1. A method for strengthening an extruded catalyst honeycomb filter body, comprising:
contacting an extruded catalyst honeycomb filter body and a siliceous formulation comprised of at least one siliceous source comprising a silicone emulsion, a silica sol, or a combination thereof;
drying the contacted filter body; and
firing the dried contacted filter body to provide the strengthened filter body.
2. The method of claim 1 wherein the catalytically active component in the extruded catalyst filter body comprises a nano-particulate zeolite, aggregates of nano-particulate zeolite, or mixtures thereof.
3. The method of claim 1 wherein the extruded catalyst filter body is formed directly from batch or continuous extruding of nano-particulate zeolite particles.
4. The method of claim 1 wherein the extruded catalyst filter body is formed indirectly from aggregates of nano-particulate zeolite by reprocessing a once-fired preformed body, cullet, or an extrudate of nano-particulate zeolite.
5. The method of claim 4 wherein reprocessing the once-fired body of material comprises consolidating nano-particulate zeolite particulates into a monolith or structured body, and partial breakup to aggregated nano-particulate zeolite.
6. The method of claim 1 wherein the extruded catalyst filter body comprises a nano-zeolite in an amount of about 20 to about 70 wt %, and an inorganic filler in an amount of about 80 to about 30 wt % based on 100 wt % of the total batch inorganic materials.
7. The method of claim 6 further comprising a pore former in from about 50 to about 90 wt % by super addition relative to the total batch inorganic materials.
8. The method of claim 1 further comprising plugging a portion of the filter channels prior to firing the dried contacted filter body or after firing the dried filter body.
9. The method of claim 1 wherein the median pore size (MPS) in the walls of the catalyst filter body as measured by mercury porosimetry is from about 4 to about 10 microns.
10. The method of claim 1 wherein the strength of the fired honeycomb filter body as measured by modulus of rupture is from about 100 to about 500 psi.
11. The method of claim 1 wherein the strength of the fired honeycomb filter body as measured by modulus of rupture is increased by at least 50% compared to a filter not contacted by the siliceous formulation.
12. The method of claim 1 wherein the strength of the fired honeycomb filter body as measured by modulus of rupture is at least 150 psi compared to a fired honeycomb filter not contacted by the siliceous formulation.
13. An extruded catalyst honeycomb filter body prepared by the method of claim 1.
14. A method for making a catalytic honeycomb filter body, comprising:
forming aggregates of at least one nano-material, the nano-material containing at least one catalyst;
extruding the nano-material aggregates to form a green catalytic filter body;
soft-firing the green body with a top soak temperature between 350 and about 850\xb0 C.;
contacting the soft-fired extruded catalyst filter body and a siliceous formulation comprised of at least one of a silicon emulsion, a silica sol, or a combination thereof;
drying the contacted filter body; and
firing the dried contacted filter body to provide catalytic honeycomb filter body.
15. A catalyst honeycomb filter body, comprising: a mixture of inorganic materials comprising a nano-particulate zeolite in an amount of about 20 to about 70 wt %, and an inorganic filler in an amount of about 80 to about 30 wt % based on 100 wt % of the total inorganic materials, and the filter body having an interstitial silica content of from about 3 to about 20 wt %.
16. A zeolite-based honeycomb body, comprising a matrix of walls comprised of: a primary phase material homogeneously distributed throughout the walls and comprising a zeolite having a SiO2 to Al2O3 molar ratio of from 5 to 300; at least one metal ion catalytic component, an interstitial siliceous component in an amount of about at least 3 to 20 wt %, the walls have a porosity of not less than 25% and a median pore diameter as measured by Hg-intrusion of at least 1 micron.
17. The honeycomb body of claim 16 wherein the porosity is at least 40%.
18. The honeycomb body of claim 16 wherein the porosity is from about 40% to about 80%.
19. The honeycomb body of claim 16 wherein the clean pressure drop is at least about 1.3 Kpa in a 3008 geometry.
20. The honeycomb body of claim 16 wherein the soot loaded pressure drop is at least about 3.5 Kpa in a 3008 geometry.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A liquid filter for filtering a source liquid, comprising:
an indicator device comprising:
(i) at least one erodable member positioned in the liquid filter to be in contact with a source liquid;
(ii) an indicator member; and
(iii) a visual indication arrangement;
wherein said erodable member is configured to:
(a) be gradually eroded by interaction with the source liquid or with an element within the source liquid and
(b) have an erosion profile that correlates to an extent of use of the liquid filter,
wherein the indicator member is configured to:
(a) be gradually displaced by a change in size of said erodable member and
(b) allow the source liquid to flow through the liquid filter when the indicator member is displaced to an end state,
wherein the end state is when the erodible member is completely eroded; and
wherein the visual indication arrangement is configured:
(a) for directly viewing said change in size of the erodable member or
(b) for directly viewing a gradual displacement of the indicator member.
2. A filter according to claim 1, wherein the liquid is water and the erodable member releases during its erosion, a substance of nutritional or health value into the water.
3. A filter according to claim 1, wherein the at least one erodable member is contained within a housing having one or more ports to permit contact between the liquid and the erodable member.
4. A liquid filter for filtering a source liquid, comprising:
an indicator device comprising:
(i) an indicator member arranged for direct viewing thereof by a user and
(ii) at least one erodable member;
wherein the indicator member is configured to:
(a) be visibly and gradually displaceable from an initial state to an end state
(b) be biased for displacement to the end state, and
(c) allow the source liquid to flow through the liquid filter when the indicator member is displaced to the end state,
wherein the end state is when the erodible member is completely eroded;
wherein the at least one erodable member is configured to:
(a) be visibly and gradually erodable through interaction with the source liquid or with an element within the liquid
(b) have an erosion profile correlating with the extent of use of the filter, and
(c) block the biased displacement of the indicator member;
wherein erosion of the at least one erodable member causes gradual displacement of the indicator member from the initial state towards the end state; and
wherein said displacement is visible to a user.
5. A filter according to claim 4, wherein the displacement bias is gravitational.
6. A filter according to claim 4, comprising an urging device for biasing displacement of the indicator member from the initial towards the end state.
7. A filter according to claim 4, wherein the displacement of the indicator member from the initial to the end state includes movement thereof within a track.
8. A filter according to claim 4, wherein the indicator member has an arm pivoted about an axis and angularly displaceable between the two states.
9. A filter according to claim 4, wherein the indicator member and the at least one erodable member are contained within a housing having one or more ports to permit contact between the liquid and the at least one erodable member.
10. An indicator device for use in combination with a liquid filtration system for filtering source liquid, the device comprising:
(i) at least one erodable member in contact with the source liquid,
wherein said at least one erodable member is configured to:
(a) be gradually eroded by interaction with the source liquid or with an element within the liquid and
(b) have an erosion profile that correlates to an extent of use of the liquid filter, and
(ii) a visual indication arrangement configured for directly viewing said change in size of the erodable member and
(iii) a gradually displaceable indicator member configured to:
(a) be gradually displaced by the change in size of said erodable member, and
(b) allow the source liquid to flow through the liquid filter when the indicator member is displaced to an end state;
wherein the end state is when the erodible member is completely eroded.
11. An indicator device for use in combination with a source liquid filtration system, comprising:
(i) an indicator member arranged for direct viewing thereof by a user and
(ii) at least one erodable member;
wherein the indicator member is configured to
(a) be visibly and gradually displaceable from an initial state to an end state,
(b) allow the source liquid to flow through the liquid filter when the indicator member is displaced to an end state, and
(c) be biased for displacement to the end state,
wherein the end state is when the erodible member is completely eroded;
wherein the at least one erodable member is configured to:
(a) be visibly and gradually erodable through interaction with the source liquid or with an element within the liquid,
(b) have an erosion profile correlating with an extent of use of the filter, and
(c) block the biased displacement of the indicator member;
wherein erosion of the at least one erodable member causes gradual displacement of the indicator member from the initial state towards the end state, and
wherein said displacement is visible to a user.
12. A liquid filtration system for filtering a source liquid, comprising:
(i) a liquid filter configured for filtering the source liquid; and
(ii) an indicator device for the status of the filter that comprises:
(a) an indicator member arranged for direct viewing thereof by a user and
(b) at least one erodable member,
wherein the indicator member is configured to:
(1) be visibly and gradually displaceable from an initial state to an end state and
(2) be biased for displacement to the end state,
(3) allow the source liquid to flow through the liquid filter when the indicator member is displaced to the end state,
wherein the end state is when the erodible member is completely eroded;
wherein the at least one erodable member is configured to:
(1) be visibly and gradually erodable through interaction with the source liquid or with an element within the liquid
(2) have an erosion profile correlating with the extent of use of the filter, and
(3) block the biased displacement of the indicator member;
wherein erosion of the at least one erodable member causes gradual displacement of the indicator member from the initial state towards the end state, and
wherein said displacement is visible to the user.
13. A method for monitoring extent of use of a filter comprising:
providing an indicator device comprising:
(i) an indicator member arranged for direct viewing thereof by a user and
(ii) at least one erodable member;
wherein the indicator member is configured to:
(a) be visibly and gradually displaceable from an initial state to an end state,
(b) allow a source liquid to flow through the filter when the indicator member is displaced to the end state, and
(c) be biased for displacement to the end state,
wherein the end state is when the erodible member is completely eroded;
wherein the at least one erodable member is configured to:
(a) be visibly and gradually erodable through interaction with liquid or with an element within the liquid
(b) have an erosion profile correlating with the extent of use of the filter, and
(c) block the biased displacement of the indicator member;
wherein erosion of the at least one erodable member causes gradual displacement of the indicator member from the initial stat towards the end state; and
monitoring a state of the indicator member,
wherein said gradual displacement of the indicator member is visible to the user.
14. A filter assembly comprising:
a liquid filter for filtering a source liquid;
a housing sized to receive said liquid filter, said housing having an opening at one of its walls;
an indicator device for the status of the filter that comprises at least one erodible member in contact with the source liquid, said indicator device being an integral part of the filter and extends out of the opening in the housing; and
a visual indication arrangement configured for directly viewing a change in size of said erodable member or for directly viewing a gradual displacement of a gradually displaceable indicator member associated with said erodable member,
wherein said indicator member is configured to:
(a) be gradually displaced by said change in size of said erodable member, and
(b) allow the source liquid to flow through the liquid filter when the indicator member is displaced to an end state,
wherein the end state is when the erodible member is completely eroded; and
wherein said erodable member is configured to:
(a) be gradually eroded by interaction with the liquid or with an element within the liquid and
(b) have an erosion profile that correlates to an extent of use of the liquid filter.
15. A filter assembly according to claim 14, wherein the liquid is water and the erodable member releases during its erosion, a substance of nutritional or health value into the water.
16. A filter according assembly to claim 14, wherein the at least one erodable member is contained within a filter housing having one or more ports to permit contact between the liquid and the erodable member.