Unifrax Corporation

Kennecott Corporation

Unifrax I LLC

John D Teneyck

Thomas M Clere

James R Olson

Steven Waisala

Joseph A Fernando

Thomas S Lacki

Russell D Smith

Kurt W Hoff

A support element is disposed between a housing and a fragile structure resiliently mounted within the housing. The support element includes an integral, substantially non-expanding ply or layer of melt-formed ceramic fibers containing at least alumina and silica. The fibers have an average diameter ranging from about 1 micron to about 14 microns and have been prepared by a process of heat treating under a time-temperature regimen of one of (i) heat treating said fibers at a temperature of 990&#xb0; C. to at least 1050&#xb0; C. for greater than 1 hour such that the treated fibers have about 5 to about 50 percent crystallinity as detected by x-ray diffraction, and a crystallite size of about 50 &#x212b; to about 500 &#x212b;, or (ii) heat treating said fibers at a temperature of greater than 1050&#xb0; C. for an effective time such that the treated fibers have about 5 to about 50 percent crystallinity as detected by x-ray diffraction, and a crystallite size of about 50 &#x212b; to about 500 &#x212b;. The resultant support element provides a minimum residual pressure for holding the fragile structure within the housing of one of at least 4 psi after at least 200 cycles of testing at 900&#xb0; C. or at least 10 psi after at least 1000 cycles of testing at 750&#xb0; C. Such a support element may be used in devices for the treatment of exhaust gases such as catalytic converters, diesel particulate traps and the like. A method of mounting a fragile structure in such a device is also provided.

Support element for fragile structures such as catalytic converters

A non-intumescent mat for providing a support structure for low temperature fragile structures in exhaust gas treatment devices, such as catalytic converters, diesel particulate traps, and like, comprising amorphous inorganic fibers. The fibers have Young's Modulus of less than about 20&#xd7;10psi and a geometric mean diameter less than about 5 &#x3bc;m. The mat is adapted to provide a holding force of at least 15 psi throughout an average mat temperature range from ambient temperature up to at least about 350&#xb0; C. The amorphous inorganic fibers are preferably melt formed fibers comprising the fiberization product of a melt comprising alumina/silica.

Amorphous non-intumescent inorganic fiber mat for low temperature exhaust gas treatment device

A non-intumescent mat for providing a support structure for low temperature fragile structures in exhaust gas treatment devices, such as catalytic converters, diesel particulate traps, and like, comprising amorphous inorganic fibers. The fibers have Young's Modulus of less than about 20&times;10,psi and a geometric mean diameter less than about 5 &mgr;m. The mat is adapted to provide a holding force of at least 15 psi throughout an average mat temperature range from ambient temperature up to at least about 350&deg; C. The amorphous inorganic fibers are preferably melt formed fibers comprising the fiberization product of a melt comprising alumina/silica.

Amorphous non-intumescent inorganic fiber mat for low temperature exhaust gas treatment devices

Composition and process for the preparation of high temperature stable continuous glass ceramic fibers with an upper temperature use limit of 2300.degree. F. are provided. The compositional formulation, in mole percent, is 62-85% SiO.sub.2, 9.5-20% Al.sub.2 O.sub.3, 5-15.5% MgO, 0.5-5% TiO.sub.x, and 0-5% ZrO.sub.2. The continuous fibers are prepared by an economical direct melt method, and demonstrate high tensile strength, high Young's modulus, and low linear thermal shrinkage characteristics.

High temperature stable continuous filament glass ceramic fiber

High temperature stable continuous filament glass ceramic fibers

A two part castable ceramic cement having low density, good thermal shock resistance, good temperature resistance and extended storage life. The first and second parts are mixed together prior to use. The first part is a slurry of solids in water. The solids comprise 0 to 10 weight percent organic fibers, about 35 to about 80 weight percent ceramic organic fibers, about 5 to about 15 weight percent colloidal silica and about 3 to about 10 weight percent organic adhesive. The second part is essentially dry and comprises from about 50 to about 100 weight percent calcium aluminate. The invention further includes a method for forming the cement by mixing the two parts and includes the cast cement resulting from casting and drying the mixed first and second parts.

Two part castable ceramic cement

The invention relates to a ceramic fiber felt or mat having an area comprising a high temperature ceramic fiber and another portion of lower temperature ceramic fiber. The two portions being joined seamlessly by an intermingling and intimate relationship of the two fiber types during the formation process. The invention further provides apparatus for formation of such ceramic fiber composites and further provides for forming such composite ceramic fiber members into modules.

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Lewiston, NY, United States of America

John D Teneyck