Unifrax I LLC

The Carborundum Company

Other

Stemcor Corporation

Unifrax Corporation

John D Ten Eyck

Amit Kumar

Joseph A Fernando

Alan R Lebold

Thomas S Lacki

James R Olson

Patrick J Gadzo

Orland C Pitts

A mounting mat for an exhaust gas treatment device includes first and second major opposite facing surfaces, leading and trailing edges, and opposite lateral edges. At least a portion of one or both of the opposite lateral edges includes an edge protectant that protects the mounting mat against erosion from hot gases encountered during the normal operation of the exhaust gas treatment device. The edge protectant remains flexible after it has been applied to the mounting mat and substantially dried. Also disclosed is an exhaust gas treatment device that includes a housing and a fragile structure mounted within the housing by the mounting mat having the edge protectant deposited thereon. Additionally disclosed are methods of making the mounting mat and an exhaust gas treatment device.

Mounting mat with flexible edge protection and exhaust gas treatment device incorporating the mounting mat

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

Exhaust gas treatment device and method for making the same

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 () comprises melt-formed, leached glass fibers high in silica content and exerts a minimum holding pressure for holding the fragile structure () within the housing () of one of (i) at least 10 kPa after 1000 cycles of testing at a hot face temperature of 900&#xb0; C., a gap bulk density of between 0.3 and 0.5 g/cm, and a percent gap expansion of 5 percent, and (ii) at least 50 kPa after 1000 cycles of testing at a hot face temperature of 300&#xb0; C., a gap bulk density of between 0.3 and 0.5 g/cm, and a percent gap expansion of 2 percent.

A flexible, resilient, intumescent mat material comprising fiber, binder, and an intumescent agent which includes a mixture of unexpanded vermiculite and expandable graphite undergoes intumescence at a lower temperature, with an enhanced degree of expansion and with a lesser degree of contraction upon prolonged heating. The intumescent mat can be employed in catalytic converters for motor vehicles and as a firestop material.

Catalytic converter

Intumescent sheet

As an article of manufacture an intumescent conforming mounting pad for fragile structures comprised of at least two plys of intumescent sheet material adhesively bonded together over a predetermined part of their adjoining faces said plys and being offset a predetermined amount lengthwise whereby said pad can be bent around a fragile structure and the ends can be joined without cracking or buckling.

Intumescent conforming mounting pad

A handleable, flexible, crack resistant intumescent sheet material for use in mounting fragile structures comprising a preformed intumescent layer, and a reinforcing layer bonded to the intumescent layer and having a tensile strength greater that the intumescent layer.

Crack resistant intumescent sheet material

A device suitable for use as a catalytic converter for purification of the exhaust gases from an internal combustion engine at continuous operating temperatures in excess of 1600.degree. F. and up to 2500.degree. F. includes a frangible ceramic monolith catalyst element resiliently mounted in a metallic housing. The monolith is wrapped in a thermally insulating layer of ceramic fibers capable of withstanding continuous exposure to temperatures of at least 2000.degree. F. A layer of intumescent material disposed between the housing and the ceramic fiber layer resiliently secures the monolith in the housing. A method of manufacture of such a device is also described.

Growing community of inventors

Lewiston, NY, United States of America

John D Ten Eyck