[특허]Mounting mat including inorganic nanoparticles and method for making the same

Mounting mat including inorganic nanoparticles and method for making the same 원문보기

IPC분류정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	F01N-003/28 C04B-030/02 D04H-001/4209 D04H-001/4218 D04H-001/46 D04H-001/52 D04H-001/541 D04H-001/587 D04H-001/645 D04H-001/72 D04H-001/732 F01N-003/20
출원번호	US-0225148 (2016-08-01)
등록번호	US-9932872 (2018-04-03)
우선권정보	EP-07118144 (2007-10-09)
발명자 / 주소	Kunze, Ulrich E. Lalouch, Lahoussaine Middendorf, Claus Krieg, Harald H.
출원인 / 주소	3M INNOVATIVE PROPERTIES COMPANY
대리인 / 주소	Knecht, III, Harold C.
인용정보	피인용 횟수 : 0 인용 특허 : 31

초록 ▼

The present invention relates to a mounting mat for mounting a pollution control device in a catalytic converter, the mounting mat comprising a non-woven mat of inorganic fibers having distributed therein inorganic particles having an average diameter of 1 nm to 100 nm and wherein the mounting mat is free of organic binder or contains organic binder in an amount of not more than 5% by weight, based on the total weight of the mounting mat. The invention further relates to a pollution control device including the mounting mat and to a method of making the mounting mat.

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1. A method of making a mounting mat comprising the steps of: (i) supplying inorganic fibers through an inlet of a forming box having an open bottom positioned over a forming wire to form a non-woven mat of fibers on the forming wire, the forming box having a plurality of fiber separating rollers provided in at least one row in the housing between the inlet and housing bottom for breaking apart clumps of fibers and an endless belt screen;(ii) capturing clumps of fibers on a lower run of the endless belt beneath fiber separating rollers and above the forming wire;(iii) conveying captured clumps of fibers on the endless belt above fiber separating rollers to enable captured clumps to release from the belt and to contact and be broken apart by the rollers;(iv) transporting the non-woven mat of fibers out of the forming box by the forming wire; and(v) compressing the non-woven mat of fibers and restraining the non-woven mat of fibers in its compressed state thereby obtaining a mounting mat having a desired thickness suitable for mounting a pollution control element in the housing of a pollution control device;wherein inorganic particles having an average diameter of 1 nm to 100 nm are provided in the mounting mat. 2. The method according to claim 1, wherein the inorganic particles are provided in the mounting mat by supplying a powder of inorganic particles to the forming box. 3. The method according to claim 1, wherein the inorganic particles are provided in the mounting mat by spraying a dispersion of the inorganic particles on the inorganic fibers before supplying the inorganic fibers to the forming box or by spraying the dispersion on the non-woven mat of fibers before or after compression thereof. 4. The method according to claim 1, wherein the mounting mat is free of organic binder or contains organic binder in an amount of not more than 5% by weight, based on the total weight of the mounting mat. 5. The method according to claim 1, wherein the inorganic particles are provided in the mounting mat in an amount in the range of from at least 0.5% to 10% by weight. 6. The method according to claim 1, further comprising: providing intumescent material in the mounting mat. 7. The method according to claim 6, wherein the intumescent material is evenly distributed within the non-woven mat. 8. The method according to claim 6, wherein the mounting mat is an intumescent mounting mat. 9. The method according to claim 1, wherein the supplied inorganic fibers are selected from melt formed ceramic fibers including annealed melt-formed ceramic fibers, sol-gel formed ceramic fibers, polycrystalline fibers, glass fibers including heat treated glass fibers, alumina-silica fibers, biosoluble fibers, and combinations thereof. 10. The method according to claim 1, further comprising: needle-punching or stitch-bonding the mounting mat. 11. The method according to claim 1, wherein the mounting mat further comprises one or more layers selected from scrims and nettings. 12. The method according to claim 11, wherein the scrim or netting comprises inorganic fibers. 13. The method according to claim 9, further comprising: providing intumescent material in the mounting mat. 14. The method according to claim 1, further comprising: disposing a scrim or netting on one or both opposite major sides of the mounting mat. 15. The method according to claim 1, wherein the inorganic particles comprise oxides of silica, alumina or zirconia, titania or silicates. 16. The method according to claim 1, wherein the inorganic particles are evenly distributed within the non-woven mat. 17. The method according to claim 1, wherein the non-woven mat contains more of the inorganic fibers by weight than the inorganic particles. 18. The method of claim 17, wherein the inorganic particles are evenly distributed within the non-woven mat. 19. The method of claim 17, wherein the mounting mat is an intumescent mounting mat. 20. A method of making a pollution control device comprising the steps of: providing a housing, a pollution control element, and a mounting mat;disposing the pollution control element within the housing; anddisposing the mounting mat between the pollution control element and the housing so as to maintain the position of the pollution control element within the housing and for absorbing mechanical and thermal shock,wherein the mounting mat is made according to the method of claim 1.

이 특허에 인용된 특허 (31)

Ichikawa, Yukihito; Ito, Eiji; Ikeshima, Koichi; Ishikawa, Masayasu, Assembly method using marked information and assembly assembled by said assembling method.
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Stroom Paul D. ; Howorth Gary F. ; Schweitzer Michael T., Catalytic converter and diesel particulate filter.
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Langer Roger L. (Hudson WI), Catalytic converter having a metallic monolith mounted by a heat-insulating mat of refractory ceramic fibers.
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Rogers John J. (St. Paul MN) Erickson John L. (White Bear Lake MN) Sanocki Stephen M. (Stillwater MN), Catalytic converter mounting mat.
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Kudo,Atsushi, Ceramic filter and exhaust gas decontamination unit.
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Kumar,Amit; Ten Eyck,John D.; Lacki,Thomas, Exhaust gas treatment device and method for making the same.
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Andersen,Carsten, Fiber distribution device for dry forming a fibrous product and method.
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Rogers John J. (Ramsey MN) Erickson John L. (Ramsey MN) Sanocki Stephen M. (Stillwater MN), Flexible nonwoven mat.
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Kortmann Wilfried (Hagen DEX) Steinberger Helmut (Leverkusen DEX) Pfeiffer Josef (Leverkusen DEX) Koemm Ulrich (Cologne DEX), Fluorine containing silicone textile-finishing agent: silicone suspension and perfluoroalkyl polymer.
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Hashimoto Akira (Sanda JPX) Hoshi Susumu (Sanda JPX), Heat-resistant expansion member.
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Suzaki Tooru (Toyota JPX) Kanome Yoshihiro (Toyota JPX) Hayakawa Masaomi (Gifu JPX) Miyashita Kunihiko (Oogaki JPX), Heat-resistant, highly expansible sheet material for supporting catalyst carrier and process for the preparation thereof.
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Zoitos Bruce ; Atkinson Richard E. A. ; Olson James R., High temperature resistant glass fiber.
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MacNeill Gerald F. (Bristol RI), High temperature resistant material.
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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.
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Miwa,Shinichi, Honeycomb structural body and canning structural body storing the honeycomb structural body.
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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.
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Olds Leonard Elmo ; Kielmeyer William Henry, Inorganic fiber composition.
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Corn Stewart H. (St. Paul MN), Intumescent mounting mat.
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Langer Roger L. (St. Paul MN) Marlor Alan J. (St. Paul MN), Intumescent sheet material.
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Langer, Roger L.; Marlor, Alan J., Intumescent sheet material containing low density fillers.
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Knowlton Barry R. (Bramalea CAX) Elgarhy Yassin (St. Laurent CAX), Method of enhancing the soil- and stain-resistance characteristics of polyamide and wool fabrics, the fabrics so treated.
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Dinwoodie, John; Wade, Kathleen E.; Young, Stella M., Method of making fibre-based products and their use.
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Roger L. Langer ; Stephen M. Sanocki ; Gary F. Howorth, Method of making multilayer sheets for firestops or mounting mats.
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Robinson John W. (Hampton SC) Lebold Alan R. (Buffalo NY) Travers Mark (Ransomville NY), Mounting mat for fragile structures such as catalytic converters.
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Langer Roger L., Multilayer intumescent sheet.
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Langer Roger L. ; Sanocki Stephen M. ; Howorth Gary F., Multilayer intumescent sheet.
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Langer Roger L. (Hudson WI) Merry Richard P. (White Bear Lake MN), Partially dehydrated vermiculite flakes and method of making same.
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Steinberger Helmut (Leverkusen DEX) Moretto Hans-Heinrich (Cologne DEX) Kortmann Wilfried (Hagen DEX) Pfeiffer Josef (Leverkusen DEX), Pile-stabilizing silicon-containing textile agents.
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MacNeil Gerald F. (Bristol RI), Seal for catalytic converter and method therefor.
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Lefkowitz Leonard R. (Latham NY) Krohn W. Henrik (Chatham NY), Stitch knitted filters for high temperature fluids and method of making them.
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Peisert, Joseph C.; Kaczorek, Kevin; Harding, Ian R.; Braunreiter, Carl J., System for securing the end cone or mounting mat of a pollution control device.
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