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A method of decreasing the expansion temperature and improving the expansion characteristics of vermiculite ore comprising subjecting vermiculite ore containing interlamellar cations to a potassium nitrate solution for a time interval sufficient to ion-exchange interlamellar cations within said ore with potassium ions. Subsequent to this ion exchange the low temperature expandable vermiculite may be expanded by heating in an oven, or incorporated in an intumescent material and heat expanded in situ, or expanded by other heating means. An intumescent sheet is provided which may be used for mounting automotive catalytic converter monoliths comprising an unexpanded vermiculite produced by the method of the invention; an inorganic fibrous material; and a binder.

Inventores: Julie C. Yang, Charles I. Sanders
Cesionario original: W. R. Grace & Co.-Conn.
Examinador principal: Edward J. Cain
Clasificación actual de EE.UU.: 523/179; 106/415; 252/378.00R; 524/450
Clasificación internacional: C08K 2114

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Citas

Patente citada Fecha de presentación Fecha de emisión Cesionario original Título
US30627531 Oct 19586 Nov 1962METHOD OF EXFOLIATING VERMICULITE
US38242979 Dic 197116 Jul 1974METHOD FOR MANUFACTURING A MOLDED ARTICLE OF EXPANDED VERMICULITE
US38308929 Dic 19711974METHOD FOR MANUFACTURING A MOLDED
US391605731 Ago 19731975INTUMESCENT SHEET MATERIAL
US430599228 Nov 197915 Dic 1981Minnesota Mining and Manufacturing CompanyIntumescent sheet material
US44015862 Sep 198130 Ago 1983TS Leasing AssociatesProcess for thermally expanding silicate-based material by an infrared heat source
US449786915 Mar 19835 Feb 1985Kabushiki Kaisha Toyota Chuo KenkyushoFormed product of vermiculite and method for producing the same
US471598712 May 198629 Dic 1987Corning Glass WorksMethod of treating phyllosilicates

Citada por

Patente citante Fecha de presentación Fecha de emisión Cesionario original Título
US525441018 Abr 199119 Oct 1993Minnesota Mining & Manufacturing CompanyPartially dehydrated vermiculite flakes and method of making same
US534064326 Feb 199323 Ago 1994W. R. Grace & Co.-Conn.Intumescent sheet material
US534486621 May 19936 Sep 1994General Electric CompanyFire resistant composites
US807104021 Sep 20106 Dic 2011Unifax I LLCLow shear mounting mat for pollution control devices
US807584316 Abr 201013 Dic 2011Unifrax I LLCExhaust gas treatment device
US817817711 Feb 200515 May 20123M Innovative Properties CompanyDuct wrap and method for fire protecting a duct
US818275231 Ene 201122 May 2012Unifrax I LLCExhaust gas treatment device
US821137328 Ago 20093 Jul 2012Unifrax I LLCMounting mat with flexible edge protection and exhaust gas treatment device incorporating the mounting mat

Reclamaciones

1. A flexible intumescent sheet comprising:

a) an unexpanded vermiculite produced by subjecting vermiculite ore containing interlamellar ions to a potassium nitrate solution for a time interval sufficient to ion-exchange interlamellar cations within said vermiculite ore with potassium ions;
b) an inorganic fibrous material; and
c) a binder.

2. An intumescent sheet of claim 1 comprising from 40% to 65% by weight of the unexpanded vermiculite.

3. An intumescent sheet of claim 1 comprising from 25% to 50% by weight of the inorganic fibrous material.

4. An intumescent sheet of claim 1 comprising from 5% to 15% by weight of the binder.

5. An intumescent sheet of claim 1 wherein the inorganic fibrous material is ceramic fibers.

6. An intumescent sheet of claim 1 wherein the binder is an organic elastomer.