Exhaust gas treatment device
View Patent ↗A mounting mat for an exhaust gas treatment device including inorganic fibers, organic binder, antioxidant, optionally clay and optionally intumescent material. The exhaust gas treatment device includes a housing, a fragile catalyst support structure resiliently mounted within the housing, and the mounting mat disposed in a gap between the housing and the fragile catalyst support structure. Additionally disclosed are methods of making a mounting mat for an exhaust gas treatment device and for making an exhaust gas treatment device incorporating the mounting mat.
1. A mounting mat for an exhaust gas treatment device comprising:
inorganic fibers selected from the group consisting of high alumina polycrystalline fibers, ceramic fibers, mullite fibers, glass fibers, biosoluble fibers, quartz fibers, silica fibers, and combinations thereof;
organic binder;
antioxidant; and
optionally an intumescent material.
2. The mounting mat of claim 1 , wherein the high alumina polycrystalline fibers comprise the fiberization product of about 72 to about 100 weight percent alumina and about 0 to about 28 weight percent silica.
3. The mounting mat of claim 1 , wherein the ceramic fibers comprise alumino-silicate fibers comprising the fiberization product of about 45 to about 72 weight percent alumina and about 28 to about 55 weight percent silica.
4. The mounting mat of claim 1 , wherein the biosoluble fibers comprise magnesia-silica fibers comprising the fiberization product of about 65 to about 86 weight percent silica, from about 14 to about 35 weight percent magnesia and about 5 weight percent of less impurities.
5. The mounting mat of claim 4 , wherein the magnesia-silica fibers comprise the fiberization product of about 70 to about 86 weight percent silica, about 14 to about 30 weight percent magnesia and about 5 weight percent or less impurities.
6. The mounting mat of claim 5 , wherein the magnesia-silica fibers comprise the fiberization product of about 70 to about 80 weight percent silica, about 18 to about 27 weight percent magnesia and 0 to 4 weight percent impurities.
7. The mounting mat of claim 1 , wherein the biosoluble fibers comprise calcia-magnesia-silica fibers comprising the fiberization product of about 45 to about 90 weight percent silica, greater than 0 to about 45 weight percent calcia, and greater than 0 to about 35 weight percent magnesia.
8. The mounting mat of claim 7 , wherein the calcia-magnesia-silica fibers comprise the fiberization product of about 60 to about 70 weight percent silica, from about 16 to about 35 weight percent calcia, and from about 4 to about 19 weight percent magnesia.
9. The mounting mat of claim 8 , wherein the calcia-magnesia-silica fibers comprise the fiberization product of about 61 to about 67 weight percent silica, from about 27 to about 33 weight percent calcia, and from about 2 to about 7 weight percent magnesia.
10. The mounting mat of claim 1 , wherein the intumescent material is selected from the group consisting of unexpanded vermiculite, ion exchanged vermiculite, heat treated vermiculite, expandable graphite, hydrobiotite, water-swelling tetrasilicic flourine mica, alkaline metal silicates, or mixtures thereof.
11. The mounting mat of claim 10 , wherein the intumescent material comprises unexpanded vermiculite.
12. The mounting mat of claim 1 , wherein the antioxidant is selected from the group consisting of primary antioxidants, secondary antioxidants, multifunctional antioxidants, and combinations thereof.
13. The mounting mat of claim 1 , wherein the inorganic fibers comprise magnesia-silica fibers, wherein the intumescent material comprises vermiculite and wherein the antioxidant comprises a blend of primary and secondary antioxidants.
14. The mounting mat of claim 13 , wherein the mounting mat comprises from about 25 to about 100 weight percent magnesia-silica fibers, from about 1 to about 30 weight percent vermiculite and from about 0.1 to about 10 of the antioxidant.
15. The mounting mat of claim 1 further comprising clay.
16. The mounting mat of claim 15 , wherein said clay is selected from the group consisting of attapulgite, ball clay, bentonite, hectorite, kyanite, kaolinite, montmorillonite, palygorskite, saponite, sepiolite, silimanite or combinations thereof.
17. The mounting mat of claim 16 , wherein the clay comprises attapulgite clay.
18. An exhaust gas treatment device comprising:
a housing;
a fragile structure resiliently mounted within the housing; and
a mounting mat disposed in a gap between the housing and the fragile structure, wherein the mounting mat comprising inorganic fibers selected from the group consisting of high alumina polycrystalline fibers, mullite fibers, ceramic fibers, glass fibers, biosoluble fibers, quartz fibers, silica fibers, and combinations thereof, organic binder, antioxidant and optionally intumescent material.
19. The exhaust gas treatment device of claim 18 , wherein the high alumina polycrystalline fibers comprise the fiberization product of about 72 to about 100 weight percent alumina and about 0 to about 28 weight percent silica.
20. The exhaust gas treatment device of claim 18 , wherein the ceramic fibers comprise alumino-silicate fibers comprising the fiberization product of about 45 to about 75 weight percent alumina and about 25 to about 55 weight percent silica.
21. The exhaust gas treatment device of claim 18 , wherein the biosoluble fibers comprise magnesia-silica fibers comprising the fiberization product of about 65 to about 86 weight percent silica and from about 14 to about 35 weight percent magnesia.
22. The exhaust gas treatment device of claim 21 , wherein the magnesia-silica fibers comprise the fiberization product of about 70 to about 86 weight percent silica, about 14 to about 30 weight percent magnesia and about 5 weight percent or less impurities.
23. The exhaust gas treatment device of claim 22 , wherein the magnesia-silica fibers comprise the fiberization product of about 70 to about 80 weight percent silica, about 18 to about 27 weight percent magnesia and 0 to 4 weight percent impurities.
24. The exhaust gas treatment device of claim 18 , wherein the biosoluble fibers comprise calcia-magnesia-silica fibers comprising the fiberization product of about 45 to about 90 weight percent silica, greater than 0 to about 45 weight percent calcia, and greater than 0 to about 35 weight percent magnesia.
25. The exhaust gas treatment device of claim 24 , wherein the calcia-magnesia-silica fibers comprise the fiberization product of about 60 to about 70 weight percent silica, from about 16 to about 35 weight percent calcia, and from about 4 to about 19 weight percent magnesia.
26. The exhaust gas treatment device of claim 25 , wherein the calcia-magnesia-silica fibers comprise the fiberization product of about 61 to about 67 weight percent silica, from about 27 to about 33 weight percent calcia, and from about 2 to about 7 weight percent magnesia.
27. The exhaust gas treatment device of claim 18 , wherein the intumescent material is selected from the group consisting of unexpanded vermiculite, ion exchanged vermiculite, heat treated vermiculite, expandable graphite, hydrobiotite, water-swelling tetrasilicic flourine mica, alkaline metal silicates, or mixtures thereof.
28. The exhaust gas treatment device of claim 27 , wherein the intumescent material comprises unexpanded vermiculite.
29. The exhaust gas treatment device of claim 18 , wherein the antioxidant is selected from the group consisting of primary antioxidants, secondary antioxidants, multifunctional antioxidants and combinations thereof.
30. The exhaust gas treatment device of claim 18 , wherein the inorganic fibers comprise magnesia-silica fibers, wherein the intumescent material comprises vermiculite and wherein the antioxidant comprises and wherein the antioxidant comprises a blend of primary and secondary antioxidants.
31. The exhaust gas treatment device of claim 30 , wherein the mounting mat comprises from about 25 to about 100 weight percent magnesia-silica fibers, from about 1 to about 30 weight percent vermiculite and from about 0.1 to about 10 of the antioxidant.
32. The exhaust gas treatment device of claim 18 , wherein the mounting mat further comprises clay.
33. The exhaust gas treatment device of claim 32 , wherein said clay is selected from the group consisting of attapulgite, ball clay, bentonite, hectorite, kyanite, kaolinite, montmorillonite, palygorskite, saponite, sepiolite, silimanite or combinations thereof.
34. The exhaust gas treatment device of claim 33 , wherein the clay comprises attapulgite clay.
35. The exhaust gas treatment device of claim 18 , wherein the inorganic fibers comprise magnesia-silica fibers, wherein the intumescent material comprises vermiculite, wherein the clay comprises attapulgite clay, and wherein the antioxidant comprises a blend of thiosynergist and secondary antioxidants.
36. The exhaust gas treatment device of claim 35 , wherein the mounting mat comprises from about 25 to about 100 weight percent magnesia-silica fibers, from about 1 to about 30 weight percent vermiculite, from about 1 to about 10 weight percent attapulgite clay and from about 0.1 to about 10 of the antioxidant.
37. The exhaust gas treatment device of claim 18 , wherein the device is a catalytic converter or diesel particulate trap.
38. An end cone for an exhaust gas treatment device comprising:
outer metallic cone;
an inner metallic cone; and
cone insulation disposed between said outer and inner metallic end cones, said cone insulation comprising inorganic fibers selected from the group consisting of high alumina polycrystalline fibers, mullite fibers, ceramic fibers, glass fibers, biosoluble fibers, quartz fibers, silica fibers, and combinations thereof, organic binder, antioxidant and optionally intumescent material.
39. The end cone for an exhaust gas treatment device of claim 38 , wherein the cone insulation further comprises clay.
40. An end cone for an exhaust gas treatment device comprising:
an outer metallic cone; and
self-supporting cone insulation comprising inorganic fibers selected from the group consisting of high alumina polycrystalline fibers, mullite fibers, ceramic fibers, glass fibers, biosoluble fibers, quartz fibers, silica fibers, and combinations thereof, organic binder, antioxidant and optionally intumescent material disposed adjacent the inner surface of said outer metallic end cone.
41. The end cone for an exhaust gas treatment device of claim 40 , wherein the self-supporting end cone insulation further comprises clay.
42. A mounting mat for an exhaust gas treatment device consisting essentially of:
inorganic fibers;
organic binder;
antioxidant; and
optionally an intumescent material.
43. The mounting mat of claim 42 , wherein the inorganic fibers are selected from the group consisting of high alumina polycrystalline fibers, ceramic fibers, mullite fibers, glass fibers, biosoluble fibers, quartz fibers, silica fibers, and combinations thereof.
44. The mounting mat of claim 43 , wherein the high alumina polycrystalline fibers comprise the fiberization product of about 72 to about 100 weight percent alumina and about 0 to about 28 weight percent silica.
45. The mounting mat of claim 43 , wherein the ceramic fibers comprise alumino-silicate fibers comprising the fiberization product of about 45 to about 72 weight percent alumina and about 28 to about 55 weight percent silica.
46. The mounting mat of claim 43 , wherein the biosoluble fibers comprise magnesia-silica fibers comprising the fiberization product of about 65 to about 86 weight percent silica, from about 14 to about 35 weight percent magnesia and about 5 weight percent of less impurities.
47. The mounting mat of claim 43 , wherein the biosoluble fibers comprise calcia-magnesia-silica fibers comprising the fiberization product of about 45 to about 90 weight percent silica, greater than 0 to about 45 weight percent calcia, and greater than 0 to about 35 weight percent magnesia.
48. The mounting mat of claim 42 , wherein the intumescent material is selected from the group consisting of unexpanded vermiculite, ion exchanged vermiculite, heat treated vermiculite, expandable graphite, hydrobiotite, water-swelling tetrasilicic flourine mica, alkaline metal silicates, or mixtures thereof.
49. The mounting mat of claim 42 , wherein the antioxidant is selected from the group consisting of primary antioxidants, secondary antioxidants, multifunctional antioxidants, and combinations thereof.
50. The mounting mat of claim 42 , wherein the inorganic fibers comprise magnesia-silica fibers, wherein the intumescent material comprises vermiculite and wherein the antioxidant comprises a blend of primary and secondary antioxidants.
51. The mounting mat of claim 50 , wherein the mounting mat comprises from about 25 to about 100 weight percent magnesia-silica fibers, from about 1 to about 30 weight percent vermiculite and from about 0.1 to about 10 of the antioxidant.
52. The mounting mat of claim 42 further comprising clay.
53. The mounting mat of claim 52 , wherein said clay is selected from the group consisting of attapulgite, ball clay, bentonite, hectorite, kyanite, kaolinite, montmorillonite, palygorskite, saponite, sepiolite, silimanite or combinations thereof.
54. An exhaust gas treatment device comprising:
a housing;
a fragile structure resiliently mounted within the housing; and
a mounting mat disposed in a gap between the housing and the fragile structure, wherein the mounting mat consists essentially of inorganic fibers, organic binder, antioxidant and optionally intumescent material.
55. The exhaust gas treatment device of claim 54 , wherein the inorganic fibers are selected from the group consisting of high alumina polycrystalline fibers, mullite fibers, ceramic fibers, glass fibers, biosoluble fibers, quartz fibers, silica fibers, and combinations thereof.
56. The exhaust gas treatment device of claim 55 , wherein the high alumina polycrystalline fibers comprise the fiberization product of about 72 to about 100 weight percent alumina and about 0 to about 28 weight percent silica.
57. The exhaust gas treatment device of claim 55 , wherein the ceramic fibers comprise alumino-silicate fibers comprising the fiberization product of about 45 to about 75 weight percent alumina and about 25 to about 55 weight percent silica.
58. The exhaust gas treatment device of claim 55 , wherein the biosoluble fibers comprise magnesia-silica fibers comprising the fiberization product of about 65 to about 86 weight percent silica and from about 14 to about 35 weight percent magnesia.
59. The exhaust gas treatment device of claim 55 , wherein the biosoluble fibers comprise calcia-magnesia-silica fibers comprising the fiberization product of about 45 to about 90 weight percent silica, greater than 0 to about 45 weight percent calcia, and greater than 0 to about 35 weight percent magnesia.
60. The exhaust gas treatment device of claim 54 , wherein the intumescent material is selected from the group consisting of unexpanded vermiculite, ion exchanged vermiculite, heat treated vermiculite, expandable graphite, hydrobiotite, water-swelling tetrasilicic flourine mica, alkaline metal silicates, or mixtures thereof.
61. The exhaust gas treatment device of claim 54 , wherein the antioxidant is selected from the group consisting of primary antioxidants, secondary antioxidants, multifunctional antioxidants and combinations thereof.
62. The exhaust gas treatment device of claim 54 , wherein the inorganic fibers comprise magnesia-silica fibers, wherein the intumescent material comprises vermiculite and wherein the antioxidant comprises a blend of primary and secondary antioxidants.
63. The exhaust gas treatment device of claim 62 , wherein the mounting mat comprises from about 25 to about 100 weight percent magnesia-silica fibers, from about 1 to about 30 weight percent vermiculite and from about 0.1 to about 10 of the antioxidant.
64. The exhaust gas treatment device of claim 54 , wherein the mounting mat further comprises clay.
65. The exhaust gas treatment device of claim 64 , wherein said clay is selected from the group consisting of attapulgite, ball clay, bentonite, hectorite, kyanite, kaolinite, montmorillonite, palygorskite, saponite, sepiolite, silimanite or combinations thereof.
66. The exhaust gas treatment device of claim 65 , wherein the inorganic fibers comprise magnesia-silica fibers, wherein the intumescent material comprises vermiculite, wherein the clay comprises attapulgite clay, and wherein the antioxidant comprises and wherein the antioxidant comprises a blend of thiosynergist and secondary antioxidants.
67. The exhaust gas treatment device of claim 54 , wherein the mounting mat comprises from about 25 to about 100 weight percent magnesia-silica fibers, from about 1 to about 30 weight percent vermiculite, from about 1 to about 10 weight percent attapulgite clay and from about 0.1 to about 10 of the antioxidant.
68. The exhaust gas treatment device of claim 54 , wherein the device is a catalytic converter or diesel particulate trap.
69. An end cone for an exhaust gas treatment device comprising:
outer metallic cone;
an inner metallic cone; and
cone insulation disposed between said outer and inner metallic end cones, said cone insulation consisting essentially of inorganic fibers, organic binder, antioxidant and optionally intumescent material.
70. The end cone for an exhaust gas treatment device of claim 69 , wherein the cone insulation further comprises clay.
71. An end cone for an exhaust gas treatment device comprising:
an outer metallic cone; and
self-supporting cone insulation consisting essentially of inorganic fibers, organic binder, antioxidant and optionally intumescent material disposed adjacent the inner surface of said outer metallic end cone.
72. The end cone for an exhaust gas treatment device of claim 71 , wherein the self-supporting end cone insulation further comprises clay.