Mounting mat for exhaust gas treatment device
View Patent ↗Disclosed is a mat or molded pre-form that may be used as a mounting mat to mount a fragile monolith within an outer housing of an exhaust gas treatment device, such as automotive catalytic converters and diesel particulate traps. The mat or pre-form may also be used as thermal insulation in the end cone regions of the exhaust gas treatment device. The mat and pre-form includes an inorganic microporous insulation component and a flexible fibrous material component. Exhaust gas treatment devices and methods for making exhaust gas treatment devices including the mat or pre-form are also disclosed.
1. A single or multiple layer mounting mat comprising microporous inorganic insulating material and a flexible fibrous material, wherein the microporous inorganic insulating material is shielded from exposure to liquid or liquid vapor, wherein
the flexible fibrous material comprises:
a layer of inorganic fibrous material having a first major surface, a second major surface opposite the first major surface and a thickness extending between the first and second major surfaces; and
a cavity formed in a portion of the layer thickness; and
the microporous inorganic insulating material comprises an insert of microporous inorganic insulation material disposed within the cavity.
2. The mounting mat of claim 1 , wherein the layer of inorganic fibrous material surrounds the outer perimeter of the insert of microporous inorganic insulation material.
3. The mounting mat of claim 1 , wherein a second layer of inorganic fibrous material is positioned over the microporous inorganic insulating material disposed within the cavity.
4. The mounting mat of claim 1 , wherein the perimeter edges of the microporous inorganic insulation insert have a hydrophobic coating thereon.
5. The mounting mat of claim 1 , wherein the major surfaces and/or the peripheral edges of the microporous inorganic insulation insert are at least partially coated with a hydrophobic coating.
6. An exhaust gas treatment device comprising:
a housing;
a fragile structure located within the housing; and
the mounting mat of claim 1 disposed between the housing and the fragile structure.
7. An end cone for an exhaust gas treatment device comprising:
an outer metallic cone;
an inner metallic cone; and
cone insulation disposed between the outer and inner metallic cones, the cone insulation comprising the mounting mat of claim 1 .
8. An end cone for an exhaust gas treatment device comprising:
an outer metallic cone; and
self-supporting cone insulation comprising the mounting mat of claim 1 disposed adjacent the inner surface of the outer metallic cone.