초록 ▼

Compositions that include a mixture of biosoluble inorganic fibers and a micaceous binder are described. The compositions can be prepared free of refractory ceramic fibers that are respirable but durable in a physiological medium. The compositions are typically in the form of a sheet material or a p

Compositions that include a mixture of biosoluble inorganic fibers and a micaceous binder are described. The compositions can be prepared free of refractory ceramic fibers that are respirable but durable in a physiological medium. The compositions are typically in the form of a sheet material or a paste and can be used, for example, as a protective packing material around the pollution control element or as an insulating material in the end cone region in a pollution control device. Sheet materials formed from the compositions have an area of a X-Y plane that decrease less than about 6 percent when heated to about 900° C.

대표청구항 ▼

1. A composition comprising: a) a micaceous binder in an amount of about 5 to about 80 weight percent on a dry weight basis, said micaceous binder consisting essentially of a crushed micaceous mineral that is non-intumescent; andb) biosoluble inorganic fibers in an amount of about 10 to about 60 wei

1. A composition comprising: a) a micaceous binder in an amount of about 5 to about 80 weight percent on a dry weight basis, said micaceous binder consisting essentially of a crushed micaceous mineral that is non-intumescent; andb) biosoluble inorganic fibers in an amount of about 10 to about 60 weight percent on a dry weight basis,wherein said composition is in the form of a sheet material suitable for use as a mounting mat of the pollution control device or as an insulating material in an end cone region of a pollution control device. 2. The composition of claim 1, wherein said sheet material having an area in a X-Y plane, the area decreasing less than about 6 percent when said sheet material is heated to about 900° C. 3. The composition of claim 1, wherein said biosoluble inorganic fibers comprise about 45 to about 90 weight percent SiO2, up to about 45 weight percent CaO, up to about 35 weight percent MgO, and less than 10 weight percent Al2O3 based on the weight of the biosoluble inorganic fibers. 4. The composition of claim 1, wherein said crushed micaceous mineral has a particle size less than about 150 micrometers. 5. The composition of claim 4, wherein said crushed micaceous mineral consists of expanded vermiculite in a crushed state, and said micaceous binder can be formed into a 5 cm×5 cm×3 mm sheet containing no other materials such that the dried sheet can be held horizontally at any edge for at least 5 minutes at 25° C. and up to 50 percent relative humidity without crumbling or otherwise falling apart. 6. The composition of claim 1, further comprising non-respirable inorganic fibers in an amount up to about 15 weight percent on a dry weight basis, wherein the non-respirable inorganic fibers have an average diameter of at least about 3 micrometers. 7. The composition of claim 1, further comprising an intumescent material in an amount up to about 80 weight percent on a dry weight basis, wherein said intumescent material has an average particle size greater than about 300 micrometers. 8. The composition of claim 1, further comprising an intumescent material in an amount up to about 80 weight percent on a dry weight basis, wherein said intumescent material comprises a micaceous mineral having a particle size greater than about 150 micrometers. 9. The composition of claim 1, further comprising an intumescent material in an amount such that said composition is an intumescent composition. 10. The composition of claim 1, further comprising a polymeric binder in an amount of about 0.1 to about 15 weight percent on a dry weight basis. 11. The composition of claim 10, wherein said polymeric binder is an elastomer. 12. The composition of claim 1, further comprising polymeric fibers. 13. The composition of claim 1, wherein said composition is in the form of a sheet material having a multilayered construction. 14. The composition of claim 1, wherein said sheet material is intumescent and further comprises an edge protector. 15. The composition of claim 1, wherein said composition is free of respirable inorganic fibers that are durable. 16. An intumescent composition comprising: a) a micaceous binder in an amount of about 15 to about 50 weight percent on a dry weight basis, wherein the micaceous binder consists of expanded vermiculite in a crushed state having a particle size less than about 150 micrometers;b) biosoluble inorganic fibers in an amount of about 15 to about 40 weight percent on a dry weight basis; andc) intumescent material in an amount of about 30 to about 60 weight percent on a dry weight basis, wherein the intumescent material comprises unexpanded vermiculite having a particle size greater than about 150 micrometers,wherein said micaceous binder can be formed into a 5 cm×5 cm×3 mm sheet containing no other materials such that the dried sheet can be held horizontally at any edge for at least 5 minutes at 25° C. and up to 50 percent relative humidity without crumbling or otherwise falling apart. 17. The composition claim 16, further comprising a polymeric binder in an amount of about 0.1 to about 15 weight percent on a dry weight basis. 18. A pollution control device comprising: a) a housing;b) a pollution control element disposed in the housing; andc) a protective material disposed in a gap between at least a portion of the housing and a portion of the pollution control element, said a protective material comprising: i) a micaceous binder in an amount of about 5 to about 80 weight percent on a dry weight basis, said micaceous binder being a crushed micaceous mineral that is non-intumescent; andii) biosoluble inorganic fibers in an amount of about 10 to about 60 weight percent on a dry weight basis,wherein said protective material is in a form suitable for use as a mounting mat of said pollution control device or as an insulating material in an end cone region of said pollution control device. 19. The pollution control device of claim 18, wherein the protective material is in the form of a sheet material or a paste. 20. The pollution control device of claim 18, wherein said biosoluble inorganic fibers comprise about 45 to about 90 weight percent SiO2, up to about 45 weight percent CaO, up to about 35 weight percent MgO, and less than 10 weight percent Al2O3 based on the weight of the biosoluble inorganic fibers. 21. The pollution control device of claim 18, wherein said micaceous binder is expanded vermiculite in a crushed state having a particle size less than about 150 micrometers, and said micaceous binder can be formed into a 5 cm×5 cm×3 mm sheet containing no other materials such that the dried sheet can be held horizontally at any edge for at least 5 minutes at 25° C. and up to 50 percent relative humidity without crumbling or otherwise falling apart. 22. The pollution control device of claim 18, wherein said protective material further comprises an intumescent material in an amount such that said protective material is intumescent. 23. The pollution control device of claim 18, wherein said protective material further comprises non-respirable inorganic fibers in an amount up to about 15 weight percent on a dry weight basis. 24. The pollution control device of claim 18, wherein said protective material having an area in an X-Y plane, said area decreasing less than about 6 percent when said pollution control device is in use. 25. A pollution control device comprising a housing and insulating material disposed in said housing, said insulating material comprising a micaceous binder in an amount of about 5 to about 80 weight percent on a dry weight basis and biosoluble fibers in an amount of about 10 to about 60 weight percent on a dry weight basis, said micaceous binder consisting of expanded vermiculite in a crushed state that is non-intumescent and has a particle size less than about 150 micrometers, and said micaceous binder can be formed into a 5 cm×5 cm×3 mm sheet containing no other materials such that the dried sheet can be held horizontally at any edge for at least 5 minutes at 25° C. and up to 50 percent relative humidity without crumbling or otherwise falling apart. 26. The pollution control device of claim 25, wherein said insulating material is cone shaped and disposed in an end cone region of said housing. 27. A method of making a pollution control device comprising providing a housing and a pollution control element;forming a protective packing material comprising a micaceous binder in an amount of about 5 to about 80 weight percent on a dry weight basis and biosoluble inorganic fibers in an amount of about 10 to about 60 weight percent on a dry weight basis, said protective packing material being in sheet form, and said micaceous binder consisting of a crushed micaceous mineral that is non-intumescent;disposing the pollution control element in the housing; andpositioning the protective packing material between at least a portion of the pollution control element and the housing such that the protective packing material mounts the pollution control element in the housing,wherein said micaceous mineral has a particle size less than about 150 micrometers and consists essentially of expanded vermiculite in a crushed state, and said micaceous binder can be formed into a 5 cm×5 cm×3 mm sheet containing no other materials such that the dried sheet can be held horizontally at any edge for at least 5 minutes at 25° C. and up to 50 percent relative humidity without crumbling or otherwise falling apart. 28. The method of claim 27, wherein the protective packing material is wrapped completely around at least a portion of the pollution control element. 29. The method of claim 27, wherein the protective packing material further comprises an intumescent material in an amount such that the protective packing material is intumescent. 30. A method of making a sheet material comprising: forming an aqueous slurry comprising a micaceous binder in an amount of about 5 weight percent to about 80 weight percent on a dry weight basis and biosoluble inorganic fibers in an amount of about 10 to about 60 weight percent on a dry weight basis, said micaceous binder consisting essentially of a crushed micaceous mineral that is non-intumescent;adding a coagulating agent to form a coagulated slurry; andremoving water from the coagulated slurry to form a sheet material. 31. The pollution control device of claim 18, wherein the protective material is in the form of a sheet material. 32. The composition of claim 1, wherein said crushed micaceous mineral has a particle size less than about 150 micrometers and consists essentially of expanded vermiculite in a crushed state, and said micaceous binder can be formed into a 5 cm×5 cm×3 mm sheet containing no other materials such that the dried sheet can be held horizontally at any edge for at least 5 minutes at 25° C. and up to 50 percent relative humidity without crumbling or otherwise falling apart.