comprising: an array of channels extending at least partially through the substrate, the array of channels separated by a porous wall; the porous wall consisting essentially of intertangled ceramic fibers bonded into a rigid structure, wherein the intertangled ceramic fibers provide a primary structure of the substrate; the intertangled ceramic fibers having a diameter in the range of about 1 micron to about 25 microns and a length in the range of about 3 microns to about 25 millimeters; an interconnected open pore network in space between the intertangled ceramic fibers, the open pore network providing between 40% and 80% porosity in the porous wall between respective ones of the array of channels; the porous honeycomb substrate produced by an extrusion process comprising; mixing ceramic fiber with additives and a fluid to form an extrudable mixture wherein the ceramic fiber comprises about 10% to about 40% by volume of the extrudable mixture; extruding the extrudable mixture into a green substrate; and curing the green substrate into the porous honeycomb substrate.