Rachel K Dahl

US Patent:

8038759, Oct 18, 2011

Filed:

Jul 12, 2008

Appl. No.:

12/172217

Inventors:

James Jenq Liu - Mason OH, US
Bilal Zuberi - Cambridge MA, US
Rachel A. Dahl - Cambridge MA, US
William M. Carty - Alfred Station NY, US

Assignee:

Geoz Technologies, Inc. - Woburn MA

International Classification:

B01D 39/20
B01D 46/00
C04B 35/03

US Classification:

55523, 552823, 553853, 55524, 55DIG 5, 55DIG 30, 60311, 4232135, 264 44, 264628, 264631, 264DIG 48, 501 9, 501 951

Abstract:

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 SiO, about 36% to about 41% by weight AlO, 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. 810per C.

US Patent:

20080292518, Nov 27, 2008

Filed:

May 24, 2007

Appl. No.:

11/753011

Inventors:

James Jeng Liu - Mason OH, US
Bilal Zuberi - Cambridge MA, US
Jerry G. Weinstein - Malta NY, US
Rachel A. Dahl - Cambridge MA, US

Assignee:

GEO2 TECHNOLOGIES, INC. - Woburn MA

International Classification:

B01D 46/04
B28B 1/00

US Classification:

422255, 264631

Abstract:

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.

US Patent:

20100048374, Feb 25, 2010

Filed:

May 28, 2009

Appl. No.:

12/473562

Inventors:

James Jenq Liu - Mason OH, US
Bilal Zuberi - Cambridge MA, US
William M. Carty - Alfred Station NY, US
Rachel A. Dahl - Yuba City CA, US
Jerry C. Weinstein - Malta NY, US
Sunilkumar C. Pillai - Oakdale PA, US
Timothy Gordon - Pittsburgh PA, US
James Marshall - Latrobe PA, US

International Classification:

C03C 10/14

US Classification:

501 4

Abstract:

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.