US 5,686,039 A · Methods of making a catalytic converter or diesel particulate filter

Abstract

The invention provides a method of making a catalytic converter for automotive exhaust gases comprising: (a) placing a catalytic converter element in a mold; (b) injecting a sufficient amount of a flowable mounting material into the mold to form a seamless continuous coating around a portion of the element, the flowable mounting material comprising 2 to 90 dry weight percent of at least one unexpanded intumescent material, 10 to 98 dry weight percent of binder, 0 to 25 dry weight percent fibers, 0 to 70 dry weight percent of one or more fillers, and a liquid; and (c) removing the catalytic converter element from the mold. In a preferred embodiment the catalytic converter element is heated to a temperature from about 60.degree. C. to about 150.degree. C. after step (c) and then said catalytic element is disposed in a housing. Analogous methods of making diesel particulate filters and high temperature rigid filters are also described.

Claims28

Dependent claims

A method of making a catalytic converter for automotive exhaust gases comprising:

(a) placing a catalytic converter element in a mold;
(b) injecting a sufficient amount of a flowable mounting material into the mold to form a seamless continuous coating around a portion of the element, the flowable mounting material comprising 2 to 90 dry weight percent of at least one unexpanded intumescent material, 10 to 98 dry weight percent of binder, 0 to 25 dry weight percent fibers, 0 to 70 dry weight percent of one or more fillers, and a liquid;
(c) removing the coated catalytic converter element from the mold.

Dependencies are inferred from the claim text.

Methods of making a catalytic converter or diesel particulate filter

Life of this patent

Methods of making a catalytic converter or diesel particulate filter

Life of this patent

Abstract

Claims28