Sunilkumar S Pillai

US Patent:

7578865, Aug 25, 2009

Filed:

Aug 18, 2006

Appl. No.:

11/465758

Inventors:

Bilal Zuberi - Cambridge MA, US
Robert G. Lachenauer - Weston MA, US
Sunilkumar C. Pillai - North Billerica MA, US
William M Carty - Alfred Station NY, US

Assignee:

GEO2 Technologies, Inc. - Woburn MA

International Classification:

B01D 39/00
B01D 39/06
B01D 39/14

US Classification:

55523, 55522, 55524

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.

US Patent:

7862641, Jan 4, 2011

Filed:

Mar 12, 2009

Appl. No.:

12/402795

Inventors:

Bilal Zuberi - Cambridge MA, US
Sunilkumar C. Pillai - North Billerica MA, US
Robert G. Lachenauer - Weston MA, US
Biprodas Dutta - Silver Spring MD, US
William M. Carty - Alfred Station NY, US

Assignee:

GEO2 Technologies, Inc. - Woburn MA

International Classification:

B01D 39/20
F01N 3/022

US Classification:

55523, 553853, 55524, 55525, 55DIG 5, 55DIG 30, 60311, 422180, 210496, 2105101, 4232132, 4233272, 428116, 502439

Abstract:

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.

US Patent:

7901480, Mar 8, 2011

Filed:

Feb 2, 2009

Appl. No.:

12/364014

Inventors:

Bilal Zuberi - Cambridge MA, US
Robert G. Lachenauer - Weston MA, US
Sunilkumar C. Pillai - North Billerica MA, US
William M Carty - Alfred Station NY, US

Assignee:

GEO2 Technologies, Inc. - Woburn MA

International Classification:

B01D 39/00
B01D 39/06
B01D 39/14
B01D 50/00

US Classification:

55523, 55522, 55524, 422177, 422178, 422179, 422180, 422181, 422182

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.

US Patent:

8057568, Nov 15, 2011

Filed:

Feb 20, 2008

Appl. No.:

12/034431

Inventors:

Bilal Zuberi - Cambridge MA, US
Sunilkumar C. Pillai - North Billerica MA, US
Biprodas Dutta - Silver Spring MD, US
William M. Carty - Alfred Station NY, US
Robert G. Lachenauer - Weston MA, US

Assignee:

GEO2 Technologies, Inc. - Woburn MA

International Classification:

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

US Classification:

55523, 552823, 553853, 55524, 55DIG 5, 60311, 422180, 264 44, 264628, 264630, 264DIG 48, 501 6, 501 7

Abstract:

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.

US Patent:

20070107395, May 17, 2007

Filed:

Dec 30, 2005

Appl. No.:

11/323429

Inventors:

Bilal Zuberi - Cambridge MA, US
Robert Lachenauer - Weston MA, US
Sunilkumar Pillai - North Billerica MA, US

International Classification:

B01D 39/20

US Classification:

055523000

Abstract:

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.

US Patent:

20070110645, May 17, 2007

Filed:

Aug 18, 2006

Appl. No.:

11/465754

Inventors:

Bilal Zuberi - Cambridge MA, US
Robert Lachenauer - Weston MA, US
Sunilkumar Pillai - North Billerica MA, US
William Carty - Alfred Station NY, US

International Classification:

B01J 8/02
B32B 19/00

US Classification:

422211000, 428688000

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.

US Patent:

20070111878, May 17, 2007

Filed:

Dec 30, 2005

Appl. No.:

11/323430

Inventors:

Bilal Zuberi - Cambridge MA, US
Robert Lachenauer - Weston MA, US
Sunilkumar Pillai - North Billerica MA, US

International Classification:

C04B 35/00

US Classification:

501095100

Abstract:

An extrudable mixture is provided for producing a highly porous substrate using an extrusion process. More particularly, the present invention enables fibers, such as organic, inorganic, glass, ceramic or metal fibers, to be mixed into a mass that when extruded and cured, forms a highly porous substrate. Depending on the particular 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. Fibers, which have an aspect ratio greater than 1, are selected according to substrate requirements, and are 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 interconnect and contact. 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.

US Patent:

20070152364, Jul 5, 2007

Filed:

Dec 30, 2005

Appl. No.:

11/322777

Inventors:

Bilal Zuberi - Cambridge MA, US
Robert Lachenauer - Weston MA, US
Sunilkumar Pillai - North Billerica MA, US

International Classification:

B29C 44/04
B29C 67/20

US Classification:

264045100, 264049000

Abstract:

A method is provided for extruding and curing a highly porous substrate. More particularly, the present invention enables fibers, such as organic, inorganic, glass, ceramic, polymer, or metal fibers, to be mixed and extruded to form a highly porous substrate. Depending on the particular 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. Fibers, which have an aspect ratio greater than 1, are selected according to substrate requirements, and are 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 interconnect and contact. 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, a catalyst host, a heat exchanger, a muffler, or a catalytic converter.