Exhaust gas treatment device and method for making the same

• US 7,033,412 B2
• Filed: 09/24/2003
• Issued: 04/25/2006
• Est. Priority Date: 09/30/2002
• Status: Active Grant

• Current Assignee: Unifrax I LLC (ASP Unifrax Holdings, Inc.)
• Original Assignee: Unifrax Corporation (ASP Unifrax Holdings, Inc.)
• Inventors: Kumar, Amit, Ten Eyck, John D., Lacki, Thomas
• Primary Examiner(s): Hopkins, Robert A.
• Application Number:
  US10/669,225
• Publication Number:
  US 20040134172A1
• Time in Patent Office: 944 Days
• Field of Search: 555/23, 55D/IG.30, 602/99, 603/01, 603/11, 422/177, 422/179, 422/221, 422/222
• US Class Current: 55/523
• CPC Class Codes: B01D 2265/024 Mounting aids
• CPC Class Codes: B01D 2279/30 for treatment of exhaust gases from IC Engines
• CPC Class Codes: B01D 46/0001 Making filtering elements
• CPC Class Codes: B01D 46/2422 Mounting of the body within a housing
• CPC Class Codes: B01D 46/2425 characterized by parameters related to the physical properties of the honeycomb structure material
• CPC Class Codes: B01D 46/2498 The honeycomb filter being defined by mathematical relationships
• CPC Class Codes: B01D 53/9454 characterised by a specific device
• CPC Class Codes: C03C 13/005 obtained by leaching of a soluble phase and consolidation
• CPC Class Codes: C03C 2217/71 Photocatalytic coatings
• CPC Class Codes: C03C 25/66 Chemical treatment, e.g. leaching, acid or alkali treatment dehydroxylation C03C25/64
• CPC Class Codes: C03C 3/06 with more than 90% silica by weight, e.g. quartz C03C3/045 takes precedence
• CPC Class Codes: F01N 2330/06 Ceramic, e.g. monoliths
• CPC Class Codes: F01N 2350/02 Fitting ceramic monoliths in a metallic housing
• CPC Class Codes: F01N 3/0211 Arrangements for mounting filtering elements in housing, e.g. with means for compensating thermal expansion or vibration
• CPC Class Codes: F01N 3/2853 using mats or gaskets between catalyst body and housing
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10S 55/30 Exhaust treatment

Abstract

A device (10) for treatment of exhaust gases includes a housing (12); a fragile structure (18) resiliently mounted within the housing (12); and a non-intumescent mounting mat (20) disposed in a gap between the housing (12) and the fragile structure (18). The mounting mat (20) comprises melt-formed, leached glass fibers high in silica content and exerts a minimum holding pressure for holding the fragile structure (18) within the housing (12) of one of (i) at least 10 kPa after 1000 cycles of testing at a hot face temperature of 900° C., a gap bulk density of between 0.3 and 0.5 g/cm³, 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° C., a gap bulk density of between 0.3 and 0.5 g/cm³, and a percent gap expansion of 2 percent.

Claims

1. A device for treatment of exhaust gases comprising:

a housing;

a fragile structure resiliently mounted within said housing; and

a non-intumescent mounting mat disposed in a gap between said housing and said fragile structure, wherein said mounting mat includes melt-formed, leached, and heat treated glass fibers containing at least 67 percent by weight silica wherein said mounting mat exerts a minimum holding pressure for holding said fragile structure within said housing of one of (i) at least about 10 kPa after 1000 cycles of testing at a hot face temperature of about 900°

C., a gap bulk density of from about 0.3 to about 0.5 g/cm³, and a percent gap expansion of about 5 percent, or (ii) at least about 50 kPa after 1000 cycles of testing at a hot face temperature of about 300°

C., a gap bulk density of from about 0.3 to about 0.5 g/cm³, and a percent gap expansion of about 2 percent.

2. The device of claim 1, wherein said housing has an inlet at one end and an outlet at an opposite end through which exhaust gases flow;

and wherein said fragile structure has an outer surface, an inlet end surface at one end in communication with said inlet of said housing and an outlet end surface at an opposite end in communication with said outlet end of said housing.

3. The device of claim 1, wherein said mounting mat comprises at least one integral, substantially non-expanding ply comprising melt-drawn, leached glass fibers containing silica.

4. The device of claim 1, wherein said leached glass fibers contain at least 90 percent by weight silica.

5. The device of claim 1, wherein said leached glass fibers contain from about 90 to less than 99 percent by weight silica.

6. The device of claim 1, wherein said leached glass fibers contain from about 93 to about 95 percent by weight silica and from about 4 to about 6 percent by weight alumina.

7. The device of claim 1, wherein said leached glass fibers contain less than about 1 percent by weight alkali or alkaline earth metals.

8. The device of claim 1, wherein said mounting mat comprises from about 50 to 100 percent by weight of said leached glass fibers.

9. The device of claim 1, wherein said mounting mat comprises at least 80 percent by weight of said leached glass fibers.

10. The device of claim 1, wherein the mounting mat is substantially free of binder.

11. The device of claim 1, wherein the leached glass fibers have a diameter greater than 3.5 microns.

12. The device of claim 1, wherein the leached glass fibers have a diameter greater than 5 microns.

13. The device of claim 1, wherein the leached glass fibers are melt drawn.

14. The device of claim 1, wherein the leached glass fibers are substantially shot free.

15. The device of claim 1, wherein the mounting mat contains greater than 0 to about 50 weight percent, based upon 100 percent by weight of the total mat, of S2-glass fibers or refractory ceramic fibers.

16. The device of claim 1, wherein the mounting mat is heat treated at a temperature of at least about 900°

C. for an effective period of time to meet the effective minimum holding pressure for holding the fragile structure within the housing.

17. The device of claim 1, wherein the leached glass fibers prior to the formation of the mounting mat are heat treated at a temperature of at least about 900°

C. for an effective period of time such that the leached glass fibers, when formed into the mounting mat, meet the minimum holding pressure for holding the fragile structure within the housing.

18. The device of claim 1, wherein the device is a catalytic converter or diesel particulate trap.

19. A method of making a device for treating exhaust gases, comprising:

providing a mounting mat comprising melt-formed glass fibers containing silica, wherein the melt-formed glass fibers are formed by

treating the melt-formed glass fibers whereby the treated glass fibers have a silica content greater than the silica content of the glass fibers prior to being treated and whereby the treated glass fibers contain at least 67 percent by weight silica;

heat treating the leached glass fibers prior to formation of the mounting mat, or heat treating the mounting mat, prior to wrapping the fragile structure;

wrapping the mounting mat around a fragile structure adapted for treating exhaust gases; and

disposing the fragile structure and the mounting mat within a housing, whereby the mounting mat holds the fragile structure resiliently within the housing, and wherein the mounting mat exerts a minimum holding pressure for holding said fragile structure within said housing of one of (i) at least about 10 kPa after 1000 cycles of testing at a hot face temperature of about 900°

C., a gap bulk density of from about 0.3 to about 0.5 g/cm³, and a percent gap expansion of about 5 percent, or (ii) at least about 50 kPa after 1000 cycles of testing at a hot face temperature of about 300°

C., a gap bulk density of from about 0.3 to about 0.5 g/cm³, and a percent gap expansion of about 2 percent.

20. The method of claim 19, wherein the step of treating the melt drawn glass fibers includes leaching the glass fibers in an acid solution.

21. The method of claim 19, wherein the step of heat treating comprises heating the fibers or mounting mat at a temperature between about 900°

C. and about 1100°

C., for greater than 1 hour.

22. The method of claim 19, wherein the step of heat treating comprises heating the fibers or mounting mat at a temperature of at least about 900°

C. for an effective period of time to meet the effective minimum holding pressure for holding the fragile structure within the housing.