Unifrax I LLC

Unifax I LLC

Unifrax Corporation

Amit Kumar

John D Ten Eyck

Thomas S Lacki

Mark E Beauharnois

Sergio David Fernandes, Jr

Scott L Misenar

Digvijay Singh Chauhan

Mark D Stahlman

A mounting mat for an exhaust gas treatment device, includes at least one layer comprising inorganic fibers and a heater in thermal communication with the layer. Also disclose is an exhaust gas treatment device comprising an outer housing, a fragile structure located in the housing and the mounting mat located between the housing and the fragile structure. A method is further disclosed for maintaining and/or increasing the temperature of a substrate of an exhaust gas treatment device comprising providing the mounting mat and transferring heat from the heater to the mounting mat in order to maintain and/or increase the temperature of the substrate and/or the exhaust gas treatment device during the battery mode of a hybrid gas/electric vehicle.

Heated mat and exhaust gas treatment device

A mounting mat for an exhaust gas treatment device includes a wet laid sheet of polycrystalline inorganic fibers that have been physically entangled while the wet laid sheet is still in a wet condition. 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 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.

Mounting mat for exhaust gas treatment device

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&#xb0; C. to about 800&#xb0; C., optionally for at least about 3 minutes. Insulation mats manufactured according to the above methods.

High temperature resistant insulation mat

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.

A mounting mat for mounting a catalyst support structure within a housing in an exhaust gas treatment device. The mounting mat includes a layer of high silica content fibers and a layer of polycrystalline and/or high alumina inorganic fibers. The exhaust gas treatment device includes an outer housing, a fragile catalyst, and a mounting mat disposed in the gap between the housing and the fragile catalyst support structure. Additionally disclosed are methods of making the mounting mat and for making an exhaust gas treatment device incorporating the mounting mat.

Mounting mat and exhaust gas treatment device

A hybrid mounting mat for mounting a catalyst support structure within a housing in an exhaust gas treatment device. The exhaust gas treatment device includes an outer housing, a fragile catalyst support structure, and a mounting mat disposed in the gap between the housing and the fragile catalyst support structure. Additionally disclosed are methods of making the hybrid mounting mat and for making an exhaust gas treatment device incorporating the mounting mat.

Multiple layer mat and exhaust gas treatment device

A mounting mat for an exhaust gas treatment device including inorganic fibers, organic binder, high temperature resistant inorganic microspheres, 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.

Use of microspheres in an exhaust gas treatment device mounting mat

A multilayer mounting mat for an exhaust gas treatment device including high temperature resistant inorganic fibers, optionally organic binder, and optionally intumescent material. A plurality of the mounting mat plies contain a substantial proportion of the inorganic fibers oriented in the x-y plane of the mounting mat. An exhaust gas treatment device includes a housing, a fragile catalyst support structure resiliently mounted within the housing, and the multilayer mounting mat disposed in a gap between the housing and the fragile catalyst support structure.

Multilayer mounting mat for pollution control devices

A mat or mat-pre-form hybrid for use in an exhaust gas treatment device, such as catalytic converters and diesel particulate traps that are used in automotive exhaust systems. The mat or hybrid may be used as a mounting mat to mount a fragile monolith within an outer housing of an exhaust gas treatment device or as thermal insulation in an end cone of the exhaust gas treatment device.

Multiple layer substrate support and exhaust gas treatment device

A device for treatment of exhaust gases includes a housing, a fragile structure resiliently mounted within the housing, and a non-intumescent mounting mat disposed in a gap between the housing and the fragile structure. The mounting mat includes a plurality of inorganic fibers that have undergone a surface treatment to increase the holding force performance of the mounting mat. Also 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.

Exhaust gas treatment device

A flexible and substantially crack resistant intumescent, non-intumescent, or hybrid mounting mat material for use in mounting fragile structures includes at least one intumescent, non-intumescent or hybrid layer containing inorganic fibers and reinforcing layer applied to the layer. Also provided is an exhaust gas treatment device including a housing, a fragile catalyst support structure mounted within the housing, and the crack resistant mounting mat disposed in a gap between the housing and the fragile catalyst support structure. Also 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.

A mounting mat for an exhaust gas treatment device including high temperature resistant ceramic fibers containing alumina and/or high temperature resistant biosoluble inorganic fibers, organic binder which at least partially liquefies at elevated temperature prior to binder burnout, colloidal inorganic oxide 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.

Low shear mounting mat for pollution control devices

Exhaust gas treatment device and method for making the same

A fluid jet cutting process for fibrous materials, such as inorganic fibrous material articles is provided. A fluid composition for use in the fluid jet cutting process is also provided. The cutting fluid composition contains a carrier fluid and coating composition for the cut surfaces of the fibrous material. An apparatus for carrying out the fluid jet cutting process of fibrous materials is also provided.

Growing community of inventors

Getzville, NY, United States of America

Amit Kumar