# US 2014/0154147 A1 · Mat for mounting a pollution control element for the treatment of exhaust gas

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 2014/0154147 A1
- Document ID: US20140154147A1
- Status: Published application
- Kind: A1
- Application number: 14/134,538
- Filed: 2013-12-19
- Published: 2014-06-05
- Earliest claimed: 2007-10-09
- Assignees: 3M Innovative Properties Company
- Applicants: 3M Innovative Properties Company
- Inventors: Ulrich E. Kunze; Lahoussaine Lalouch; Claus Middendorf; Harald H. Krieg
- Web page: https://patentgrep.com/patent/US20140154147A1

## CPC

- C03B 37/10: Non-chemical treatment (surface treatment of fibres or filaments made from glass, minerals or slags C03C25/00)
- D04H 1/4218: Glass fibres
- D04H 1/46: by needling or like operations to cause entanglement of fibres (D04H1/45 takes precedence; needling machines D04H18/00)
- D04H 1/52: by applying or inserting filamentary binding elements
- D04H 1/5412: {sheath-core}
- D04H 1/5418: {Mixed fibres, e.g. at least two chemically different fibres or fibre blends}
- D04H 1/587: characterised by the bonding agents used
- D04H 1/645: Impregnation followed by a solidification process
- D04H 1/70: characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H 1/732: by fluid current, e.g. air-lay
- B27N 3/04: from fibres
- F01N 3/2853: {using mats or gaskets between catalyst body and housing}
- F01N 3/2871: {the mats or gaskets having an additional, e.g. non-insulating or non-cushioning layer, a metal foil or an adhesive layer}
- F01N 2330/102: fibrous material being fiber reinforced polymer made of plastic matrix reinforced by fine glass or in the form of a loose mass of filaments or fibers
- Y10T 428/249921: Web or sheet containing structurally defined element or component
- Y10T 428/26: Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
- Y10T 442/10: Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
- Y10T 442/691: Inorganic strand or fiber material only
- C03B: MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- B27N: MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL (containing cementitious material B28B; shaping of substances in a plastic state B29C; fibreboards made from fibrous suspensions D21J; drying F26B17/00)
- F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The present invention relates to a mat for mounting one or more pollution control elements in a pollution control device for the treatment of exhaust gases, said mat comprising heat-treated glass fibers containing Al2O3 in an amount of 10 to 30% by weight and SiO2 in an amount of 52 to 65% by weight based on the total weight of the glass fibers.

## Claims

### Claim 1 (depends on 15)

A mat for mounting one or more pollution control elements in a pollution control device for the treatment of exhaust gases, said mat being made according to the method of claim 15.

### Claim 2

(canceled)

### Claim 3

(canceled)

### Claim 4 (depends on 15)

The method according to claim 15, wherein the heat-treated glass fibers are amorphous.

### Claim 5 (depends on 15)

The method according to claim 15, wherein glass fibers are selected from the group consisting of E-glass, S-glass, S2-glass, R-glass and combinations thereof.

### Claim 6 (depends on 15)

The method according to claim 15, wherein the heat-treated glass fibers have a diameter of greater than 4.0 μm and a length of from about 0.1 cm to about 15 cm.

### Claim 7

(canceled)

### Claim 8

(canceled)

### Claim 9 (depends on 15)

The method according to claim 15, wherein the mat is an intumescent mat.

### Claim 10

(canceled)

### Claim 11 (depends on 15)

The method according to claim 15, wherein the mat has an internal surface and an external surface, and said method further comprises applying a coating on the internal surface of the mat having a solid component content in the range of from about 5 g/m2 to 100 g/m2, and applying a coating on the external surface of the mat having a solid component content in the range of from about 0.5 g/m2 to 10 g/m2.

### Claim 12

(canceled)

### Claim 13 (depends on 1)

A pollution control device comprising a support structure for a catalyst and a casing to house the support structure and arranged between the support structure and casing a mat according to claim 1.

### Claim 14 (depends on 13)

The pollution control device of claim 13 being a catalytic converter of a gasoline engine.

### Claim 15

A method of making mounting mats for use in a pollution control device, said method comprising:
(i) heat-treating glass fibers comprising Al2O3 in an amount of 10 to 30% by weight and SiO2 in an amount of 52 to 65% by weight based on the total weight of the glass fibers with a temperature of between 300° C. and about 50° C. below the softening point of the glass;
(ii) supplying the heat treated glass fibers through an inlet of a forming box having an open bottom positioned over a forming wire to form a 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;
(iii) capturing clumps of fibers on a lower run of the endless belt beneath fiber separating rollers and above the forming wire;
(iv) 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;
(v) transporting the mat of fibers out of the forming box by the forming wire; and
(vi) compressing the mat of fibers and restraining the 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 catalytic converter.

### Claim 16

A method of making mounting mats for use in a pollution control device, said method comprising:
(i) supplying glass fibers comprising Al2O3 in an amount of 10 to 30% by weight and SiO2 in an amount of 52 to 65% by weight based on the total weight of the glass fibers through an inlet of a forming box having an open bottom positioned over a forming wire to form a 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 mat of fibers out of the forming box by the forming wire; and
(v) compressing the mat of fibers and restraining the 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 catalytic converter,
(vi) heat-treating the mat of fibers at a temperature of between 300° C. and about 50° C. below the softening point of the glass fibers.

### Claim 17 (depends on 15)

The method according to claim 15, wherein said heat-treating is performed for a period of time from about 2 minutes to about 1 hour so as to improve the heat resistance and high temperature resiliency of the glass fibers.

### Claim 18 (depends on 16)

The method according to claim 16, wherein said heat-treating is performed for a period of time from about 2 minutes to about 1 hour so as to improve the heat resistance and high temperature resiliency of the glass fibers.

### Claim 19 (depends on 16)

A mat for mounting one or more pollution control elements in a pollution control device for the treatment of exhaust gases, said mat being made according to the method of claim 16.

### Claim 20 (depends on 16)

The method according to claim 16, wherein the heat-treated glass fibers are amorphous.

### Claim 21 (depends on 16)

The method according to claim 16, wherein glass fibers are selected from the group consisting of E-glass, S-glass, S2-glass, R-glass and combinations thereof.

### Claim 22 (depends on 16)

The method according to claim 16, wherein the heat-treated glass fibers have a diameter of greater than 4.0 μm and a length of from about 0.1 cm to about 15 cm.

### Claim 23 (depends on 16)

The method according to claim 16, wherein the mat is an intumescent mat.

### Claim 24 (depends on 16)

The method according to claim 16, wherein the mat has an internal surface and an external surface, and said method further comprises applying a coating on the internal surface of the mat having a solid component content in the range of from about 5 g/m2 to 100 g/m2, and applying a coating on the external surface of the mat having a solid component content in the range of from about 0.5 g/m2 to 10 g/m2.

### Claim 25 (depends on 19)

A pollution control device comprising a support structure for a catalyst and a casing to house the support structure and, arranged between the support structure and casing, a mat according to claim 19.

### Claim 26 (depends on 25)

The pollution control device of claim 25 being a catalytic converter of a gasoline zengine.