3m Innovative Properties Company

Minnesota Mining and Manufacturing Company

Richard P Merry

Stephen M Sanocki

Loyd R Hornback, Iii

Joel H Sabean

Paul D Stroom

Lahoussaine Lalouch

Anne N De Rovere

Michael D Swan

Roger L Langer

Kenneth Robert Dillon

Ryan C Shirk

Gary F Howorth

Ulrich E Kunze

Troy K Ista

Javier E Gonzalez

Richard L Bloom

Thomas L Tompkins

Ian R I Harding

Roger I Langer

Steven C Schroeer

Philip D Coates, Jr

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

The present invention provides a multilayer mounting mat for mounting a pollution control element. The mounting mat comprises a layer of intumescent material between two non-intumescent layers defining opposite major sides of the mounting mat. The mounting mat in accordance with the present invention is suitable for mounting a pollution control element in a pollution control device and is in particular suitable for mounting fragile monolith such as thin-wall and ultra thin-wall monoliths. Also, the mounting mats conveniently exhibit a good or excellent holding pressure over a wide temperature range and can be formulated in an inexpensive way. The invention also provides a pollution control device comprising a pollution control element arranged in a casing with the mounting mat disposed between the casing and pollution control element.

Mounting mat for mounting monolith in a pollution control device

Tubular, continuous, seamless, compressible, resilient mounting article comprising inorganic fibers, and having an inner curved surface, a central longitudinal axis, and a uniform internal cross-sectional area along the central longitudinal axis. The mounting articles are useful, for example, in mounting pollution control elements in pollution control devices.

Tubular, continuous, seamless, compressible, resilient mounting articles and pollution control devices comprising the same

Non-woven mat including basalt and amorphous refractory ceramic fibers, bio-soluble ceramic fibers, and/or heat-treated silica fibers. Embodiments of the non-woven mat surprisingly have a Resiliency Value after three thermal cycles from 25&#xb0; C. to 700&#xb0; C./400&#xb0; C. of the Real Condition Fixture Test at least 1.1 times greater than the Resiliency Value of a comparable non-woven mat consisting of any individual type of fibers of the non-woven mat. The non-woven mats are useful, for example, in pollution control devices and other thermal insulation applications.

Mounting mat and pollution control device with the same

Non-woven mat including magnesium aluminum silicate glass fibers and amorphous refractory ceramic fibers, bio-soluble ceramic fibers, and/or heat-treated silica fibers. Embodiments of the nonwoven mat surprisingly have a Resiliency Value after three thermal cycles from 25&#xb0; C. to 700&#xb0; C./400&#xb0; C. of the Real Condition Fixture Test at least 1.1 times greater than the Resiliency Value of a comparable non-woven mat consisting of any individual type of fibers of the non-woven mat. The non-woven mats are useful, for example, in pollution control devices and other thermal insulation applications.

A double-walled exhaust system component having glass bubbles disposed between inner and outer pipes and method of making the same. The glass bubbles have a size distribution wherein, on a bulk volume basis, at least 90 percent of the glass bubbles have a size of less than 150 micrometers.

Insulated double-walled exhaust system component and method of making the same

A double-walled exhaust system component having hollow ceramic microspheres disposed between inner and outer pipes and method of making the same. The hollow ceramic microspheres have a size distribution wherein, on a bulk volume basis, at least 90 percent of the hollow ceramic microsphere have a size of less than 150 micrometers.

Inorganic fiber mounting and insulating sheet materials for use in pollution control devices with at least one edge of the inorganic fiber sheet material having at least one group of two or more fibers fused together. A pollution control device comprising such a sheet material. A process for cutting at least one section from a sheet containing inorganic fiber material, where the sheet material is suitable for use in a pollution control device. The fibrous sheet material is cut so that the cut edge has at least one group of two or more fibers fused together. A laser beam can be used to cut the desired section out of the inorganic fiber sheet material.

Pollution control device and inorganic fiber sheet material with a fused edge

An exhaust system component () for use in an exhaust system of a motor vehicle. The exhaust system component comprises a double wall surrounding a space () through which exhaust gas may flow when the exhaust system component is in use in an exhaust system. The double wall is comprised of a first and second metal wall () that define between them a gap. The gap comprises an insulation material () made of chopped aluminium or magnesium aluminium silicate glass fibers. The insulation material can be in the form of, for example, an end cone perform. The exhaust system component can be an exhaust pipe ().

Exhaust system component having insulated double wall

The present invention provides a mounting mat () for mounting a pollution control monolith () in a pollution control device (). The mounting mat has a bulk density of 0.12 to 0.3 g/cmand comprises (i) a layer of chopped magnesium aluminium silicate glass fibers and (ii) a layer of ceramic fibers obtainable from a sol-gel process. Preferably, the layer of chopped magnesium aluminium silicate glass fibers and the layer of ceramic fibers define opposite major surfaces of the mat. The present invention further provides a pollution control device (), comprising a pollution control monolith () arranged in a metallic casing () with the mounting mat () disposed between the metallic casing () and pollution control monolith ().

Mounting mat for a catalytic converter

A pollution control device suitable for use with an internal combustion engine (e.g., a diesel engine) and comprising a pollution control element arranged in a casing with non-woven mat disposed between the casing and the pollution control element, said non-woven mat being a non-intumescent mat comprising at least 90% by weight based on the total weight of the mat of chopped magnesium aluminum silicate glass fibers that have a number average diameter of 5&#x3bc; or more and a length of 0.5 to 15 cm, said glass fibers being needle punched or stitch bonded and said mat being free or substantially free of organic binder.

Mat for mounting a pollution control element in a pollution control device for the treatment of exhaust gas

Multilayer mats, pollution control devices containing the multilayer mats, and methods of making the multilayer mats are described. The multilayer mats include an intumescent layer sandwiched between two non-intumescent layers. The non-intumescent layers contain inorganic fibers and have a larger area than the intumescent layer.

Sandwich hybrid mounting mat

Multilayer mats, pollution control devices containing the multilayer mats, and methods of making the multilayer mats are provided. The multilayer mats include a non-intumescent layer sandwiched between two intumescent layers. The outer layers of the mats contain intumescent materials.

Multilayer mats for use in pollution control devices

A pollution control device has a metal housing, a solid pollution control device disposed within the metal housing, and a mounting mat disposed between the pollution control element and the housing for positioning the pollution control element and for absorbing mechanical and thermal shock. The mounting mat includes a layer of intumescent material having at least one insert formed of a resilient, flexible, fibrous non-intumescent material. The insert is positioned along at least a portion of at least one lateral edge of the mounting mat to prevent erosion of the intumescent material and to provide a seal between the pollution control element and the housing.

Growing community of inventors

Saint Paul, MN, United States of America

Richard P Merry