High Temperature Resistant Insulation Mat

Patent metadata

Field	Value
Publication number	US-2016244001-A1
Application number	US-201514845984-A
Country	US
Kind code	A1
Filing date	Sep 4, 2015
Priority date	Feb 24, 2015
Publication date	Aug 25, 2016
Grant date	—

Abstract

Methods of forming insulation mats including: providing a mixture of fibers comprising first inorganic fibers and second inorganic fibers, wherein the first inorganic fibers shrink by no more than about 2 percent and the second fibers shrink by about 5 to about 15 percent when the mixture of fibers is heat treated; wet-forming a web of fibers from the mixture of fibers; entangling the web of fibers to form an insulation mat; heat-treating the insulation mat; and drying the web of fibers and/or the insulation mat after said wet-forming and prior to or during said heat treating; and wherein the insulation mat includes substantially no non-fibrous binder material prior to said heat treating the insulation mat at a temperature of from about 500° C. to about 800° C., optionally for at least about 3 minutes. Insulation mats manufactured according to the above methods.

First claim

What is claimed is:

1 . A method of forming an insulation mat comprising:
providing a mixture of fibers comprising first inorganic fibers and second inorganic fibers, wherein the first inorganic fibers shrink by no more than about 2 percent and the second fibers shrink by about 5 to about 15 percent when the mixture of fibers is heat treated at a temperature of from about 500° C. to about 800° C., optionally for at least about 3 minutes; wet-forming a web of fibers from the mixture of fibers; entangling the web of fibers to form an insulation mat; heat-treating the insulation mat at a temperature of from about 500° C. to about 800° C.; and drying the web of fibers and/or the insulation mat after said wet-forming and prior to or during said heat treating; wherein the insulation mat comprises substantially no non-fibrous binder material prior to said heat treating the insulation mat.

2 . The method of claim 1 , wherein said providing a mixture of inorganic fibers comprises mixing the first inorganic fibers with the second inorganic fibers.

3 . The method of claim 1 , wherein said entangling the web of inorganic fibers comprises at least one of needling or hydroentangling.

4 . The method of claim 1 , wherein said heat treating the insulation mat comprises exposing the insulation mat to a temperature of from about 500° C. to about 800° C. for at least about 3 minutes.

5 . The method of claim 1 , further comprising adding a binder to the insulation mat after said heat treating the insulation mat.

6 . The method of claim 1 , wherein the first inorganic fibers are present in the mixture of fibers in an amount of at least about 80 percent by weight.

7 . The method of claim 1 , wherein the first inorganic fibers comprise at least one of biosoluble fibers or refractory ceramic fibers.

8 . The method of claim 1 , wherein the first inorganic fibers shrink by no more than about 2 percent when heat treated at a temperature of from about 500° C. to about 800° C.

9 . The method of claim 1 , wherein the second inorganic fibers are present in the mixture of fibers in an amount of up to about 20 percent by weight

10 . The method of claim 1 , wherein the second inorganic fibers comprise at least one of silica fibers, S-glass fibers, S2-glass fibers, E-glass fibers or fiberglass fibers.

11 . The method of claim 1 , wherein the second inorganic fibers shrink by about 5 to about 15 percent when heat treated at a temperature of from about 500° C. to about 800° C.

12 . An insulation mat prepared according to the method of claim 1 .

13 . The insulation mat of claim 12 , having a tensile strength of from about 40 kPa to about 110 kPa.

14 . The insulation mat of claim 12 , having a density of from about 90 kg/m 3 to about 200 kg/m 3 .

15 . The insulation mat of claim 12 , having a basis weight of from about 400 gsm to about 5,000 gsm.

16 . An insulation mat comprising first inorganic fibers and second inorganic fibers, having at least one of:
a tensile strength of from about 40 kPa to about 110 kPa, optionally from about 80 kPa to about 105 kPa; a density of from about 90 kg/m 3 to about 200 kg/m 3 , optionally from about 90 kg/m 3 to about 150 kg/m 3 , further optionally from about 100 kg/m 3 to about 150 kg/m 3 ; or a basis weight of from about 400 gsm to about 5,000 gsm, optionally from about 400 gsm to about 4,000 gsm; wherein the first inorganic fibers shrink by no more than about 2 percent and the second fibers shrink by about 5 to about 15 percent when the insulation mat is heat treated at a temperature of from about 500° C. to about 800° C.

17 . The insulation mat of claim 16 , wherein the first inorganic fibers are present in the mixture of fibers in an amount of at least about 80 percent by weight.

18 . The insulation mat of claim 16 , wherein the second inorganic fibers are present in the mixture of fibers in an amount of up to about 20 percent by weight.

19 . The insulation mat of claim 16 , wherein the first inorganic fibers comprise at least one of biosoluble fibers or refractory ceramic fibers.

20 . The insulation mat of claim 16 , wherein the second inorganic fibers comprise at least one of silica fibers, S-glass fibers, S2-glass fibers, E-glass fibers or fiberglass fibers.

21 . The insulation mat of claim 16 , wherein the first inorganic fibers shrink by no more than about 2 percent when heat treated at a temperature of from about 500° C. to about 800° C.

22 . The insulation mat of claim 16 , wherein the second inorganic fibers shrink by about 5 to about 15 percent when heat treated at a temperature of from about 500° C. to about 800° C.

Assignees

• Unifrax I Llc

Inventors

• Chauhan Digvijay Singh
• Kumar Amit
• Lacki Thomas S

Classifications

• D04H1/4209

  Inorganic fibres · CPC title

• D04H1/58

  by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives (in combination with needling D04H1/488) · CPC title

• D04H1/492

  by fluid jet (D04H1/49 takes precedence) · CPC title

• F01N13/14

  having thermal insulation {(exhaust manifolds F01N13/102)} · CPC title

• B60R13/0876 Primary

  for mounting around heat sources, e.g. exhaust pipes · CPC title