CA2571297A1 - Exhaust gas treatment device and method for making the same - Google Patents

Exhaust gas treatment device and method for making the same Download PDF

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Publication number
CA2571297A1
CA2571297A1 CA002571297A CA2571297A CA2571297A1 CA 2571297 A1 CA2571297 A1 CA 2571297A1 CA 002571297 A CA002571297 A CA 002571297A CA 2571297 A CA2571297 A CA 2571297A CA 2571297 A1 CA2571297 A1 CA 2571297A1
Authority
CA
Canada
Prior art keywords
fibers
percent
mounting mat
silica
glass fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002571297A
Other languages
French (fr)
Other versions
CA2571297C (en
Inventor
John D. Ten Eyck
Amit Kumar
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Unifrax 1 LLC
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Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of CA2571297A1 publication Critical patent/CA2571297A1/en
Application granted granted Critical
Publication of CA2571297C publication Critical patent/CA2571297C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/9454—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific device
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2422—Mounting of the body within a housing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/42—Coatings containing inorganic materials
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/66—Chemical treatment, e.g. leaching, acid or alkali treatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2279/00—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses
    • B01D2279/30—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses for treatment of exhaust gases from IC Engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2310/00—Selection of sound absorbing or insulating material
    • F01N2310/14—Wire mesh fabric, woven glass cloth or the like
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
    • F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49345—Catalytic device making

Abstract

A device for treatment of exhaust gases includes a housing (12), a fragile structure (18) resiliently mounted within the housing (12), and a non-intumescent mounting mat (20) disposed in a gap between the housing (12) and the fragile structure (12). The mounting mat (20) includes a plurality of inorganic fibers that have undergone a surface treatment to increase the holding force performance of the mounting mat (20). Also disclosed are methods of making a mounting mat (20) for an exhaust gas treatment device and for making an exhaust gas treatment device incorporating the mounting mat (20).

Claims (22)

1. A device for treatment of exhaust gases comprising:
a housing;

a fragile structure resiliently mounted within said housing; and a substantially non-expanding mounting mat disposed in a gap between said housing and said fragile structure, wherein said mounting mat includes inorganic fibers having a holding pressure performance-increasing surface treatment thereon.
2. The device of claim 1, wherein said fibers are selected from alumina, alumino-silicate fibers, alumina/magnesia/silica fibers, calcia/magnesia/silica fibers, magnesia/silica fibers, S-glass fibers, E-glass fibers, quartz fibers, and silica fibers.
3. The device of claim 2, wherein said mounting mat comprises at least one integral, substantially non-expanding layer of melt-formed, leached glass fibers containing at least 67 percent by weight silica.
4. The device of claim 3, wherein said substantially non-expanding mounting mat exerts a minimum holding pressure for holding said fragile structure within said housing of at least about 10 kPa after 1000 cycles of testing at a hot face temperature of about 900°C, a gap bulls density of from about 0.3 to about 0.5 g/cm3, and a percent gap expansion of about 5 percent.
5. The device of claim 3, wherein said non-expanding mounting mat exerts a minimum holding pressure for holding said fragile structure within said housing of at least about 50 kPa after 1000 cycles of testing at a hot face temperature of about 300°C, a gap bulk density of from about 0.3 to about 0.5 g/cm3, and a percent gap expansion of about 2 percent.
6. The device of claim 3, wherein said leached glass fibers contain at least about 90 percent by weight silica.
7. The device of claim 6, wherein said leached glass fibers contain from about 93 to about 95 percent by weight silica and from about 4 to about 6 percent by weight alumina.
8. The device of claim 1, wherein said mounting mat is further characterized by at least one of the following:

i) wherein said fibers of the mounting mat contain less than about 1 percent by weight alkali metal or alkaline earth metal;

ii) wherein the leached glass fibers of the mounting mat have a diameter greater than about 3.5 microns;

iii) wherein the leached glass fibers of the mounting mat are substantially shot free; and iv) wherein the mounting mat is substantially free of binder.
9. The device of claim 1, wherein said mounting mat comprises from about 50 to 100 percent by weight of said leached glass fibers.
10. The device of claim 1, wherein said holding pressure performance-increasing surface treatment comprises a coating of a holding pressure increasing agent.
11. The device of claim 10, wherein said holding pressure performance increasing agent comprises an inorganic particulate material selected from the group consisting of dispersions of colloidal alumina, colloidal silica, colloidal zirconia, or mixtures thereof.
12. The device of claim 1, wherein the mounting mat is heat treated at a temperature of at least about 900°C for an effective period of time to provide a minimum holding pressure for holding the fragile structure within the housing of one of (i) at least 50 kPa after 1000 cycles of testing at a hot face temperature of 300°C, a gap bulk density of between 0.3 and 0.5 g/cm3, and a percent gap expansion of 2 percent and (ii) at least 10 kPa after 1000 cycles of testing at a hot face temperature of 900°C, a gap bulk density of between 0.3 and 0.5 g/cm3, and a percent gap expansion of 5 percent.
13. The device of claim 1, wherein the device is a catalytic converter or diesel particulate trap.
14. A method of making a device for treating exhaust gases of claim 1 comprising:
providing a mounting mat comprising inorganic fibers having a holding pressure performance increasing surface treatment on at least a portion of the exterior surfaces of the fibers;
wrapping the mounting mat around a portion of a fragile structure adapted for treating exhaust gases; and disposing the fragile structure and the mounting mat within a housing, whereby the mounting mat holds the fragile structure resiliently within the housing.
15. The method of claim 14, wherein the mounting mat inorganic fibers comprise melt-formed glass fibers containing silica, wherein the melt-formed glass fibers are formed by treating the melt-formed glass fibers whereby the treated glass fibers have a silica content greater than the silica content of the glass fibers prior to being treated and whereby the treated glass fibers contain at least 67 percent by weight silica, and applying a holding pressure performance increasing surface treatment to at least a portion of the exterior surfaces of the inorganic fibers.
16. The method of claim 14, wherein the step of treating the melt-formed glass fibers includes leaching the glass fibers in an acid solution.
17. The method of claim 14, further comprising the step of heat treating comprises heating the fibers or mounting mat at a temperature of at least about 900°C for an effective period of time to provide an effective minimum holding pressure for holding the fragile structure within the housing of one of (i) at least 50 kPa after 1000 cycles of testing at a hot face temperature of 300°C, a gap bulk density of between 0.3 and 0.5 g/cm3, and a percent gap expansion of 2 percent, and (ii) at least 10 kPa after 1000 cycles of testing at a hot face temperature of 900°C, a gap bulk density of between 0.3 and 0.5 g/cm3, and a percent gap expansion of 5 percent.
18. The method of claim 14, wherein said holding pressure increasing agent is selected from the group consisting of dispersions of colloidal alumina, colloidal silica, colloidal zirconia, and mixtures thereof.
19. A method for making the mounting mat of claim 1 for holding a fragile structure within the housing of an exhaust gas treatment device comprising:
providing inorganic fibers;

applying a holding pressure performance increasing surface treatment to at least a portion of the exterior surfaces of at least a portion of the inorganic fibers; and incorporating the surface treated inorganic fibers into a mat structure, wherein the holding pressure performance of the mounting mat containing the surface treated inorganic fibers is greater than a mounting mat containing the same inorganic fibers without the surface treatment.
20. The method of claim 19, wherein the inorganic fibers are selected from alumino-silicate fibers, alumina/magnesia/silica fibers, calcia/magnesia/silica fibers, magnesia/silica fibers, S-glass fibers, E-glass fibers, quartz fibers, and silica fibers.
21. The method of claim 19, wherein said holding pressure increasing agent is selected from the group consisting of dispersions of colloidal alumina, colloidal silica, colloidal zirconia, and mixtures thereof.
22. The method of claim 19, further comprising heat treating comprises heating the leached glass fibers at a temperature of at least about 300°C or at least about 900°C for an effective period of time to provide a minimum holding pressure for holding the fragile structure within the housing of one of (i) at least 50 kPa after 1000 cycles of testing at a hot face temperature of 300°C, a gap bulk density of between 0.3 and 0.5 g/cm3, and a percent gap expansion of 2 percent, and (ii) at least 10 kPa after 1000 cycles of testing at a hot face temperature of 900°C, a gap bulk density of between 0.3 and 0.5 g/em3, and a percent gap expansion of 5 percent.
CA2571297A 2004-06-29 2005-06-29 Exhaust gas treatment device and method for making the same Expired - Fee Related CA2571297C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US58380004P 2004-06-29 2004-06-29
US60/583,800 2004-06-29
PCT/US2005/023408 WO2006004974A2 (en) 2004-06-29 2005-06-29 Exhaust gas treatment device and method for making the same

Publications (2)

Publication Number Publication Date
CA2571297A1 true CA2571297A1 (en) 2006-01-12
CA2571297C CA2571297C (en) 2011-02-01

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA2571297A Expired - Fee Related CA2571297C (en) 2004-06-29 2005-06-29 Exhaust gas treatment device and method for making the same

Country Status (14)

Country Link
US (3) US7971357B2 (en)
EP (1) EP1761324B1 (en)
JP (2) JP4982363B2 (en)
KR (2) KR20070048662A (en)
CN (1) CN101098744B (en)
AR (1) AR054074A1 (en)
BR (1) BRPI0512698B8 (en)
CA (1) CA2571297C (en)
MX (1) MXPA06015069A (en)
MY (1) MY148596A (en)
RU (1) RU2388522C2 (en)
TW (1) TWI380850B (en)
WO (1) WO2006004974A2 (en)
ZA (1) ZA200610604B (en)

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