An extruded porous substrate having inorganic bonds

C - Chemistry – Metallurgy – 04 – B

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C04B 35/76 (2006.01) B01D 39/20 (2006.01)

Patent

CA 2660833

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.

L'invention concerne un procédé de fabrication d'un substrat hautement poreux. La présente invention permet plus particulièrement de combiner des fibres, telles que des fibres organiques, inorganiques, de verre, de céramique, polymères ou métalliques avec des liants et des additifs et de les extruder pour former un substrat poreux. Selon le choix des constituants utilisés pour former un mélange extrudable, la présente invention permet d'obtenir des porosités de substrats d'environ 60 % à environ 90 % et permet également des avantages de procédé à d'autres porosités. Le mélange extrudable peut utiliser une large variété de fibres et d'additifs et est adaptable à une large variété d'environnements de fonctionnement et d'applications. Les additifs peuvent être choisis pour former des liaisons inorganiques entre les fibres chevauchantes dans le substrat extrudé, lesdites liaisons fournissant une meilleure résistance et de meilleures performances du substrat poreux dans une variété d'applications, telles que par exemple la filtration et en tant qu'hôte pour des procédés catalytiques, tels que les pots catalytiques.

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