Exhaust gas treatment device
AssigneeUnifrax I LLC
InventorAmit Kumar
Life of this patent
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Abstract
A flexible and substantially crack resistant intumescent, non-intumescent, or hybrid mounting mat material for use in mounting fragile structures includes at least one intumescent, non-intumescent or hybrid layer containing inorganic fibers and reinforcing layer applied to the layer. Also provided is an exhaust gas treatment device including a housing, a fragile catalyst support structure mounted within the housing, and the crack resistant mounting mat disposed in a gap between the housing and the fragile catalyst support structure. Also disclosed are methods of making a mounting mat for an exhaust gas treatment device and for making an exhaust gas treatment device incorporating the mounting mat.
Claims60
A substantially crack resistant mounting mat for an exhaust gas treatment device comprising:
- at least one layer having opposite facing major surfaces;
- and
- a reinforcing coating layer applied to at least a portion of at least one of said major surfaces,
- wherein the reinforcing coating layer does not substantially affect the performance properties of the mounting mat and increases the crack resistance of the mounting mat as compared to the same mounting mat without the reinforcing coating layer.
An exhaust gas treatment device comprising:
- a housing;
- a fragile catalyst support structure mounted within said housing;
- and
- a mounting mat disposed in a gap between said housing and said fragile catalyst support structure, wherein said mounting mat comprises an intumescent, non-intumescent or hybrid layer having opposite facing major surfaces and a reinforcing coating layer applied to at least a portion of at least one of said major surfaces, wherein the reinforcing coating layer does not substantially affect the performance properties of the mounting mat and increases the crack resistance of the mounting mat as compared to the same mounting mat without the reinforcing coating layer.
A method for making a mounting mat for holding a fragile catalyst support structure within the housing of an exhaust gas treatment device comprising:
- providing or preparing an intumescent, non-intumescent, or hybrid layer having opposite facing major surfaces;
- and
- applying a flexible reinforcing coating layer to at least a portion of at least one of said major surfaces of said intumescent or non-intumescent sheet layer, wherein the reinforcing coating layer does not substantially affect the performance properties of the mounting mat and increases the crack resistance of the mounting mat as compared to the same mounting mat without the reinforcing coating layer.
A method of making a device for treating exhaust gases comprising:
- wrapping an intumescent or non-intumescent layer having opposite facing major surfaces and a reinforcing coating layer applied to at least a portion of at least one of said major surfaces around a portion of a fragile catalyst support structure for treating exhaust gases, wherein the reinforcing coating layer does not substantially affect the performance properties of the mounting mat and increases the crack resistance of the mounting mat as compared to the same mounting mat without the reinforcing coating layer;
- and
- locating the wrapped fragile catalyst support structure within a housing, whereby the mounting mat holds the fragile structure resiliently within the housing.
An end cone for an exhaust gas treatment device comprising:
- outer metallic cone;
- an inner metallic cone;
- and
- cone insulation disposed between said outer and inner metallic end cones, said cone insulation comprising an intumescent, non-intumescent, or hybrid layer having opposite facing major surfaces and a reinforcing coating layer applied to at least a portion of at least one of said major surfaces, wherein the reinforcing coating layer does not substantially affect the performance properties of the mounting mat and increases the crack resistance of the mounting mat as compared to the same mounting mat without the reinforcing coating layer.
Dependencies are inferred from the claim text.