GEO2 TECHNOLOGIES, INC. Patent applications |
Patent application number | Title | Published |
20110151181 | Fiber Enhanced Porous Substrate - A porous honeycomb substrate having about 10% to about 60% by volume ceramic fiber is fabricated in a variety of material compositions. The fiber material is combined with particle-based materials to reaction-form composite structures forming a porous matrix. The porous honeycomb substrate exhibits an open pore network of porosity from the fiber component to provide high permeability for various applications such as filtration and catalytic hosting of chemical processes. | 06-23-2011 |
20100247396 | Selective Catalytic Reduction Filter and Method of Using Same - A Selective Catalytic Reduction (SCR) filter is provided for use in emission control systems, for example, on the exhaust gas from an internal combustion engine. The SCR filter has a substrate constructed using bonded fiber structures, which cooperate to form a highly uniform open cell network, as well as to provide a uniform arrangement of pores. The substrate typically is provided as a wall-flow honeycomb structure, and in one example, is manufactured using an extrusion process. In this way, the substrate has many channel walls, each having an inlet surface and an outlet surface. The inlet surface has a uniform arrangement of pores that form a soot capture zone, where soot and other particulate matter is captured from an exhaust gas. A NOx conversion catalyst is disposed inside the channel wall, where NOx and ammonia in the exhaust gas are reacted to less harmful substances. Because of the uniform pore structure and open cell arrangement inside the channel wall, the filter is capable of being heavily loaded with catalyst, while avoiding undue increase in backpressure to the internal combustion engine. | 09-30-2010 |
20100150790 | Catalyzing Lean NOx Filter and Method of Using Same - A NOx trapping filter is provided for use in emission control systems, for example, on the exhaust gas from an internal combustion engine. The NOx trapping filter has a substrate constructed using bonded fiber structures, which cooperate to form a highly uniform open cell network, as well as to provide a uniform arrangement of pores. The substrate typically is provided as a wall-flow honeycomb structure, and in one example, is manufactured using an extrusion process. In this way, the substrate has many channel walls, each having an inlet surface and an outlet surface. The inlet surface has a uniform arrangement of pores that form a soot capture zone, where soot and other particulate matter is captured from an exhaust gas. A NOx adsorber material is disposed in the filter to trap NOx during lean operation of the engine. A NOx conversion catalyst is also disposed inside the channel wall, where NOx and excess hydrocarbons in the exhaust gas are reacted to less harmful substances when the engine system is operated in a rich condition. Because of the uniform pore structure and open cell arrangement inside the channel wall, the filter is capable of being heavily loaded with catalyst, adsorber, while avoiding undue increase in backpressure to the internal combustion engine. | 06-17-2010 |
20100075845 | Method and Apparatus for an Extruded Ceramic Biosoluble Fiber Substrate - A porous ceramic substrate is disclosed that is fabricated from biosoluble ceramic fibers. Porosity and permeability of the substrate is provided by intertangled biosoluble fibers, that can be formed into a honeycomb form substrate through an extrusion process. The fibrous structure is formed from mixing biosoluble fibers with additives that include a bonding agent, and a fluid to provide an extrudable mixture. The structure is sintered at a temperature that exceeds the glass formation temperature of the bonding agent, but less than the maximum operational limits of the biosoluble fiber, to form a structure that has sufficient strength and porosity to provide for filtration and/or as a catalytic host. | 03-25-2010 |
20090173687 | Extruded Porous Substrate and Products Using The Same - 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. | 07-09-2009 |
20090166910 | System and Method for Twin Screw Extrusion of a Fibrous Porous Substrate - This invention provides a system and method for forming a fibrous porous ceramic substrate that employs a screw extruder, and illustratively, a twin screw extruder to form a substrate by directing a homogeneous, wetted and mixed group of substrate components through a screw extruder die under pressure. The components of the mixture can be initially mixed in a substantially dry state by an appropriate mixer to form a homogeneous powder with a high dispersal of materials therein. The powder can be continuously mixed and conveyed to a feeder of the extruder. Along the path of the extruder, fluid can be introduced at a metered rate, along with other additives, such as colloidal silica (glass binder). The extruder's twin, co-rotating shafts include a combination of screw elements for feeding the mixture and shear-inducing mixing elements (kneading blocks) for thoroughly mixing fluid into the dry components. The wetted components pass through alternating sets of transport screws and kneading blocks until the kneaded, wetted mixture finally enter a vacuum section of the extruder where a vacuum is applied to remove excess air pockets and/or bubbles from the mixture. The mixture is thereafter driven through the die head where it exits as a continuous, extruded shape. Such a shape can comprise a honeycomb useful in filtration applications. The extruder can include a cooling system. The fifer in the mixture can be mullite. Alternatively the mixture can form a silicon carbide or other type of porous substrate matrix. | 07-02-2009 |
20090092786 | Fibrous aluminum titanate substrates and methods of forming the same - A porous fibrous honeycomb substrate having an aluminum titanate composition and methods of producing the same are provided herein. Precursors of aluminum titanate are provided in an extrudable mixture that includes fiber materials to form a green honeycomb substrate. When cured, the precursors of aluminum titanate form an aluminum titanate composition, with the fiber materials defining the porous microstructure. Various composite structures including aluminum titanate are provided to form a porous honeycomb substrate that can be configured to be filtration media and/or a catalytic host. | 04-09-2009 |
20090068438 | Porous Washcoat-Bonded Fiber Substrate - A porous substrate and method of forming a porous substrate including providing a fiber material, providing at least one extrusion aid, and providing at least one washcoat precursor. The fiber material, the at least one extrusion aid and the at least one washcoat precursor are mixed to provide an extrudable batch. The extrudable batch is extruded into a green substrate. The green substrate is fired to form a porous rigid substrate and to form a washcoat at least partially coating the fiber material | 03-12-2009 |
20090035511 | Fiber-Based Ceramic Substrate and Method of Fabricating the Same - Low cost aluminosilicate fibers are used to form a ceramic substrate material using inorganic binders that promote the formation of stable compounds that inhibit the formation of crystal silica, or cristobalite, when the substrate is used or exposed to high operating temperatures. The aluminosilicate fibers are mixed with additives including organic and inorganic binders and a fluid to form a plastic mixture. The plastic mixture is formed into a green substrate, and subsequently cured into the ceramic substrate. The fiber-based constituents permit the formation of rigid porous structures for filtration, insulation, and high temperature processes and chemical reactions. | 02-05-2009 |
20090000260 | Fibrous Cordierite Materials - 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 | 01-01-2009 |
20080292842 | Carbon Fiber Substrate and Method for Forming the Same - A porous carbon fiber substrate and method of forming the same including providing a fiber material including carbon, providing at least one extrusion aid and providing at least one bonding phase material. The fiber material, the at least one extrusion aid and the at least one bonding phase material are mixed with a fluid. The mixed fiber material, at least one extrusion aid, at least one bonding phase material and fluid are extruded into a green honeycomb substrate. The green honeycomb substrate is fired, enabling bond formation and forming a porous carbon fiber honeycomb substrate. | 11-27-2008 |
20080292518 | Cordierite Fiber Substrate and Method for Forming the Same - 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. | 11-27-2008 |
20080286179 | Method and Apparatus for an Extruded Ceramic Biosoluble Fiber Substrate - A porous ceramic substrate is disclosed that is fabricated from biosoluble ceramic fibers. Porosity and permeability of the substrate is provided by intertangled biosoluble fibers, that can be formed into a honeycomb form substrate through an extrusion process. The fibrous structure is formed from mixing biosoluble fibers with additives that include a bonding agent, and a fluid to provide an extrudable mixture. The structure is sintered at a temperature that exceeds the glass formation temperature of the bonding agent, but less than the maximum operational limits of the biosoluble fiber, to form a structure that has sufficient strength and porosity to provide for filtration and/or as a catalytic host. | 11-20-2008 |
20080283465 | LOW COEFFICIENT OF THERMAL EXPANSION BONDING SYSTEM FOR A HIGH POROSITY CERAMIC BODY AND METHODS OF MANUFACTURE - A porous ceramic body comprises a plurality of fibers and a bonding system bonding a portion of at least two fibers of the plurality of fibers. The plurality of fibers has a first coefficient of thermal expansion. The bonding system has a second coefficient of thermal expansion lower than the first coefficient of thermal expansion. In some embodiments, when the plurality of fibers and the bonding system are combined the resulting porous ceramic body has a third coefficient of thermal expansion which is at least about 10% less than the first coefficient of thermal expansion. | 11-20-2008 |
20080256936 | Selective Catalytic Reduction Filter and Method of Using Same - A Selective Catalytic Reduction (SCR) filter is provided for use in emission control systems, for example, on the exhaust gas from an internal combustion engine. The SCR filter has a substrate constructed using bonded fiber structures, which cooperate to form a highly uniform open cell network, as well as to provide a uniform arrangement of pores. The substrate typically is provided as a wall-flow honeycomb structure, and in one example, is manufactured using an extrusion process. In this way, the substrate has many channel walls, each having an inlet surface and an outlet surface. The inlet surface has a uniform arrangement of pores that form a soot capture zone, where soot and other particulate matter is captured from an exhaust gas. A NOx conversion catalyst is disposed inside the channel wall, where NOx and ammonia in the exhaust gas are reacted to less harmful substances. Because of the uniform pore structure and open cell arrangement inside the channel wall, the filter is capable of being heavily loaded with catalyst, while avoiding undue increase in backpressure to the internal combustion engine. | 10-23-2008 |
20080242535 | Honeycomb Structural Body and Method of Fabricating the Same - A fibrous silicon carbide substrate is disclosed that is formed from a reaction between carbon fibers and silicon additives, to provide in-situ silicon carbide fibers. The fibrous structure is formed from a paper-making process of carbon or organic fibers that form a plurality of lamination members. The lamination members, each having a plurality of through holes, that when aligned in a lamination direction, form a honeycomb array of channels. The lamination members can be adapted into a wall-flow configuration for use in filtration of the exhaust of internal combustion engines. | 10-02-2008 |
20080242530 | Low coefficient of thermal expansion materials including nonstoichiometric cordierite fibers and methods of manufacture - A fibrous ceramic material comprises a plurality of fibers having a R | 10-02-2008 |
20080241032 | Catalyzing Lean NOx Filter and Method of Using Same - A NOx trapping filter is provided for use in emission control systems, for example, on the exhaust gas from an internal combustion engine. The NOx trapping filter has a substrate constructed using bonded fiber structures, which cooperate to form a highly uniform open cell network, as well as to provide a uniform arrangement of pores. The substrate typically is provided as a wall-flow honeycomb structure, and in one example, is manufactured using an extrusion process. In this way, the substrate has many channel walls, each having an inlet surface and an outlet surface. The inlet surface has a uniform arrangement of pores that form a soot capture zone, where soot and other particulate matter is captured from an exhaust gas. A NOx adsorber material is disposed in the filter to trap NOx during lean operation of the engine. A NOx conversion catalyst is also disposed inside the channel wall, where NOx and excess hydrocarbons in the exhaust gas are reacted to less harmful substances when the engine system is operated in a rich condition. Because of the uniform pore structure and open cell arrangement inside the channel wall, the filter is capable of being heavily loaded with catalyst, adsorber, while avoiding undue increase in backpressure to the internal combustion engine. | 10-02-2008 |
20080241014 | Low coefficient of thermal expansion materials including modified aluminosilicate fibers and methods of manufacture - A fibrous ceramic material comprises a plurality of fibers having a modified aluminosilicate compositional structure (i.e., x(RO).y(Al | 10-02-2008 |
20080236145 | Emission Control System using a Multi-Function Catalyzing Filter - A multi-function filter is provided for use in emission control systems, for example, on the exhaust gas from an internal combustion engine. The filter has a substrate constructed using bonded fiber structures, which cooperate to form a highly uniform open cell network, as well as to provide a uniform arrangement of pores. The substrate typically is provided as a wall-flow honeycomb structure, and in one example, is manufactured using an extrusion process. In this way, the substrate has many channel walls, each having an inlet surface and an outlet surface. The inlet surface has a uniform arrangement of pores that form a soot capture zone, where soot and other particulate matter is captured from an exhaust gas. A gas conversion catalyst is disposed inside the channel wall, where one or more pollutants in the exhaust gas are converted to less harmful substances. Because of the uniform pore structure and open cell arrangement inside the channel wall, the filter is capable of being heavily loaded with catalyst, while avoiding undue increase in backpressure to the internal combustion engine. | 10-02-2008 |
20080210090 | Extruded Porous Ceramic Fuel Cell Reformer Cleanup Substrate - A fuel cell reformer cleanup substrate is an extruded porous substrate of fiber-based inorganic materials. More particularly, the present invention enables an efficient fuel cell reformate cleanup filtration using a highly porous, and permeable honeycomb substrate having a washcoat that adsorbs impurities in the reformate stream upstream of a fuel cell. The porous substrate can be fabricated using an extrusion process and a number of washcoat compositions can be disposed within the porous substrate to provide adsorption of the reformate impurities. | 09-04-2008 |
20080199369 | Extruded porous substrate and products using the same - 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. | 08-21-2008 |