The disclosure relate generally to structures, forms, and monoliths, and methods of preparing the same. This disclosure can produce uniform structured passageways or channels of active material, including adsorbent or catalyst, by imprinting or molding features into a paste on a support that can be subsequently assembled into a gas or liquid treating structure, i.e. a monolith. The paste, which can include an active material, binder, and other potential additives, can be applied to the support or pushed through a support (as in a mesh) as a thin film. The paste can be imprinted, stamped, shaped or otherwise handled to give features of desired height, shape, width, and positioning. When stacked or rolled, the features of one layer contact a subsequent layer, which seal to form passageways. The resulting structure can have high cell-density (>1000 cells per square inch) and a large volume fraction of active material.

The disclosure relate generally to structures, forms, and monoliths, and methods of preparing the same. This disclosure can produce uniform structured passageways or channels of active material, including adsorbent or catalyst, by imprinting or molding features into a paste on a support that can be subsequently assembled into a gas or liquid treating structure, i.e. a monolith. The paste, which can include an active material, binder, and other potential additives, can be applied to the support or pushed through a support (as in a mesh) as a thin film. The paste can be imprinted, stamped, shaped or otherwise handled to give features of desired height, shape, width, and positioning. When stacked or rolled, the features of one layer contact a subsequent layer, which seal to form passageways. The resulting structure can have high cell-density (>1000 cells per square inch) and a large volume fraction of active material.

A process for manufacturing a porous abradable coating includes: filling a mold with hollow glass or thermosetting polymer beads and a slurry; and sintering heat treatment to obtain a ceramic layer with pores. A maximum sintering temperature of the green body of the ceramic part is either higher than the melting temperature of the hollow glass beads so that at the end of the sintering heat treatment the hollow glass beads are melted, or higher than the decomposition temperature of the hollow thermosetting polymer beads so that at the end of the sintering heat treatment the hollow thermosetting polymer beads are decomposed.

A process for manufacturing a porous abradable coating includes: filling a mold with hollow glass or thermosetting polymer beads and a slurry; and sintering heat treatment to obtain a ceramic layer with pores. A maximum sintering temperature of the green body of the ceramic part is either higher than the melting temperature of the hollow glass beads so that at the end of the sintering heat treatment the hollow glass beads are melted, or higher than the decomposition temperature of the hollow thermosetting polymer beads so that at the end of the sintering heat treatment the hollow thermosetting polymer beads are decomposed.

A honeycomb body made of a composite material for fire-resistant lightweight structures including honeycomb cells having a cross section is provided. The cell walls of the honeycomb cells are produced from a composite material. The composite material has at least one carrier, for example a woven fabric or a laid fabric made of fibers, and a matrix into which the carrier is embedded. The matrix includes a silicon-based ceramic material, of which the proportion by mass in the matrix along the cell walls is at least 30 wt. %. A method for producing such a ceramic honeycomb body and a honeycomb tube as an intermediate product for the same are also provided. A flat semi-finished product as a curable intermediate product for the production of fire-resistant fiber composite lightweight structures, which has a matrix mixture including dispersed silicon particles, is also provided.

A honeycomb body made of a composite material for fire-resistant lightweight structures including honeycomb cells having a cross section is provided. The cell walls of the honeycomb cells are produced from a composite material. The composite material has at least one carrier, for example a woven fabric or a laid fabric made of fibers, and a matrix into which the carrier is embedded. The matrix includes a silicon-based ceramic material, of which the proportion by mass in the matrix along the cell walls is at least 30 wt. %. A method for producing such a ceramic honeycomb body and a honeycomb tube as an intermediate product for the same are also provided. A flat semi-finished product as a curable intermediate product for the production of fire-resistant fiber composite lightweight structures, which has a matrix mixture including dispersed silicon particles, is also provided.

A catalytic composition is built up from a ceramic material including a catalytic material and a first inorganic binder and a second inorganic binder and a catalytic structure made thereof. Preferably, the structure is made by a colloidal ceramic shaping technique. The structure is usable for catalytic or ion exchange applications as well. It is demonstrated that the catalytic structures have excellent mechanical, physicochemical and catalytic properties.

A catalytic composition is built up from a ceramic material including a catalytic material and a first inorganic binder and a second inorganic binder and a catalytic structure made thereof. Preferably, the structure is made by a colloidal ceramic shaping technique. The structure is usable for catalytic or ion exchange applications as well. It is demonstrated that the catalytic structures have excellent mechanical, physicochemical and catalytic properties.

A method of forming a ceramic matrix composite component is provided. The method includes applying a first amount of adhesive across a surface of a release film, providing a first ceramic foam panel including a plurality of channels formed on a first side of the first ceramic foam panel, contacting the first ceramic foam panel and the release film such that adhesive transfers to the first side of the first ceramic foam panel, and coupling the first ceramic foam panel to a second ceramic foam panel.

A method of forming a ceramic matrix composite component is provided. The method includes applying a first amount of adhesive across a surface of a release film, providing a first ceramic foam panel including a plurality of channels formed on a first side of the first ceramic foam panel, contacting the first ceramic foam panel and the release film such that adhesive transfers to the first side of the first ceramic foam panel, and coupling the first ceramic foam panel to a second ceramic foam panel.