EP1388649B1 - Mat for mounting a pollution control monolith in a pollution control device for the treatment of exhaust gas of a diesel engine powered machine - Google Patents

Mat for mounting a pollution control monolith in a pollution control device for the treatment of exhaust gas of a diesel engine powered machine Download PDF

Info

Publication number
EP1388649B1
EP1388649B1 EP02078103A EP02078103A EP1388649B1 EP 1388649 B1 EP1388649 B1 EP 1388649B1 EP 02078103 A EP02078103 A EP 02078103A EP 02078103 A EP02078103 A EP 02078103A EP 1388649 B1 EP1388649 B1 EP 1388649B1
Authority
EP
European Patent Office
Prior art keywords
mat
pollution control
control device
fibers
glass
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP02078103A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP1388649A1 (en
Inventor
Richard P. Merry
Ulrich Kunze
Mike D. Swan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3M Innovative Properties Co
Original Assignee
3M Innovative Properties Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to DE60230603T priority Critical patent/DE60230603D1/de
Application filed by 3M Innovative Properties Co filed Critical 3M Innovative Properties Co
Priority to AT02078103T priority patent/ATE419456T1/de
Priority to EP02078103A priority patent/EP1388649B1/en
Priority to JP2004524580A priority patent/JP4575159B2/ja
Priority to US10/522,492 priority patent/US7704459B2/en
Priority to PCT/US2003/021455 priority patent/WO2004011785A1/en
Priority to CN03820939XA priority patent/CN1678821B/zh
Priority to BRPI0313074-6A priority patent/BR0313074B1/pt
Priority to AU2003247946A priority patent/AU2003247946A1/en
Priority to KR1020057001725A priority patent/KR101037241B1/ko
Priority to MXPA05001251A priority patent/MXPA05001251A/es
Priority to EP03771589A priority patent/EP1561018A1/en
Publication of EP1388649A1 publication Critical patent/EP1388649A1/en
Priority to ZA200501650A priority patent/ZA200501650B/en
Application granted granted Critical
Publication of EP1388649B1 publication Critical patent/EP1388649B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0814—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0828—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
    • F01N3/0842—Nitrogen oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
    • F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
    • F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
    • F01N3/2864—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing the mats or gaskets comprising two or more insulation layers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2310/00—Selection of sound absorbing or insulating material

Definitions

  • the present invention relates to pollution control devices that include a mounting mat for mounting a diesel pollution control monolith in the pollution control device.
  • the invention relates to pollution control devices that are intended for the treatment of the exhaust of a diesel engine.
  • the mounting mat of the pollution control device is designed so that it is particularly suited for lower temperature applications such as diesel catalytic converters or other pollution control monoliths adapted for reducing pollution from the exhaust of diesel engines.
  • Diesel pollution control devices include catalytic converters and diesel particulate filters or traps.
  • the pollution control devices typically comprise a metal housing with a monolithic element securely mounted within the casing by a resilient and flexible mounting mat.
  • Pollution control devices are universally employed on motor vehicles to control atmospheric pollution.
  • Two types of devices are currently in widespread use - catalytic converters and diesel particulate filters or traps.
  • Catalytic converters contain a catalyst, which is typically coated on a monolithic structure mounted within a metallic housing.
  • the monolithic structures are typically ceramic, although metal monoliths have also been used.
  • the catalyst oxidizes carbon monoxide and hydrocarbons and reduces the oxides of nitrogen in automobile exhaust gases to control atmospheric pollution.
  • Diesel particulate filters or traps are typically wall flow filters, which have honeycombed, monolithic structures typically made from porous crystalline ceramic materials. Alternate cells of the honeycombed structure are typically plugged such that exhaust gas enters in one cell and is forced through the porous wall to an adjacent cell where it can exit the structure. In this way, the small soot particles that are present in diesel exhaust gas are collected.
  • the monoliths and in particular the ceramic pollution control monoliths, used in pollution control devices are fragile and susceptible to vibration or shock damage and breakage. They have a coefficient of thermal expansion generally an order of magnitude less than the metal housing which contains them. This means that as the pollution control device is heated the gap between the inside peripheral wall of the housing and the outer wall of the monolith increases. Even though the metallic housing undergoes a smaller temperature change due to the insulating effect of the mat, the higher coefficient of thermal expansion of the metallic housing causes the housing to expand to a larger peripheral size faster than the expansion of the monolithic element. Such thermal cycling occurs hundreds of times during the life and use of the pollution control device.
  • mounting mats are disposed between the ceramic monolith and the metal housing. These mats must exert sufficient pressure to hold the monolith in place over the desired temperature range but not so much pressure as to damage the ceramic monolith.
  • mounting mats described in the art have been developed for mounting catalytic converters for treatment of exhaust from gasoline engines which typically operate at high temperature.
  • Known mounting mats include intumescent sheet materials comprised of ceramic fibers, intumescent materials and organic and/or inorganic binders.
  • Intumescent sheet materials useful for mounting a catalytic converter in a housing are described in, for example, U.S. Pat. Nos. 3,916,057 (Hatch et al.), 4,305,992 (Langer et al.) 5,151,253 (Merry et al.) 5,250,269 (Langer) and 5,736,109 (Howorth et al.).
  • non-intumescent mats comprised of polycrystalline ceramic fibers and binder have been used especially for the so-called ultra thin-wall monoliths, which have significantly lower strength due to their extremely thin cell walls.
  • Examples of non-intumescent mats are described in, for example, U.S. Pat. Nos. 4,011,651 (Bradbury et al.), 4,929,429 (Merry), 5,028,397 (Merry), 5,996,228 (Shoji et al.), and 5,580,532 (Robinson et al.).
  • Polycrystalline fibers are much more expensive than normal, melt formed ceramic fibers and, therefore, mats using these fibers are only used where absolutely necessary as, for example, with ultra thin-wall monoliths.
  • US 5,290,522 describes a catalytic converter having a non-woven, mounting mat comprising at least 60 % by weight shot-free high strength magnesium aluminosilicate glass fibers having a diameter greater than 5 micrometers.
  • the mounting mats taught in this reference are primarily intended for use in high temperature applications as can be seen from the test data in the examples where the mats are subjected to exhaust gas temperatures of more than 700°C.
  • US 5,380,580 describes a flexible non-woven mat comprising shot-free ceramic oxide fibers selected from the group consisting of (a) aluminosilicate fibers comprising aluminum oxide in the range from 60 to about 85 % by weight and silicon oxide in the range of 40 to about 15 % by weight silicon oxide, based on the total weight of said aluminosilicate -based fibers, said aluminosilicate-based fibers being at least 20 % by weight crystalline (b) crystalline quartz fibers and (c) mixtures of (a) and (b), and wherein the combined weight of said aluminosilicate-based fibers and said crystalline quartz fibers is at least 50 % by weight of the total weight of said non-woven mat.
  • shot-free ceramic oxide fibers selected from the group consisting of (a) aluminosilicate fibers comprising aluminum oxide in the range from 60 to about 85 % by weight and silicon oxide in the range of 40 to about 15 % by weight silicon oxide, based on the total weight
  • the flexible non-woven mat can additionally comprise high strength fibers selected from the group consisting of silicon carbide fibers, silicon nitride fibers, carbon fibers, silicon nitride fibers, glass fibers, stainless steel fibers, brass fibers, fugitive fibers, and mixtures thereof.
  • Diesel Oxidation Catalysts are used on modern diesel engines to oxidize the soluble organic fraction (SOF) of the diesel particulate emitted.
  • SOF soluble organic fraction
  • TDI turbo-charged direct injection
  • This temperature is below the temperature needed to expand most intumescent mats. The expansion is needed to develop and maintain appropriate pressure within the catalytic converter. Additionally, this temperature is too low to burn out the organic binder contained in intumescent mat materials. At these temperatures the binder only softens, which acts to interfere with the resiliency of the ceramic fibers.
  • a non-woven and non-intumescent mat comprising at least 90% by weight based on the total weight of the mat of chopped magnesium aluminium silicate glass fibers that have a number average diameter of 5 ⁇ m or more and a length of 0.5 to 15cm, whereby the glass fibers are needle punched or stitch bonded and the mat is free or substantially free of organic binder.
  • substantially free' is meant that the amount of binder is not more than 1% by weight based on the weight of the mat, preferably not more than 0.5% by weight.
  • the mat is used in a pollution control device for the treatment of exhaust from a diesel engine of a machine.
  • the diesel engine may be included in a stationary machine such as for example in a power generator or in a motor vehicle.
  • the mounting mat mounts a diesel pollution control monolith in a metallic casing of the pollution control device and is typically arranged between the metallic casing and the diesel pollution control monolith.
  • a mat for mounting a diesel pollution control monolith in a metallic casing of a pollution control device the mat being a non-intumescent mat comprising at least 90% by weight based on the total weight of the mat of chopped magnesium aluminium silicate glass fibers that have a number average diameter of 5 ⁇ m or more and a length of 0.5 to 15cm, the glass fibers being needle punched or stitch bonded, the mat being free or substantially free of organic binder and being comprised of at least two layers of the chopped magnesium aluminium silicate glass fibers, wherein the two layers are differing in their glass fiber composition.
  • a mat according to this aspect was found to be particularly suitable for optimizing performance and manufacturing cost of a mounting mat for pollution control devices for diesel engine exhaust.
  • a method of treating exhaust gas from a diesel engine by subjecting the exhaust gas to a pollution control device comprising a diesel pollution control monolith arranged in a metallic casing with non-woven mat disposed between the metallic casing and the diesel pollution control monolith, 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 aluminium silicate glass fibers that have a number average diameter of 5 ⁇ m or more and a length of 0.5 to 15cm, said glass fibers being needle punched or stitch bonded and said mat being free or substantially free of organic binder.
  • diesel pollution control monolith is meant a monolithic structure that is suitable for and/or adapted for reducing the pollution caused by exhaust from a diesel engine and in particular includes monolithic structures that are operative in reducing the pollution at low temperatures, e.g. of 350°C or less.
  • Diesel pollution control monoliths include without limitation catalytic converters, diesel particulate traps and NOx absorbers or traps.
  • magnesium aluminium silicate glass fibers' includes glass fibers that comprise oxides of silicon, aluminium and magnesium without excluding the presence of other oxides, in particular other metal oxides.
  • pollution control device 10 comprises metallic casing 11 with generally frusto-conical inlet and outlet ends 12 and 13, respectively.
  • a diesel pollution control monolith 20 e.g. formed of a honeycombed monolithic body having a plurality of gas flow channels (not shown) there through.
  • mounting mat 30 comprising the chopped magnesium aluminosilicate glass fibers which serves to tightly but resiliently support monolithic element 20 within the casing 11.
  • Mounting mat 30 holds diesel pollution control monolith 20 in place in the casing and seals the gap between the diesel pollution control monolith 20 and casing 11 to thus prevent or minimize diesel exhaust gases from by-passing diesel pollution control monolith 20.
  • the metallic casing can be made from materials known in the art for such use including stainless steel.
  • Examples of diesel pollution control monoliths for use in the pollution control device 10 include catalytic converters and diesel particulate filters or traps.
  • Catalytic converters contain a catalyst, which is typically coated on a monolithic structure mounted within a metallic housing.
  • the catalyst is typically adapted to be operative and effective and low temperature, typically not more than 350°C.
  • the monolithic structures are typically ceramic, although metal monoliths have also been used.
  • the catalyst oxidizes carbon monoxide and hydrocarbons and reduces the oxides of nitrogen in exhaust gases to control atmospheric pollution. While in a gasoline engine all three of these pollutants can be reacted simulataneously in a so-called "three way converter", most diesel engines are equipped with only a diesel oxidation catalytic converter.
  • Catalytic converters for reducing the oxides of nitrogen which are only in limited use today for diesel engines, generally consist of a separate catalytic converter.
  • Suitable ceramic monoliths used as catalyst supports are commercially available from Corning Inc. (Corning N.Y) under the trade name of "CELCOR” and commercially available from NGK Insulated Ltd (Nagoya, Japan) under the trade name of "HONEYCERAM", respectively.
  • Diesel particulate filters or traps are typically wall flow filters, which have honeycombed, monolithic structures typically made from porous crystalline ceramic materials. Alternate cells of the honeycombed structure are typically plugged such that exhaust gas enters in one cell and is forced through the porous wall to an adjacent cell where it can exit the structure. In this way, the small soot particles that are present in diesel exhaust gas are collected.
  • Suitable Diesel particulate filters made of cordierite are commercially available from Coming Inc. (Corning N.Y.) and NGK Insulated Inc. (Nagoya, Japan). Diesel particulate filters made of Silicon Carbide are commercially available from Ibiden Co. Ltd. (Japan) and are described in, for example, JP 2002047070A .
  • the magnesium aluminium silicate glass fibers used in the non-woven mounting mat have an average diameter of at least 5 ⁇ m and a length between 0.5 and 15cm, preferably between 1 and 12cm. Preferably, the average diameter will be at least 7 ⁇ m and is typically in the range of 7 to 14 ⁇ m.
  • the glass fibers are preferably individualized.
  • a tow or yarn of fibers can be chopped, for example, using a glass roving cutter (commercially available, for example, under the trade designation "MODEL 90 GLASS ROVING CUTTER” from Finn & Fram, Inc., of Pacoma, Calif.), to the desired length (typically in the range from about 0.5 to about 15 cm).
  • the fibers typically are shot free or contain a very low amount of shot, typically less than 1% by weight based on total weight of fibers.
  • the fibers are typically reasonably uniform in diameter, i.e. the amount of fibers having a diameter within +/- 3 ⁇ m of the average is generally at least 70% by weight, preferably at least 80% by weight and most preferably at least 90% by weight of the total weight of the magnesium aluminium silicate glass fibers.
  • the mat may contain up to 10% by weight of fibers other than magnesium aluminium silicate glass fibers.
  • the mat will consist of only magnesium aluminium silicate glass fibers. If other fibers are contained in the mat, they will typically be amorphous fibers and they should preferably also have an average diameter of at least 5 ⁇ m.
  • the mat will be free or essentially free of fibers that have a diameter of 3 ⁇ m or less, more preferably the mat will be free or essentially free of fibers that have a diameter of less than 5 ⁇ m. Essentially free here means that the amount of such small diameter fibers is not more than 2% by weight, preferably not more than 1% by weight of the total weight of fibers in the mat.
  • the cut or chopped fibers can be separated by passing them through a conventional two zone Laroche Opener (e.g. commercially available from Laroche S.A., Cours la Ville, France) .
  • the fibers can also be separated by passing them through a hammer mill, preferably a blow discharge hammer mill (e.g., commercially available under the trade designation "BLOWER DISCHARGE MODEL 20 HAMMER MILL” from C.S. Bell Co. of Tiffin, Ohio).
  • a blow discharge hammer mill e.g., commercially available under the trade designation "BLOWER DISCHARGE MODEL 20 HAMMER MILL" from C.S. Bell Co. of Tiffin, Ohio.
  • the fibers can be individualized using a conventional blower such as that commercially available under the trade designation "DAYTON RADIAL BLOWER," Model 3C 539, 31.1 cm (12.25 inches), 3 horsepower from W. W.
  • the chopped fibers normally need only be passed through the Laroche Opener once. When using the hammer mill, they generally must be passed though twice. If a blower is used alone, the fibers are typically passed through it at least twice. Preferably, at least 50 percent by weight of the fibers are individualized before they are formed into a nonwoven mat.
  • cut or chopped fibers greater than about 15 cm are also useful in preparing the nonwoven mat, they tend to be more difficult to process. Separation of the fibers tends to increase the loftiness (i.e., decrease the bulk density) of the fibers making up the nonwoven mat thereby lowering the density of the resulting mat.
  • an antistatic lubricant e.g., such as that commercially available under the trade designation "NEUTROSTAT” from Simco Co. Inc., of Hatfield, N.J.
  • a commercially available under the trade designation "NEUTROSTAT” from Simco Co. Inc., of Hatfield, N.J.
  • the magnesium aluminium silicate glass fibers preferably comprise between 10 and 30% by weight of aluminium oxide, between 52 and 70% by weight of silicium oxide and between 1 and 12 % of magnesium oxide.
  • the weight percentage of the aforementioned oxides are based on the theoretical amount of Al 2 O 3 , SiO 2 and MgO.
  • the magnesium aluminium silicate glass fiber may contain additional oxides.
  • additional oxides that may be present include sodium or potassium oxides, boron oxide and calcium oxide.
  • magnesium aluminium silicate glass fibers include E-glass fibers which typically have a composition of about 55% of SiO 2 , 11% of Al 2 O 3 , 6% of B 2 O 3 , 18% of CaO, 5% of MgO and 5% of other oxides; S and S-2 glass fibers which typically have a composition of about 65% of SiO 2 , 25% of Al 2 O 3 and 10% of MgO and R-glass fibers which typically have a composition of 60% of SiO 2 , 25% of Al 2 O 3 , 9% of CaO and 6% of MgO.
  • E-glass, S-glass and S-2 glass are available for example from Advanced Glassfiber Yarns LLC and R-glass is available from Saint-Gobain Vetrotex.
  • chopped, individualized fibers are fed into a conventional web-forming machine (commercially available, for example, under the trade designation "RANDO WEBBER” from Rando Machine Corp. of Ard, N.Y.; or "DAN WEB” from ScanWeb Co. of Denmark), wherein the fibers are drawn onto a wire screen or mesh belt (e.g., a metal or nylon belt).
  • a "DAN WEB”-type web-forming machine the fibers are preferably individualized using a hammer mill and then a blower. Fibers having a length greater than about 2.5 cm tend to become entangled during the web formation process.
  • the mat can be formed on or placed on a scrim.
  • the resulting mat typically has sufficient handleability to be transferred to a needle punch machine without the need for a support (e.g., a scrim).
  • the nonwoven mat can also be made using conventional wet-forming or textile carding.
  • the fiber length is preferably about 0.5 to about 6 cm.
  • the fiber length is preferably about 5 to about 10 cm.
  • a needle-punched nonwoven mat refers to a mat wherein there is physical entanglement of fibers provided by multiple full or partial (preferably, full) penetration of the mat, for example, by barbed needles.
  • the nonwoven mat can be needle punched using a conventional needle punching apparatus (e.g., a needle puncher commercially available under the trade designation "DILO" from Dilo of Germany, with barbed needles (commercially available, for example, from Foster Needle Company, Inc., of Manitowoc, Wis.)) to provide a needle-punched, nonwoven mat.
  • Needle punching which provides entanglement of the fibers, typically involves compressing the mat and then punching and drawing barbed needles through the mat.
  • the nonwoven mat is needle punched to provide about 5 to about 60 needle punches/cm 2 .
  • the mat is needle punched to provide about 10 to about 20 needle punches/cm 2 .
  • the needle-punched, nonwoven mat has a weight per unit area value in the range from about 1000 to about 3000 g/m 2 , and in another aspect a thickness in the range from about 0.5 to about 3 centimeters.
  • Typical bulk density under a 5 kPA load is in the range 0.1 - 0.2 g/cc.
  • the nonwoven mat can be stitchbonded using conventional techniques (see e.g., U.S. Pat. No. 4,181,514 (Lefkowitz et al.), the disclosure of which is incorporated herein by reference for its teaching of stitchbonding nonwoven mats).
  • the mat is stitchbonded with organic thread.
  • a thin layer of an organic or inorganic sheet material can be placed on either or both sides of the mat during stitchbonding to prevent or minimize the threads from cutting through the mat.
  • an inorganic thread such as ceramic or metal (e.g., stainless steel) can be used.
  • the spacing of the stitches is usually from 3 to 30 mm so that the fibers are uniformly compressed throughout the entire area of the mat.
  • the mat may be comprised of a plurality of layers of the magnesium aluminium silicate glass fibers.
  • Such layers may be distinguished from each other in the average diameter of the fibers used, the length of the fibers used and/or the chemical composition of the fibers used. Since the heat resistance and mechanical strength of fibers at temperature vary with their composition and to a lesser degree fiber diameter, fiber layers can be selected to optimize performance while minimizing cost.
  • a nonwoven mat consisting of a layer of S-2 glass combined with a layer of E-glass can be used to mount a diesel catalytic converter.
  • the S-2 glass layer is placed directly against the hotter, monolith side of the catalytic converter while the E-glass layer is against the cooler, metal housing side of the catalytic converter.
  • the layered combination mat can withstand considerably higher temperatures than a mat consisting of only E-glass fibers at greatly reduced cost compared to a mat consisting of only S-2 glass fibers.
  • the layered mats are made by first forming the individual non-woven layers having a specific type of fiber using the forming techniques described earlier. These layers are then needle bonded together to form the finished mat having the desired discrete layers.
  • the mounting mats of the invention are particularly suitable for mounting a diesel pollution control monolith in a pollution control device.
  • the mount density of the mat i.e. the bulk density of the mat after assembly, should be at least 0.2 g/cm 3 to provide sufficient pressure to hold the monolith securely in place.
  • the mount density should be between about 0.25 g/cm 3 and 0.45 g/cm 3 .
  • the pollution control device has excellent performance characteristics for use in low temperature applications such as in the treatment of diesel engine exhaust.
  • the pollution control device may be used in a stationary machine to treat the exhaust emerging from a diesel engine contained therein. Such stationary machines include for example power sources for generating electricity or pumping fluids.
  • the pollution control device is in particular suitable for the treatment of exhaust from diesel engines in motor vehicles.
  • motor vehicles include trains, buses, trucks and 'low capacity' passenger vehicles.
  • 'low capacity' passenger vehicles is meant a motor vehicle that is designed to transport a small number of passengers, typically not more than 15 persons. Examples thereof include cars, vans and so-called mono-volume cars.
  • the pollution control device is particularly suitable for the treatment of exhaust from turbo charged direct injection diesel engines (TDI) which are more and more frequently used in motor vehicles in particular in Europe.
  • TDI turbo charged direct injection diesel engines
  • This test models actual conditions found in a pollution control device with a monolith or diesel particulate trap during typical use, and measures the pressure exerted by the mounting material under those modelled use conditions.
  • the RCFT method is described in detail in Material Aspects in Automotive Pollution control devices, ed. Hans Bode, Wiley-VCH, 2002, pp.- 206-208 .
  • the hot vibration test was used to further evaluate the suitability of the mounting mat according to the present invention as a mounting mat for a low temperature, pollution control device for diesel engines.
  • the hot vibration test involved passing exhaust gas through a pollution control device element mounted with a mounting mat in a metallic casing (referred to as a test assembly below) while simultaneously subjecting the converter assembly to mechanical vibration sufficient to serve as an accelerated durability test.
  • test assembly comprised :
  • a conventional shaker table (commercially available from Unholtz-Dickie Corp. of Wallingford, Conn./USA) was employed to provide vibration to the test assembly.
  • the heat source comprised a natural gas burner capable of supplying gas inlet temperature to the converter of up to 1000° C.
  • the converter was equipped with a thermocouple to measure the interface temperature between the outside surface of the monolith and the inside surface of mounting mat.
  • the exhaust gas temperature was cycled (raised and lowered repeatedly) so as to put extra stress on the mounting mat material.
  • a 15-hour thermal conditioning stage was carried out before the shaking segment of the test was started.
  • the thermal conditioning stage consisted of 5 cycles of two hours at a selected elevated temperature followed by 1 hour at 50 °C.
  • vibration on random type vibration was employed to generate further stress and simulate accelerated ageing of the test assembly under use conditions.
  • the vibration began at a vibration level of 1.75 g (in this vibration test, 'g' represents the force of gravity) on a random .01 g2 / Hz (approximately 10 g peak).
  • the vibration was continued for 3 hours at the selected elevated temperature and then stopped.
  • the test assembly was allowed to cool to 50° C and held there for 1 hour without shaking.
  • the vibration level was then doubled (i.e. 3.5 g sine on .02 g 2 / hz random) as the test assembly was heated for an additional 3 hours at temperature.
  • the vibration was then stopped for a second hour and cooling to and holding at 50° C.
  • the vibration parameters just described were doubled and the cycle (comprising 3 hrs shaking at the selected elevated temperature and 1 hour at 50° C) was repeated.
  • the vibration parameters were again doubled, for a total 4 steps, i.e. until vibration parameters comprising a sine of 28 g's on 0.16 g 2 / hz random (approximately 61 g peak) were attained.
  • the test assembly was subjected further to the last set of vibration parameters until test assembly failure was noted or until at least 14 cycles at 28 g's sine on 0.16 g 2 / hz random was reached.
  • the test apparatus for the Cyclical Compression Test comprised: a) a commercially available test instrument (commonly known as a tensile tester) comprising a lower fixed portion and an upper portion movable apart from the lower portion in the vertical direction at a rate defined as the "crosshead speed" and bearing a load cell capable of measuring forces up to 30 kN ( MTS TM Model Alliance RT/30, available from Material Test Systems, Cary, North carolina), b) a first quartz tube (50.8 mm in diameter x 20 cm long) attached in a vertical manner to the fixed lower portion of the instrument, c) a second quartz tube (50.8 mm in diameter x 20 cm long) attached in a vertical manner to the load cell on the upper portion of the instrument, d) a thermocouple extended through the upper quartz tube to make contact with the test assembly and e) an electrically heated oven having a brick lining bearing a tubular hole arranged such that it intimately surrounded the portions of the two quartz tubes nearest one another.
  • the test assembly consisted of three discs superimposed upon one another:
  • test assembly was placed between the upper end of the lower quartz tube and the lower end of the upper quartz tube in a manner such that the three discs of the test assembly were arranged vertically with relation to each other.
  • the gap distances were selected so that the mounting mat sample to be tested had a density corresponding to the recommended mount density for a given material at the smaller "gap 1" and at the "larger gap 2" a density of 10 % above the density at smaller "gap 1", these parameters being selected based on mat densities commonly encountered when mounting mats are employed under actual use conditions.
  • the two gap distances thus selected were then programmed into the instrument, the oven was closed around the test assembly and heated to and held at 250° C, and finally the instrument was programmed to repeatedly move from one gap distance to the other, thus repeatedly increasing and decreasing pressure on the sample disc located in the test assembly between the two quartz discs.
  • the cross-head speed was 5.0 mm/min and there was essentially no dwell time at either of the "gap 1" or "gap 2" positions.
  • the pressure exerted by the sample disc at any one time was recorded in units of kilo Pascal (kPa).
  • the compression cycle was repeated 1000 times.
  • S-2 glass fibers 40 liters of S-2 glass fibers of approximately 9 ⁇ m in average diameter and 2.54cm in length were obtained from Advanced Glassfiber Yarns LLC (AGY). The fibers were essentially shot free.
  • the glass fibers were opened in a two-zone Laroche opener.
  • the first zone had a feed speed of 2 m/min and a Lickerin roll speed of 2,500 rev/min.
  • the second zone had a feed speed of 4 m/min and a Lickerin roll speed of 2,500 rev/min.
  • the output speed was 6.5 m/min.
  • the opened fibers were then fed into a conventional web-forming machine (commercially available under the trade designation "Rando Webber” from Rando Machine Corp. of Ard, N.Y., wherein the fibers were blown onto a porous metal roll to form a continuous web.
  • the continuous web was then needle-bonded on a conventional needle tacker.
  • the needle speed was 100 cycles/min and the output speed was 1.1 m/min.
  • the "weight per area" of the mounting mat could be adjusted as desired. In tests where the value of "weight per area" substantially influences the test results, this parameter is indicated along with the test results.
  • Table 1 The composition of the mounting mat of Example 1 is summarized in Table 1 below.
  • Example 1 The mat of Example 1 was tested according to the RCFT method described above under Test Methods. A family of three data curves was generated, representing each of three cycles. The mounting mats of Example 1 displayed a very uniform pressure over the temperature range examined and provided a pressure well above the minimum pressure ( about 40 kPa) needed to hold the monolith securely in place.
  • the RCFT data for Example 1 are shown in figure 2 .
  • the X-axis represents the temperature scale for the simulated monolith temperature and the simulated skin temperature.
  • the temperature range represented in figure 1 was from 20 to 300°C at the line indicated with 'A' and from 300 (indicated by the line 'B') back to 50°C.
  • the ranges were respectively 20 to 100°C and 100°C to 25°C.
  • the interval between lines A and B indicates a period of 15 minutes for which the sample was held at the maximum temperature.
  • the Y-axis represents the pressure measured.
  • the scale was from 0 to 500 kPa.
  • Curve 1 to 3 represent the results of the 1 st to 3 rd cycle respectively. An adequate holding force over the entire temperature range tested was found as can be seen in figure 2 .
  • Example 1 was also subjected to the Hot Vibration Test as described above under Test Methods.
  • the Hot Vibration Test was performed at two temperatures: 300 ° C and 500° C, respectively. At 300° C, the mat of Example 1 had not failed after 72 hours. At 500° C, Example 1 had not failed after 80 hours. Hot Vibration Test results are summarized below in Table 2.
  • Example 2 was prepared by the method described in Example 1 with the exception that E-glass fibers (chopped glass strands, diameter 9 ⁇ m, chopped to a length of 1 inch (25.4 mm) available from Advanced Glassfiber Yarns LLC (AGY), Aiken, South Carolina/USA) were employed.
  • E-glass fibers chopped glass strands, diameter 9 ⁇ m, chopped to a length of 1 inch (25.4 mm) available from Advanced Glassfiber Yarns LLC (AGY), Aiken, South Carolina/USA.
  • AGY Advanced Glassfiber Yarns LLC
  • Example 2 Tests on the mat of Example 2 include the Cyclical Compression Test. Results are summarized in Table 3 and show that at diesel pollution control device temperatures (i.e. average mat temperature of 250 °C), the mat keeps 86.3 % of its original pressure after 1000 compression cycles. Example 2 was also tested in the RCFT using the same conditions as used in example 1. Example 2 maintained adequate holding force over the entire temperature range.
  • R-glass fibers 60 % SiO 2 , 25 % Al 2 O 3 , 9% CaO, and 6 % MgO having a diameter of ca. 10 ⁇ m, chopped to a length of 36 mm, obtained from Saint-Gobain Vetrotex, were processed into a web by the method described in Example 1.
  • the composition of the mat of Example 4 is summarized in Table 1.
  • Tests on the R-glass mat of Example 3 include the Cyclical Compression Test. Results are summarized in Table 3 below and show that at diesel pollution control device temperatures (i.e. average mat temperature of 250 °C), the mat keeps 95.5 % of its original pressure after 1000 compression cycles.
  • Example 3 was performed on the mat of Example 3 in the same way as for the mat of example 1 except that the simulated temperature range for the monolith was from 25°C to 500°C and 25 to 200°C for the skin. Example 3 maintained adequate holding force over the entire temperature range.
  • a two layer mat was prepared by laminating two separately prepared layers together.
  • the first layer comprised R-glass.
  • the second layer comprised E-glass.
  • the two layers were put together by needle-bonding.
  • the mounting mat formed in this manner had two discrete layers of glass of differing compositions.
  • the composition of the two layer mat of Example 4 is summarized in Table 1.
  • Example 4 The two layer mat of Example 4 was subjected to the RCFT Test using the temperature conditions of example 3.
  • a two layer mat was prepared by laminating two separately prepared layers together.
  • the first layer comprised S-2 glass.
  • the second layer comprised E-glass.
  • the two layers were put together by needle bonding.
  • the mounting mat formed in this manner had two discrete layers of glass of differing compositions.
  • the composition of the mat of Example 5 is summarized in Table 1.
  • Example 5 was subjected to the Cyclical Compression Test. Results are summarized in Table 3 and show that at diesel converter temperatures (i.e. average mat temperature of 250 °C), the mat keeps 82.2% of its original pressure after 1000 compression cycles.
  • Comparative Example 1 (C1) comprised a binder-free, non-woven fiber mat made of Belcotex silica fibers having a fiber diameter of 9 microns, obtained from Belchem Fiber Materials GmbH, Brand-Erbisdorf, Germany.
  • Comparative Example 2 comprised a non-woven, binder-free fiber mat made of silica fibers commercially available under the name Silcosoft TM from BGF industries in Altvista, Virginia.
  • the fibers in the mat have an average diameter of 9 microns.
  • Comparative Example 3 comprised a commercially available intumescent pollution control device mounting mat. It comprises about 55 % unexpanded vermiculite, about 37 % fiber, and about 8 % organic binder. The fibers are melt-formed, amorphous, shot-containing alumina/silica fibers having a diameter of about 2-3 microns having a length of not more than 0.5 inch.
  • Comparative Example 3 was tested according to the Hot Vibration Test at 300° C. The sample failed after 8 hours. Hot Vibration Test results are summarized in Table 2 Comparitive Example 3 was also tested in the Cyclical Compression Test. Results are shown in Table 3 and show that at diesel pollution control device temperatures (i.e. average mat temperature of 250 °C), the mat keeps only 25.3 % of its original pressure after 1000 cycles which is unacceptably low. Comparitive Example 3 was also tested in the RCFT test using the temperature conditions of example 1. An unacceptably low holding force already after the first cycle was noted.
  • Comparative Example 4 comprised a reduced vermiculite intumescent pollution control device mounting mat that is commercially available. It comprised about 37 % unexpanded vermiculite, about 54 % fiber, and about 9 % organic binder. The fibers were the same as those of comparative example 3.
  • Comparative Example 4 was tested according to the Hot Vibration Test at both 300° C and 500° C. The sample failed after 8 hours at 300° C and failed after 18 hours at 500° C. Hot Vibration Test results are summarized in Table 2.
  • Comparative Example 5 comprised a wet laid mat prepared from melt-formed, amorphous, shot containing alumina silicate fibers available as Kaowool Bulk Fibers from Thermal Ceramics in Augusta, Georgia.
  • the fibers have a diameter of 2- 3 microns and a length of about 0.5 inch.
  • Comparative Example 5 was tested according to the Cyclical Compression Test described above under Test Methods and exhibited a percent retention of 49.8% which is unacceptable for use in a pollution control device for diesel engines. Cyclical Compression Test results are summarized in Table 3.
  • Comparative Example 6 comprised "a non-woven binder-free mat material" commercially available from Thermal Ceramics UK Lmtd. Wirrel, Merseyside, England as Ultrafelt TM Paper having a density of 12 lb/ft3 (0.2 g/cm 3 )
  • the mat is a needle bonded mat of alumina/silica fibers (47% Al 2 O 3 and 53% SiO 2 ). According to the technical data sheet of the manufacturer of the mat, the fibers would have a length that is longer than typically used in paper making. This would indicate the fibers would have a length of more than 0.5 inch.
  • Comparative Example 6 was also tested according to the Cyclical Compression Test described above under Test Methods and exhibited a percent retention of 41.2%, which is unacceptable low. Cyclical Compression Test results are summarized in Table 3.
  • Comparative Example 7 comprised a commercially available non-intumescent pollution control device mounting mat made of high alumina polycrystalline ceramic fibers.
  • the fibers are essentially shot-free and have an average diameter of 3 microns.
  • Comparative Example 7 was also tested according to the Cyclical Compression Test described above under Test Methods and exhibited a percent retention of 81.1 %. Cyclical Compression Test results are summarized in Table 3. Retention force of these very expensive fibers were acceptable, but not as good as the present invention.
  • Table 2 Summary of results from the hot vibration test Ex. Mount Density (g/cm 3 ) Peak Temp.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Inorganic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Filtering Of Dispersed Particles In Gases (AREA)
  • Glass Compositions (AREA)
  • Processes For Solid Components From Exhaust (AREA)
  • Nonwoven Fabrics (AREA)
EP02078103A 2002-07-31 2002-07-31 Mat for mounting a pollution control monolith in a pollution control device for the treatment of exhaust gas of a diesel engine powered machine Expired - Lifetime EP1388649B1 (en)

Priority Applications (13)

Application Number Priority Date Filing Date Title
AT02078103T ATE419456T1 (de) 2002-07-31 2002-07-31 Matte für die lagerung einer monolithen reinigungsvorrichtung in einer abgasreinigungsvorrichtung für die behandlung von abgasen einer dieselbrennkraftmaschine
EP02078103A EP1388649B1 (en) 2002-07-31 2002-07-31 Mat for mounting a pollution control monolith in a pollution control device for the treatment of exhaust gas of a diesel engine powered machine
DE60230603T DE60230603D1 (de) 2002-07-31 2002-07-31 Matte für die Lagerung einer monolithen Reinigungsvorrichtung in einer Abgasreinigungsvorrichtung für die Behandlung von Abgasen einer Dieselbrennkraftmaschine
US10/522,492 US7704459B2 (en) 2002-07-31 2003-07-08 Mat for mounting a pollution control element in a pollution control device for the treatment of exhaust gas
PCT/US2003/021455 WO2004011785A1 (en) 2002-07-31 2003-07-08 Mat for mounting a pollution control element in a pollution control device for the treatment of exhaust gas
CN03820939XA CN1678821B (zh) 2002-07-31 2003-07-08 将污染控制元件安装在处理废气的污染控制装置中的垫片
JP2004524580A JP4575159B2 (ja) 2002-07-31 2003-07-08 ディーゼルエンジン排気ガス装置用の汚染制御装置及び汚染制御装置において汚染制御要素を実装するためのマット
BRPI0313074-6A BR0313074B1 (pt) 2002-07-31 2003-07-08 emaranhado para montagem de um elemento de controle de poluição em um invólucro de um dispositivo de controle de poluição, dispositivo de controle de poluição, máquina e método de tratar gás de escapamento de um motor a diesel.
AU2003247946A AU2003247946A1 (en) 2002-07-31 2003-07-08 Mat for mounting a pollution control element in a pollution control device for the treatment of exhaust gas
KR1020057001725A KR101037241B1 (ko) 2002-07-31 2003-07-08 배기 가스 처리용 공해 제어 장치에 공해 제어 요소를 장착하기 위한 매트
MXPA05001251A MXPA05001251A (es) 2002-07-31 2003-07-08 Placa para montar elemento de control de la contaminacion en dispostivo de control de la contaminacion para el tratamiento de gas de escape.
EP03771589A EP1561018A1 (en) 2002-07-31 2003-07-08 Mat for mounting a pollution control element in a pollution control device for the treatment of exhaust gas
ZA200501650A ZA200501650B (en) 2002-07-31 2005-02-24 Mat for mounting a pollution control element in a pollution control device for the treatment of exhaust gas

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP02078103A EP1388649B1 (en) 2002-07-31 2002-07-31 Mat for mounting a pollution control monolith in a pollution control device for the treatment of exhaust gas of a diesel engine powered machine

Publications (2)

Publication Number Publication Date
EP1388649A1 EP1388649A1 (en) 2004-02-11
EP1388649B1 true EP1388649B1 (en) 2008-12-31

Family

ID=30129223

Family Applications (2)

Application Number Title Priority Date Filing Date
EP02078103A Expired - Lifetime EP1388649B1 (en) 2002-07-31 2002-07-31 Mat for mounting a pollution control monolith in a pollution control device for the treatment of exhaust gas of a diesel engine powered machine
EP03771589A Withdrawn EP1561018A1 (en) 2002-07-31 2003-07-08 Mat for mounting a pollution control element in a pollution control device for the treatment of exhaust gas

Family Applications After (1)

Application Number Title Priority Date Filing Date
EP03771589A Withdrawn EP1561018A1 (en) 2002-07-31 2003-07-08 Mat for mounting a pollution control element in a pollution control device for the treatment of exhaust gas

Country Status (11)

Country Link
EP (2) EP1388649B1 (zh)
JP (1) JP4575159B2 (zh)
KR (1) KR101037241B1 (zh)
CN (1) CN1678821B (zh)
AT (1) ATE419456T1 (zh)
AU (1) AU2003247946A1 (zh)
BR (1) BR0313074B1 (zh)
DE (1) DE60230603D1 (zh)
MX (1) MXPA05001251A (zh)
WO (1) WO2004011785A1 (zh)
ZA (1) ZA200501650B (zh)

Families Citing this family (29)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU2002335798A1 (en) 2001-10-09 2003-04-22 3M Innovative Properties Company Compositions containing biosoluble inorganic fibers and micaceous binders
EP1669485A4 (en) * 2003-09-03 2008-03-05 Paramount Glass Mfg Co Ltd GLASS WOOL SHAPED ARTICLE AND METHOD FOR PRODUCING THE SAME
US7550118B2 (en) 2004-04-14 2009-06-23 3M Innovative Properties Company Multilayer mats for use in pollution control devices
US7645426B2 (en) 2004-04-14 2010-01-12 3M Innovative Properties Company Sandwich hybrid mounting mat
CN100462126C (zh) * 2004-05-18 2009-02-18 揖斐电株式会社 蜂窝结构体及废气净化装置
KR101352705B1 (ko) 2004-12-13 2014-02-06 쓰리엠 이노베이티브 프로퍼티즈 컴파니 장착 매트 및 장착 매트를 사용하는 오염 제어 장치
KR20080063394A (ko) 2005-10-13 2008-07-03 쓰리엠 이노베이티브 프로퍼티즈 컴파니 다층 장착 매트와 이 다층 장착 매트를 포함하는 오염 제어장치
KR20170124608A (ko) 2005-10-19 2017-11-10 쓰리엠 이노베이티브 프로퍼티즈 컴파니 다층 장착 매트와 이 다층 장착 매트를 포함하는 오염 제어 장치
US7682578B2 (en) 2005-11-07 2010-03-23 Geo2 Technologies, Inc. Device for catalytically reducing exhaust
US7682577B2 (en) 2005-11-07 2010-03-23 Geo2 Technologies, Inc. Catalytic exhaust device for simplified installation or replacement
GB0525375D0 (en) 2005-12-14 2006-01-18 3M Innovative Properties Co Mounting mat for a pollution control device
US7722828B2 (en) 2005-12-30 2010-05-25 Geo2 Technologies, Inc. Catalytic fibrous exhaust system and method for catalyzing an exhaust gas
WO2007143437A2 (en) 2006-06-01 2007-12-13 3M Innovative Properties Company Multilayer mounting mat
FR2904657B1 (fr) * 2006-08-02 2008-10-31 Faurecia Sys Echappement Dispositif de purification des gaz d'echappement de vehicule automobile.
JP4268182B2 (ja) 2006-09-29 2009-05-27 イビデン株式会社 排気ガス処理装置およびその製造方法
JP2009085091A (ja) * 2007-09-28 2009-04-23 Ibiden Co Ltd マット材、排気ガス処理装置および消音装置
KR101548395B1 (ko) 2007-10-09 2015-08-28 쓰리엠 이노베이티브 프로퍼티즈 컴파니 오염 제어 요소를 장착하기 위한 장착 매트의 제조 방법
JP5869220B2 (ja) 2007-10-09 2016-02-24 スリーエム イノベイティブ プロパティズ カンパニー 無機ナノ粒子を含有するマウンティングマット並びにその作製方法
WO2010062591A1 (en) 2008-11-03 2010-06-03 3M Innovative Properties Company Mounting mat and pollution control device with the same
WO2010062588A1 (en) 2008-11-03 2010-06-03 3M Innovative Properties Company Mounting mat and pollution control device with the same
JP2010168706A (ja) * 2009-01-26 2010-08-05 Ibiden Co Ltd マット材、排気ガス処理装置およびマット材を製造する方法
CN102421598B (zh) 2009-03-13 2014-12-17 3M创新有限公司 垫及带垫装置
JP2011026755A (ja) * 2009-07-01 2011-02-10 Ibiden Co Ltd マット材および排気ガス処理装置
EP2451634A1 (en) * 2009-07-09 2012-05-16 3M Innovative Properties Company Tubular, continuous, seamless, compressible, resilient mounting articles and pollution control devices comprising the same
EP2299074B1 (en) 2009-09-18 2015-08-12 3M Innovative Properties Company Mounting mat
CN102639832B (zh) * 2009-10-13 2017-02-08 3M创新有限公司 非织造垫和使用该非织造垫的污染控制设备
JP5872841B2 (ja) * 2011-10-21 2016-03-01 イビデン株式会社 マット材及び排ガス浄化装置
EP2848720B1 (en) * 2013-09-12 2016-03-02 3M Innovative Properties Company Use of a lubricant in a mounting mat and method for making such a mat
EP3663451A1 (en) * 2018-12-03 2020-06-10 3M Innovative Properties Company Fiber mat for mounting and/or protecting a device

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS63165562A (ja) * 1986-12-27 1988-07-08 電気化学工業株式会社 耐熱性無機繊維成形体及びその製造方法
US5290522A (en) * 1993-01-07 1994-03-01 Minnesota Mining And Manufacturing Company Catalytic converter mounting mat
KR960700371A (ko) * 1993-01-07 1996-01-20 테릴 켄트 퀼리 가요성 부직 매트(flexible nonwoven mat)
US6245301B1 (en) * 1993-08-20 2001-06-12 3M Innovative Properties Company Catalytic converter and diesel particulate filter
US5431992A (en) * 1993-11-05 1995-07-11 Houpt; Ronald A. Dual-glass fibers and insulation products therefrom
US5453116A (en) * 1994-06-13 1995-09-26 Minnesota Mining And Manufacturing Company Self supporting hot gas filter assembly
JPH0893445A (ja) * 1994-09-26 1996-04-09 Isuzu Ceramics Kenkyusho:Kk ディーゼルパティキュレートフィルタ
US5611832A (en) * 1994-09-21 1997-03-18 Isuzu Ceramics Research Institute Co., Ltd. Diesel particulate filter apparatus
GB9615720D0 (en) * 1996-07-26 1996-09-04 Ici Plc Composite mat
ATE289859T1 (de) * 1998-12-08 2005-03-15 Unifrax Corp Amorphe und nicht schwellfähige anorganische faserlatte für vorrichtung zur behandlung von abgasen bei niedrigen teperaturen

Also Published As

Publication number Publication date
JP4575159B2 (ja) 2010-11-04
WO2004011785A1 (en) 2004-02-05
BR0313074B1 (pt) 2012-04-17
CN1678821A (zh) 2005-10-05
EP1561018A1 (en) 2005-08-10
EP1388649A1 (en) 2004-02-11
DE60230603D1 (de) 2009-02-12
MXPA05001251A (es) 2005-06-08
ATE419456T1 (de) 2009-01-15
ZA200501650B (en) 2006-10-25
KR101037241B1 (ko) 2011-05-25
AU2003247946A1 (en) 2004-02-16
JP2006516043A (ja) 2006-06-15
CN1678821B (zh) 2011-06-08
BR0313074A (pt) 2005-07-12
KR20060038349A (ko) 2006-05-03

Similar Documents

Publication Publication Date Title
EP1388649B1 (en) Mat for mounting a pollution control monolith in a pollution control device for the treatment of exhaust gas of a diesel engine powered machine
US7704459B2 (en) Mat for mounting a pollution control element in a pollution control device for the treatment of exhaust gas
US20200199796A1 (en) Mat having long and short inorganic fibers
US9494071B2 (en) Mounting mat for mounting monolith in a pollution control device
KR101134262B1 (ko) 단열된 이중벽을 갖는 배기 시스템 부품
ZA200600185B (en) Mounting mat for a catalytic converter
US7854904B2 (en) Mounting mat for a catalytic converter
JP2015222076A (ja) 実装マット及びこの実装マットを備えた汚染防止装置
WO2010062591A1 (en) Mounting mat and pollution control device with the same

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AT BE BG CH CY CZ DE DK EE ES FI FR GB GR IE IT LI LU MC NL PT SE SK TR

AX Request for extension of the european patent

Extension state: AL LT LV MK RO SI

17P Request for examination filed

Effective date: 20040809

AKX Designation fees paid

Designated state(s): AT BE BG CH CY CZ DE DK EE ES FI FR GB GR IE IT LI LU MC NL PT SE SK TR

17Q First examination report despatched

Effective date: 20041022

17Q First examination report despatched

Effective date: 20041022

GRAP Despatch of communication of intention to grant a patent

Free format text: ORIGINAL CODE: EPIDOSNIGR1

GRAS Grant fee paid

Free format text: ORIGINAL CODE: EPIDOSNIGR3

GRAA (expected) grant

Free format text: ORIGINAL CODE: 0009210

AK Designated contracting states

Kind code of ref document: B1

Designated state(s): AT BE BG CH CY CZ DE DK EE ES FI FR GB GR IE IT LI LU MC NL PT SE SK TR

REG Reference to a national code

Ref country code: GB

Ref legal event code: FG4D

Ref country code: CH

Ref legal event code: EP

REF Corresponds to:

Ref document number: 60230603

Country of ref document: DE

Date of ref document: 20090212

Kind code of ref document: P

REG Reference to a national code

Ref country code: IE

Ref legal event code: FG4D

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: FI

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20081231

Ref country code: NL

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20081231

NLV1 Nl: lapsed or annulled due to failure to fulfill the requirements of art. 29p and 29m of the patents act
PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: ES

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20090411

Ref country code: BE

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20081231

Ref country code: EE

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20081231

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: PT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20090601

Ref country code: SE

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20090331

Ref country code: CZ

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20081231

Ref country code: AT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20081231

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SK

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20081231

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: DK

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20081231

PLBE No opposition filed within time limit

Free format text: ORIGINAL CODE: 0009261

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: NO OPPOSITION FILED WITHIN TIME LIMIT

26N No opposition filed

Effective date: 20091001

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: BG

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20090331

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: MC

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20090731

REG Reference to a national code

Ref country code: CH

Ref legal event code: PL

GBPC Gb: european patent ceased through non-payment of renewal fee

Effective date: 20090731

REG Reference to a national code

Ref country code: FR

Ref legal event code: ST

Effective date: 20100331

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: LI

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20090731

Ref country code: CH

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20090731

Ref country code: FR

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20090731

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: IT

Payment date: 20090727

Year of fee payment: 8

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: GB

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20090731

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: IE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20090731

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: GR

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20090401

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: LU

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20090731

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: IT

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20100731

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: TR

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20081231

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: CY

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20081231

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: DE

Payment date: 20180717

Year of fee payment: 17

REG Reference to a national code

Ref country code: DE

Ref legal event code: R119

Ref document number: 60230603

Country of ref document: DE

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: DE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20200201