3M Innovative Properties Company

Minnesota Mining and Manufacturing Company

Gary F Howorth

Stephen M Sanocki

Roger L Langer

David Scott Seitz

Dale L May

Richard P Merry

John J Rogers

Tien T Wu

Claus Middendorf

Javier E Gonzalez

Anne N De Rovere

Michael Patrick M Mandanas

Paul D Stroom

Kerstin C Rosen

Andrew B Supina

Ian R I Harding

Shailendra B Rathod

Patrick Welter

Michael T Schweitzer

Toshiyuki Watanabe

A method of making nonwoven fibrous materials suitable for use in a pollution control device or as a firestop, where the method comprises: providing a first slurry comprising water, first inorganic fibers, a first organic binder, and a first neutral pH flocculent; removing first waste water from the first slurry; optionally forming a first nonwoven fibrous material from the first slurry; providing a second slurry comprising a quantity of the first waste water, an optional quantity of relatively clean water, second inorganic fibers, a second organic binder, and a second flocculent that is the same and/or a different flocculent than that used in the first slurry; and forming a second nonwoven fibrous material from the second slurry. The addition of the first waste water in the second slurry does not adversely affect the flocculation of the second organic binder in the second slurry.

Using recycled waste water to make nonwoven fibrous materials suitable for use in a pollution control device or in a firestop

A structure comprising at least one inorganic layer comprising inorganic materials suitable for use in a pollution control device. A friction-inducing material is disposed on at least one side of the inorganic layer. The deposited friction-inducing material defines a higher friction area exhibiting a static coefficient of friction higher than that of the inorganic materials. A lower friction layer is disposed so as to cover at least a portion of the higher friction area and define an exposed surface area of the structure. The exposed surface area exhibits a lower static coefficient of friction than that of the higher friction area. The lower friction layer no longer covers a substantial portion of the higher friction area, after the pollution control device is assembled.

Pollution control device structure with lower friction surface and underlying higher friction surface

A mounting mat () comprising at least one inorganic layer () comprising inorganic materials suitable for mounting a pollution control element in a pollution control device. A friction-inducing material () is disposed on at least one side of the inorganic layer (). The deposited friction-inducing material () defines a higher friction area exhibiting a static coefficient of friction higher than that of the inorganic materials. A lower friction layer () is disposed so as to cover at least a portion of the higher friction area and define an exposed surface area of the mounting mat (). The exposed surface area exhibits a lower static coefficient of friction than that of the higher friction area. The lower friction layer () no longer covers a substantial portion of the higher friction area, after the mounting mat () mounts a pollution control element () in a pollution control device ().

Mounting mat with lower friction surface for assembling and higher friction surface for mounting

Compositions that include a mixture of biosoluble inorganic fibers and a micaceous binder are described. The compositions can be prepared free of refractory ceramic fibers that are respirable but durable in a physiological medium. The compositions are typically in the form of a sheet material or a paste and can be used, for example, as a protective packing material around the pollution control element or as an insulating material in the end cone region in a pollution control device. Sheet materials formed from the compositions have an area of a X-Y plane that decrease less than about 6 percent when heated to about 900&#xb0; C.

Compositions containing biosoluble inorganic fibers and micaceous binders

Mounting materials for pollution control devices comprising biosoluble fibers, heat treated silica fibers having a silica content of greater than about 67 percent by weight (pbw) based on a total weight of the fibers, and intumescent material, with an optional binder component, are disclosed. Methods for making and using the materials are also disclosed.

Mounting mats and pollution control devices using same

A method of forming a multilayer sheet suitable for use as a mat for mounting a pollution control element or as a firestop. The method comprises providing one aqueous slurry and another aqueous slurry, each slurry containing inorganic materials suitable for making a mounting mat for a pollution control element or a firestop. The two aqueous slurries can be separated from one aqueous slurry. The method can also comprise depositing the one slurry onto a permeable substrate; partially removing water from the one slurry to form the one layer on the substrate; and depositing the other slurry onto the one layer. One layer is dried out of the one slurry and another layer is dried out of the other slurry so as to form the multilayer sheet.

Method of making multilayer sheets for firestops or mounting mats

The invention provides a multilayer intumescent mat or sheet that is useful as a mounting for a pollution control device or as a firestop. In one aspect, the multilayer intumescent sheet of the invention comprises a non-moldable flexible non-intumescent layer and a non-moldable flexible intumescent layer comprising an intumescent material wherein the layers form a single sheet without the use of auxiliary bonding means. In another aspect, the multilayer intumescent sheet of the invention comprises a first non-moldable intumescent layer comprising a first intumescent material and a second non-moldable intumescent layer comprising a second intumescent material, the first and second intumescent materials being different, wherein the layers form a single sheet without the use of auxiliary bonding means. The invention also provides a pollution control device comprising a multilayer sheet of the invention disposed between a monolith and a housing.

Multilayer intumescent sheet and pollution control device

Catalytic converter or diesel particulate filter or trap having edge protectant which reduces erosion of a lateral edge of an intumescent mounting mat when exposed to hot, impinging gases.

Catalytic converter and diesel particulate filter

The invention provides a multilayer intumescent mat or sheet that is useful as a mounting for a pollution control device or as a firestop. In one aspect, the multilayer intumescent sheet of the invention includes a non-moldable flexible non-intumescent layer and a non-moldable flexible intumescent layer including an intumescent material wherein the layers form a single sheet without the use of auxiliary bonding means. In another aspect, the multilayer intumescent sheet of the invention includes a first non-moldable intumescent layer including a first intumescent material and a second non-moldable intumescent layer comprising a second intumescent material, the first and second intumescent materials being different, wherein the layers form a single sheet without the use of auxiliary bonding means. The invention also provides a pollution control device including a multilayer sheet of the invention disposed between a monolith and a housing.

Multilayer intumescent sheet

A composite for mounting a catalytic converter or diesel particulate filter. The composite comprises a flexible mat and a layer of an intumescent paste comprising an intumescent material. A catalytic converter element and diesel particulate filter comprising such a composite are also described.

Composite mounting system

The invention provides a catalytic converter or diesel particulate filter comprising: (a) a housing; (b) a catalytic converter element or diesel particulate filter element disposed within said housing; and (c) a flexible intumescent sheet material disposed between said catalytic converter element and said housing; wherein said flexible intumescent sheet material comprises 1 to 70 dry weight percent of at least one unexpanded intumescent material, from greater than 20 to 50 dry weight percent of organic binder, 5 to less than 79 dry weight percent of inorganic binder, and 0 to 70 dry weight percent of one or more fillers.

Growing community of inventors

Oakdale, MN, United States of America

Gary F Howorth