Repositionable mounting material, pollution control device, and methods of making the same

A repositionable mounting material comprising:

• a mounting material having first and second opposed major surfaces and comprising inorganic fibers;
• and
• a layer of repositionable pressure-sensitive adhesive inwardly disposed along at least a portion of the first major surface, wherein the layer of repositionable pressure-sensitive adhesive comprises:
• adhesive microspheres having a first particle size distribution with at least one first mode, each of which has a D50 of at least 30 micrometers;
• and
• binder particles, wherein the binder particles have a second particle size distribution with at least one second mode, each of which has a D50 that is less than 10 micrometers, and wherein at least one of the at least one second modes has a D50 below one micrometer,
• wherein the repositionable mounting material is repositionably adherable to a monolith adapted for use in a pollution control device, and wherein a reference mounting material, prepared identically to the repositionable mounting material, except without the binder particles, is not repositionably adherable to the monolith.

A method of making a repositionable mounting material, the method comprising:

• providing a mounting material having first and second major surfaces and comprising bonded inorganic fibers;
• and
• applying a dryable composition to at least a portion of the Major surface of the mounting material, wherein the dryable composition comprises:
• adhesive microspheres having a first particle size distribution with at least one first mode, each of which has a D50 of at least 30 micrometers;
• and
• binder particles, wherein the binder particles have a second particle size distribution with at least one second mode, each of which has a D50 that is less than 10 micrometers, and wherein at least one of the at least one second modes has a D50 below one micrometer;
• and
• at least partially drying the dryable composition to provide a layer of repositionable pressure-sensitive adhesive inwardly disposed along at least a portion of the first major surface, wherein the repositionable mounting material is repositionably adherable to a monolith adapted for use in a pollution control device, and wherein a reference mounting material, prepared identically to the repositionable mounting material, except without the hinder particles, is not repositionably adherable to the monolith.

A method of making a repositionable mounting material, the method comprising:

• providing a mounting material having a major surface and comprising bonded inorganic fibers;
• and
• applying a first dryable composition to at least a portion of the major surface of the mounting material, wherein the first dryable composition comprises adhesive microspheres having a first particle size distribution with at least one mode, each of which has a D50 of at least 30 micrometers;
• applying a second dryable composition comprising binder particles to at least a portion of the major surface of the mounting material;
• and
• at least partially drying the first and second dryable compositions to provide a layer of repositionable pressure-sensitive adhesive inwardly disposed along at least a portion of the first major surface, wherein the repositionable mounting material is repositionably adherable to a monolith adapted for use in a pollution control device.