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 ar
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.
대표청구항▼
What is claimed is: 1. A multilayer mat comprising: an intumescent layer having opposite outer edges, opposite ends, a first major surface and a second major surface opposite the first major surface, said intumescent layer having an area A1; a first non-intumescent layer facing the first major surf
What is claimed is: 1. A multilayer mat comprising: an intumescent layer having opposite outer edges, opposite ends, a first major surface and a second major surface opposite the first major surface, said intumescent layer having an area A1; a first non-intumescent layer facing the first major surface of said intumescent layer, said first non-intumescent layer comprising inorganic fibers and said first non-intumescent layer having opposite outer edges, opposite ends, and an area A2 that is greater than area A1, wherein said first non-intumescent layer has a major surface facing said intumescent layer with a first trough in said major surface, and wherein said intumescent layer is positioned in said first trough; and a second non-intumescent layer facing the second major surface of said intumescent layer, said second non-intumescent layer comprising inorganic fibers and said second non-intumescent layer having opposite outer edges, opposite ends, and an area A3 that is greater than area A1, wherein said intumescent layer is sandwiched between said first and second non-intumescent layers and positioned entirely within the area A2 of said first non-intumescent layer and the area A3 of said second non-intumescent layer, with at least one of the outer edges of said mat being free of intumescent material. 2. The multilayer mat of claim 1, wherein area A2 is substantially equal to area A3 and said first non-intumescent layer is aligned with said second non-intumescent layer. 3. The multilayer mat of claim 1, wherein said first non-intumescent layer has a length L2 and said second non-intumescent layer has a length substantially equal to length L2 and wherein said first non-intumescent layer has a width W2 and said second non-intumescent layer has a width substantially equal to width W2. 4. The multilayer mat of claim 3, wherein said intumescent layer has a width W1 that is less than W2, said intumescent layer has a length L1 that is substantially equal to L2, and said second non-intumescent layer contacts said first non-intumescent layer along at least one edge of said multilayer mat. 5. The multilayer mat of claim 1, wherein said first non-intumescent layer contacts said second non-intumescent layer along at least one edge of the mat. 6. The multilayer mat of claim 1, wherein said intumescent layer is divided into at least two segments that are separated from each other. 7. The multilayer mat of claim 1, wherein said intumescent layer has a thickness that is 5 to 25 percent of a total mat thickness. 8. The multilayer mat of claim 1, wherein said second non-intumescent layer has a major surface facing said intumescent layer with a second trough in said major surface aligned with the first trough, and wherein said intumescent layer is positioned in the first and the second trough. 9. The multilayer mat of claim 1, wherein said multilayer mat is free of intumescent material along at least one lateral outer edge of said multilayer mat. 10. A pollution control device comprising: an outer housing having an interior major surface; a pollution control element; and a multilayer mounting mat positioned between said pollution control element and said outer housing, wherein the multilayer mounting mat has a major surface in contact with the internal major surface of the housing, and wherein the multilayer mat comprises: an intumescent layer having opposite outer edges, opposite ends, a first major surface and a second major surface opposite the first major surface, said intumescent layer having an area A1; a first non-intumescent layer facing the first major surface of said intumescent layer, said first non-intumescent layer comprising inorganic fibers and said first non-intumescent layer having opposite outer edges, opposite ends, and an area A2 that is greater than area A1; and a second non-intumescent layer facing the second major surface of said intumescent layer, said second non-intumescent layer comprising inorganic fibers and said second non-intumescent layer having opposite outer edges, opposite ends, and an area A3 that is greater than area A1, wherein said intumescent layer is sandwiched between said first and second non-intumescent layers and positioned entirely within the area A2 of said first non-intumescent layer and the area A3 of said second non-intumescent layer, with at least one of the outer edges of said mat being free of intumescent material, wherein one of the first or second non-intumescent layers has a major surface, and wherein the major surface of the multilayer mat in contact with the internal major surface of the housing is the major surface of one of the first or second non-intumescent layer. 11. The pollution control device of claim 10, wherein said multilayer mat is free of intumescent material along at least one lateral outer edge of said multilayer mat. 12. The pollution control device of claim 10, wherein area A2 is substantially equal to area A3 and said first non-intumescent layer is aligned with said second non-intumescent layer. 13. The pollution control device of claim 10, wherein said first non-intumescent layer has a length L2 and said second non-intumescent layer has a length substantially equal to length L2 and wherein said first non-intumescent layer has a width W2 and said second non-intumescent layer has a width substantially equal to width W2. 14. The pollution control device of claim 13, wherein said intumescent layer has a length W1 that is less than W2, said intumescent layer has a length L1 that is substantially equal to L2, and said second non-intumescent layer contacts said first non-intumescent layer along at least one edge of said multilayer mat. 15. The pollution control device of claim 10, wherein said first non-intumescent layer contacts said second non-intumescent layer along at least one edge of said mat, said at least one edge being positioned at a gas inlet side of said pollution control device. 16. The pollution control device of claim 10, wherein said intumescent layer is divided into at least two segments that are separated from each other. 17. The pollution control device of claim 16, wherein said pollution control element has an elliptical cross-section and the segments of said intumescent layer are positioned over portions of said pollution control element with a smaller radius of curvature. 18. A pollution control device comprising: an outer housing having an interior major surface; a pollution control element; and a multilayer mounting mat positioned between said pollution control element and said outer housing, wherein the multilayer mat comprises: an intumescent layer having opposite outer edges, opposite ends, a first major surface and a second major surface opposite the first major surface, said intumescent layer having an area A1; a first non-intumescent layer facing the first major surface of said intumescent layer, said first non-intumescent layer comprising inorganic fibers and said first non-intumescent layer having opposite outer edges, opposite ends, and an area A2 that is greater than area A1; and a second non-intumescent layer facing the second major surface of said intumescent layer, said second non-intumescent layer comprising inorganic fibers and said second non-intumescent layer having opposite outer edges, opposite ends, and an area A3 that is greater than area A1, wherein said intumescent layer is sandwiched between said first and second non-intumescent layers and positioned entirely within the area A2 of said first non-intumescent layer and the area A3 of said second non-intumescent layer, with at least one of the outer edges of said mat being free of intumescent material, and wherein one of the first or second non-intumescent layers has a major surface in contact with the internal major surface of the housing, wherein said first non-intumescent layer has a major surface facing said intumescent layer with a first trough in said major surface, wherein said intumescent layer is positioned in said first trough, and wherein said second non-intumescent layer has a major surface facing said intumescent layer with a second trough in said major surface aligned with the first trough, and wherein said intumescent layer is positioned in the first and the second trough. 19. A method of forming the multilayer mat of claim 1, said method comprising: providing an intumescent layer having a first major surface and a second major surface opposite said first major surface, said intumescent layer having opposite outer edges, opposite ends and an area A1; positioning a first non-intumescent layer facing the first major surface of said intumescent layer, said first non-intumescent layer comprising inorganic fibers and having opposite outer edges, opposite ends and an area A2 that is greater than area A1; and positioning a second non-intumescent layer facing the second major surface of said intumescent layer, said second non-intumescent layer being aligned with said first non-intumescent layer and comprising inorganic fibers, said second non-intumescent layer having opposite outer edges, opposite ends and an area A3 that is greater than area A1, wherein said intumescent layer is sandwiched between said first and second non-intumescent layers and positioned entirely within the area A2 of said first non-intumescent layer and the area A3 of said second non-intumescent layer, with at least one of the outer edges of said mat being free of intumescent material, and wherein said forming comprises molding to prepare a first non-intumescent layer having a major surface facing said intumescent layer with a first trough in said major surface, and wherein the method includes positioning said intumescent layer in said first trough. 20. The method of claim 19, wherein area A2 is substantially equal to area A3 and said first non-intumescent layer is aligned with said second non-intumescent layer. 21. The method of claim 19, wherein said first non-intumescent layer has a length L2 and said second non-intumescent layer has a length substantially equal to length L2 and wherein said first non-intumescent layer has a width W2 and said second non-intumescent layer has a width substantially equal to width W2. 22. The method of claim 21, wherein said intumescent layer has a width W1 that is less than W2, said intumescent layer has a length L1 is substantially equal to L2, and said multilayer mat is free of intumescent material along at least one edge of said multilayer mat. 23. The method of claim 19, wherein said intumescent layer has a thickness that is 5 to 25 percent of a total mat thickness. 24. The method of claim 19, wherein said positioning comprises preparing an intumescent layer having at least two segments and separating the segments. 25. The method of claim 19, said method further comprising cutting said multilayer mat to a size suitable for use as a mounting mat in a pollution control device.
연구과제 타임라인
LOADING...
LOADING...
LOADING...
LOADING...
LOADING...
이 특허에 인용된 특허 (45)
Zettel Steven (Cranston RI), Barrier strip for a support mat in a catalytic converter.
Lebold Alan R. (2526 Danielle Dr. Niagara Falls ; Niagara County NY 14304) Ten Eyck John D. (1458 Ridge Rd. Lewiston ; Niagara County NY 14092), Catalytic converter.
TenEyck John D. (Lewiston NY) Clere Thomas M. (Williamsville NY) Olson James (Youngstown NY) Waisala Steven (Aurora OH), High temperature stable continuous filament glass ceramic fiber.
Olds Leonard E. (977 S. Lake Gulch Rd. Castle Rock CO 80104) Kielmeyer William H. (3374 W. Chenango Ave. Englewood CO 80110), Inorganic fiber composition.
Foster Michael Ralph ; Lawrence Robert Anthony ; Myers Stephen Joe ; Turek Alan Gerard, Method for making a catalytic converter containing a multiple layer mat.
Hodges Michael F. (952 Liberty La. North Canton OH 44720) Storms Hugh H. (3990-11 Batton St. ; NW. North Canton OH 44720) Davis Victor M. (4215 Powell St. Parkersburg WV 26101), Method for making refractory lined duct and duct formed thereby.
Wirth, Georg; W?rner, Siegfried; Zacke, Peter, Method for mounting and insulating ceramic monoliths in an automobile exhaust system and a mounting produced according to this method.
Robinson John W. (Hampton SC) Lebold Alan R. (Buffalo NY) Travers Mark (Ransomville NY), Method of making a mounting mat for fragile structures such as catalytic converters.
Robinson John W. (Hampton SC) Lebold Alan R. (Buffalo NY) Travers Mark (Ransomville NY), Mounting mat for fragile structures such as catalytic converters.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.