High temperature resistant insulation mat
View Patent ↗Methods of forming insulation mats including: providing a mixture of fibers comprising first inorganic fibers and second inorganic fibers, wherein the first inorganic fibers shrink by no more than about 2 percent and the second fibers shrink by about 5 to about 15 percent when the mixture of fibers is heat treated; wet-forming a web of fibers from the mixture of fibers; entangling the web of fibers to form an insulation mat; heat-treating the insulation mat; and drying the web of fibers and/or the insulation mat after said wet-forming and prior to or during said heat treating; and wherein the insulation mat includes substantially no non-fibrous binder material prior to said heat treating the insulation mat at a temperature of from about 500° C. to about 800° C., optionally for at least about 3 minutes. Insulation mats manufactured according to the above methods.
1. A method of forming an insulation mat comprising:
providing a mixture of fibers comprising first inorganic fibers and second inorganic fibers, wherein the first inorganic fibers shrink by no more than about 2 percent and the second fibers shrink by about 5 to about 15 percent when the mixture of fibers is heat treated at a temperature of from about 500° C. to about 800° C., optionally for at least about 3 minutes;
wet-forming a web of fibers from the mixture of fibers;
entangling the web of fibers to form an insulation mat;
heat-treating the insulation mat at a temperature of from about 500° C. to about 800° C.; and
drying the web of fibers and/or the insulation mat after said wet-forming and prior to or during said heat treating;
wherein the insulation mat comprises substantially no non-fibrous binder material prior to said heat treating the insulation mat.
2. The method of claim 1 , wherein said providing a mixture of inorganic fibers comprises mixing the first inorganic fibers with the second inorganic fibers.
3. The method of claim 1 , wherein said entangling the web of inorganic fibers comprises at least one of needling or hydroentangling.
4. The method of claim 1 , wherein said heat treating the insulation mat comprises exposing the insulation mat to a temperature of from about 500° C. to about 800° C. for at least about 3 minutes.
5. The method of claim 1 , further comprising adding a binder to the insulation mat after said heat treating the insulation mat.
6. The method of claim 1 , wherein the first inorganic fibers are present in the mixture of fibers in an amount of at least about 80 percent by weight.
7. The method of claim 1 , wherein the first inorganic fibers comprise at least one of biosoluble fibers or refractory ceramic fibers.
8. The method of claim 1 , wherein the first inorganic fibers shrink by no more than about 2 percent when heat treated at a temperature of from about 500° C. to about 800° C.
9. The method of claim 1 , wherein the second inorganic fibers are present in the mixture of fibers in an amount of up to about 20 percent by weight.
10. The method of claim 1 , wherein the second inorganic fibers comprise at least one of silica fibers, S-glass fibers, S2-glass fibers, E-glass fibers or fiberglass fibers.
11. The method of claim 1 , wherein the second inorganic fibers shrink by about 5 to about 15 percent when heat treated at a temperature of from about 500° C. to about 800° C.
12. An insulation mat prepared according to the method of claim 1 .
13. The insulation mat of claim 12 , having a tensile strength of from about 40 kPa to about 110 kPa.
14. The insulation mat of claim 12 , having a density of from about 90 kg/m 3 to about 200 kg/m 3 .
15. The insulation mat of claim 12 , having a basis weight of from about 400 gsm to about 5,000 gsm.
16. An insulation mat comprising first inorganic fibers and second inorganic fibers, having at least one of:
a tensile strength of from about 40 kPa to about 110 kPa, optionally from about 80 kPa to about 105 kPa;
a density of from about 90 kg/m 3 to about 200 kg/m 3 , optionally from about 90 kg/m 3 to about 150 kg/m 3 , further optionally from about 100 kg/m 3 to about 150 kg/m 3 ; or
a basis weight of from about 400 gsm to about 5,000 gsm, optionally from about 400 gsm to about 4,000 gsm;
wherein the first inorganic fibers shrink by no more than about 2 percent and the second fibers shrink by about 5 to about 15 percent when the insulation mat is heat treated at a temperature of from about 500° C. to about 800° C.
17. The insulation mat of claim 16 , wherein the first inorganic fibers are present in the mixture of fibers in an amount of at least about 80 percent by weight.
18. The insulation mat of claim 16 , wherein the second inorganic fibers are present in the mixture of fibers in an amount of up to about 20 percent by weight.
19. The insulation mat of claim 16 , wherein the first inorganic fibers comprise at least one of biosoluble fibers or refractory ceramic fibers.
20. The insulation mat of claim 16 , wherein the second inorganic fibers comprise at least one of silica fibers, S-glass fibers, S2-glass fibers, E-glass fibers or fiberglass fibers.
21. The insulation mat of claim 16 , wherein the first inorganic fibers shrink by no more than about 2 percent when heat treated at a temperature of from about 500° C. to about 800° C.
22. The insulation mat of claim 16 , wherein the second inorganic fibers shrink by about 5 to about 15 percent when heat treated at a temperature of from about 500° C. to about 800° C.