Mounting mat for pollution control elements

Abstract

Mat (1) for mounting a pollution control element in a housing, comprising inorganic fibre material. At an edge surface (20) of the mat a plurality of fibres (30) are heat fused to form fusion volumes (90). The average number of fusion volumes per square millimetre of the edge surface is at least 100, and at least 80% of the fusion volumes have a projected size of between 10 m and 100 m.

Claims

1. A mat comprising: a fibre material comprising inorganic fibres and defining first and second opposed major surfaces of the mat, and at least one edge surface connecting the major surfaces at a portion of their peripheries, wherein the edge surface defines an edge plane, and at which edge surface a plurality of the inorganic fibres of the fibre material are heat fused such as to form a plurality of fusion volumes, wherein each fusion volume has a projected size, defined by the longest geometric extension of a parallel projection of the fusion volume onto the edge plane, and wherein the average number of fusion volumes per square millimetre of the edge plane is at least 100, characterized in that at least 80% of the fusion volumes have a projected size of between 10 m and 100 m.

2. The mat of claim 1, wherein the fibres of the fibre material have a nominal average diameter of between 4.5 m and 6.5 m.

3. The mat of claim 1, wherein the mat has a thickness of between 0.5 cm and 5.0 cm, in an uncompressed state.

4. The mat of claim 1, wherein the fibre material is a nonwoven material.

5. The mat of claim 1, wherein the fibre material has a mass density of between 500 g/m.sup.2 and 8000 g/m.sup.2.

6. The mat of claim 1, wherein the inorganic fibres comprise alumina fibres and/or silica fibres and/or alumina-silica fibres.

7. The mat of claim 1, wherein the plurality of inorganic fibres are heat fused by laser radiation.

8. The mat of claim 1, wherein the fibre material is a nonwoven material, wherein the fibres of the fibre material are alumina-silica fibres having a nominal average diameter of 5.5 m, and wherein the edge surface is a geometric plane.

9. The mat of claim 1, having a thickness of between 10 mm and 15 mm in an uncompressed state, wherein the fibre material is a nonwoven material.

10. A device comprising the mat of claim 1, the mat being arranged in a gap between opposing elements.

11. The device of claim 10, wherein said device is a pollution control device, one opposing element is a housing, the other opposing element is a pollution control element arranged in the housing, and the mat is arranged in a gap between at least a portion of the housing and a portion of the pollution control element.

12. The mat of claim 1, wherein said mat is for mounting a pollution control element in a housing.

13. A method of forming a mat, wherein the mat comprises a fibre material comprising inorganic fibres and defining first and second opposed major surfaces of the mat, and at least one edge surface connecting the major surfaces at a portion of their peripheries, wherein the edge surface defines an edge plane, the method comprising a step of applying heat to the edge surface a) in such a manner, that a plurality of fibres of the inorganic fibre material at the edge surface are heat fused such as to form a plurality of fusion volumes, wherein each fusion volume has a projected size, defined by the longest geometric extension of a parallel projection of the fusion volume onto the edge plane, and b) in such a manner that the average number of fusion volumes per square millimetre of the edge plane is at least 100, and c) in such a manner that at least 80% of the fusion volumes have a projected size of between 10 m and 100 m.

14. The method of claim 13, wherein the step of applying heat to the edge surface is performed using a laser.

15. The method of claim 13, wherein the step of applying heat to the edge surface is performed by, or simultaneously with, a cutting process for generating the edge surface.

16. The method of claim 13, further comprising a step of generating the edge surface, this step being performed before the step of applying heat to the edge surface.

17. The method of claim 13, further comprising a step of soaking a portion of the mat comprising the edge surface with water, this step being performed before the step of applying heat to the edge surface.

18. The method of claim 13, wherein said method is for forming a mat for mounting a pollution control element in a housing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will now be described in more detail with reference to the following Figures exemplifying particular embodiments of the invention:

(2) FIG. 1 Perspective sketch of a first mat for mounting a pollution control element;

(3) FIG. 2 Sketched side view of the first mat, in more detail;

(4) FIG. 3 Sketched side view of the first mat;

(5) FIG. 4 Sketched perspective view of a corner of the first mat;

(6) FIG. 5 Perspective sketch of a mat according to the disclosure, showing fusion volumes generated in heat treating the edge surface;

(7) FIG. 6 Microphotograph of an edge surface of an untreated mat;

(8) FIG. 7 Microphotograph of an edge surface of a heat-treated mat according to the present disclosure, having 109 fusion volumes in a 1 mm.sup.2 sample area;

(9) FIG. 8 Microphotograph of an edge surface of a heat-treated mat according to the present disclosure, having 104 fusion volumes in a 1 mm.sup.2 sample area;

(10) FIG. 9 Microphotograph of an edge surface of a heat-treated mat, having 40 fusion volumes in a 1 mm.sup.2 sample area; and

(11) FIG. 10 Microphotograph of an edge surface of a heat-treated mat, having 12 fusion volumes per mm.sup.2.

DETAILED DESCRIPTION

(12) Referring to FIGS. 1-4, the geometry of a mat for mounting a pollution control element in a housing is illustrated, and terms used herein are explained. FIG. 1 is a perspective sketch of a mat 1 for mounting a pollution control element in a housing. The mat 1 comprises a fibre material (not shown in FIG. 1) comprising inorganic fibres. The fibre material defines a first, upper major surface 10 and an opposed second, lower major surface 11. Several edge surfaces 20, of which some are not visible, connect the major surfaces 10, 11 at their peripheries.

(13) The mat 1 is shown flat, that is to say, its parallel opposite major surfaces 10, 11 extend in width directions x and in length directions y. In use, the mat 1 is generally wrapped circumferentially around a pollution control element.

(14) FIG. 2 shows an edge of the mat 1 in a sketched side view in more detail. The mat 1 comprises a non-woven fibre material comprising inorganic fibres 30, of which only two fibres are provided with reference numbers, to enhance clarity. Fibres 30 in the material extend, in the thickness direction z, to an upper portion 60 of the mat 1, and in the opposite thickness direction z up to a lower portion 70. In one of the width directions, fibres 30 extend to an edge portion 40. The fibres 30 as such form an open structure at the edge portion 40.

(15) While FIG. 2 is an illustration of the physical fibres 30, FIG. 3 additionally shows the envelope surfaces defined by the fibres 30. The end points of fibres 30 at the edge portion 40 define a surface, the edge surface 20, which is a geometric plane, enveloping the ends of the fibres 30 at the edge portion 40 and extending orthogonal to the drawing plane. The edge surface 20 delimits the mat 1 in width direction x.

(16) Similarly, the end points of fibres 30 at the upper portion 60 of the mat 1 define a surface, the upper major surface 10, which is a geometric plane enveloping the ends of the fibres 30 at the upper portion 60. The end points of fibres 30 at the lower portion 70 of the mat 1 define a surface, the lower major surface 11, which is a geometric plane enveloping the ends of the fibres 30 at the lower portion 70. The upper and lower major surfaces 10, 11 delimit the mat 1 in thickness directions z.

(17) FIG. 4 shows, in a perspective sketch, a corner of the mat 1 in detail. Two edge surfaces 20 are visible, which meet at the corner 50 of the mat 1. The edge surfaces 20 are geometric planes, orthogonal to each other, formed by cutting the mat 1 with a laser beam out of a larger sheet of fibre material. For the left-hand edge surface 20, the edge plane 80 is shown. It is a virtual geometric plane, defined by the edge surface 20. In FIG. 4, only the edge plane 80 of the left-hand edge surface 20 is shown, however, also the right-hand edge surface 20 defines its own edge plane, which is not drawn for clarity.

(18) While an edge surface 20 may be curved in certain mats, for example in circular mats, the edge plane 80 is always a plane and serves as a projection plane to determine projected size of fusion volumes, as will be explained in the following.

(19) Fusion volumes are not shown in the sketched views of FIGS. 1-4, because their typical projected sizes are in the range of 10 m to 100 m, which is too small to be visible with the unaided eye from viewing distances like the ones used for FIGS. 1-4.

(20) FIG. 5 illustrates, in a perspective sketch, a way of performing heat treatment of an edge surface 20 of a mat 1 according to the invention with an infrared laser. The laser beam 100 is directed orthogonally towards the edge surface 20. In order to cover the entire edge surface 20, the laser beam 100 scans the edge surface 20 in z direction, while the mat 1 is transported linearly in +x direction indicated by arrow 110. Alternatively, the laser could be moved relative to the mat 1, or the laser beam 100 could scan in x directions. As the laser beam 100 scans over the edge surface 20 and heats the fibre material, fibres 30 are heat-fused, either alone or with other fibres 30, and form fusion volumes 90 at the edge surface 20. The laser beam scan pattern is a pattern of parallel vertical lines on the edge surface 20. The horizontal spacing between two subsequent scan lines (grid space) can be varied. A suitable typical value for grid space with a 300 Watt CO.sub.2 laser is 0.8 mm. The vertical speed with which the laser beam 100 scans along each vertical scan line can be adjusted, too. A suitable typical scan speed value for a 300 W CO.sub.2 laser is 1 m/s.

(21) The laser can be operated with a front optics for focussing the laser beam 100. In order to obtain more and smaller fusion volumes 90, however, the edge surface 20 is not arranged in the focal plane of the laser front optics, but a few centimetres behind the laser beam focus. This also results in acceleration of the heat treatment, because the slightly defocused laser beam 100 covered a greater area of the edge surface 20 than a focussed beam. The distance between the focal plane of the laser beam 100 and the edge surface 20, measured along the beam 100, is referred to herein as focus distance. A suitable typical value for the focus distance is 60 mm. By using the laser beam 100 out of its focus, the beam diameter on the edge surface 20 is larger, so that a larger portion of the edge surface 20 can be heat fused at the same time.

(22) FIGS. 7-10 show images of inorganic fibres 30 of the fibre material at respective edge surfaces 20, heat fused to form fusion volumes 90 which appear as white structures of generally circular, but rather irregular shape. FIG. 6 shows an edge surface 20 of an untreated fibre material not exhibiting any fusion volumes.

(23) FIGS. 6-10 are microphotographs, taken with a scanning electron microscope viewing orthogonally at the edge surface 20, in order to minimize distortion of the image. The Figures show portions of edge surfaces 20 of sample mats made from the same fibre material, but having been subjected to different heat treatment or to no heat treatment at all. The edge surfaces 20 were generated by die cutting a sheet of inorganic fibre material having a weight of 2200 g/m.sup.2. The fibres 30 of that material had a nominal average diameter of 5.5 m. A CO.sub.2 laser of 300 Watt nominal power was used for heat treatment. The microphotographs contain minute indications of the projected sizes of certain fusion volumes 90.

(24) FIG. 6 is a microphotograph, taken with a scanning electron microscope, of an edge surface 20 which has not been subjected to heat treatment. The entire horizontal bar below the bottom right corner of the photograph indicates a length of 300 m.

(25) FIG. 7 is a microphotograph of an edge surface 20 of a mat 1 according to the present disclosure, after heat treatment according to the present disclosure. The photograph shows inorganic fibres 30 of the fibre material, heat fused to form fusion volumes 90, which appear as white structures of generally circular, but rather irregular shape. The laser was operated at a grid space of 0.8 mm, a scan speed of 1 m/s and a focus distance of 60 mm.

(26) The solid bar at the bottom right corner corresponds to a length of 1 mm on the edge surface 20 and indicates the scale of the microphotograph being about 1:60 (depending on how it is reproduced). The microphotograph thus covers an area of approximately 1.7 mm by 1.3 mm of the edge surface 20.

(27) A 1 mm1 mm area of the heat-treated edge surface 20 shown in FIG. 7 was analyzed for number and projected size of the fusion volumes 90. There were 109 fusion volumes identified. 100 of these (92%) had a projected size of between 10 m and 100 m. When the Fibre Loss Test described herein was performed on a sample of this material, a weight loss of 0.21% was measured. These results were entered into Table 1 as Example 1.

(28) FIG. 8 is a microphotograph of an edge surface 20 of a mat 1 according to the present disclosure, after heat treatment, different from the heat treatment of the edge surface 20 described in relation to FIG. 7. The laser was operated at a grid space of 0.8 mm, a scan speed of 1 m/s and a focus distance of 40 mm. The solid bar at the bottom right corner indicates a length of 1 mm on the edge surface 20 and indicates the scale of the microphotograph.

(29) A 1 mm1 mm area of the heat-treated edge surface 20 shown in FIG. 8 was analyzed for number and projected size of the fusion volumes 90. There were 104 fusion volumes 90 identified. 102 of these (98%) had a projected size of between 10 m and 100 m. When the Fibre Loss Test described herein was performed on a sample of this material, a weight loss of 0.28% was measured. These results were entered into Table 1 as Example 2.

(30) FIG. 9 is a microphotograph of an edge surface 20 of a further mat. The edge surface 20 of this mat has been heat treated, but different from the heat treatment of the edge surfaces 20 described in relation to FIGS. 7 and 8. In order to produce the edge surface 20 shown in FIG. 9, the laser was operated at a grid space of 0.8 mm, a scan speed of 1 m/s and a focus distance of only 10 mm. The solid bar at the bottom right corner indicates a length of 1 mm on the edge surface 20 and indicates the scale of the microphotograph.

(31) A 1 mm1 mm area of the heat-treated edge surface 20 shown in FIG. 9 was analyzed for number and projected size of the fusion volumes 90. There were 40 fusion volumes 90 identified. 14 of these (35%) had a projected size of between 10 m and 100 m. Most fusion volumes 90 had a projected size of more than 100 m. When the Fibre Loss Test described herein was performed on a sample of this material, a weight loss of 0.45% was measured. These results were entered into Table 1 as Comparative Example 1.

(32) FIG. 10 is a microphotograph of an edge surface 20 of a further mat. The edge surface 20 of this mat has been heat treated in the same way as the edge surface described in the context of FIG. 7. However, the edge surface 20 shown in FIG. 10 was sprayed with water before heat treating. In order to produce the edge surface 20 shown in FIG. 10, the laser was operated at a grid space of 0.8 mm, a scan speed of 1 m/s and a focus distance of 40 mm. The solid bar at the bottom right corner indicates a length of 500 m on the edge surface 20 and indicates the scale of the microphotograph.

(33) Probably due to uneven water spraying, fusion volumes were created mainly in the bottom portion of the area shown in the photograph. A 1 mm1 mm area in the bottom portion of the heat-treated edge surface 20 shown in FIG. 10 was analyzed for number and projected size of the fusion volumes 90. There were only 12 fusion volumes 90 identified. 11 of these (92%) had a projected size of between 10 m and 100 m. Most fusion volumes 90 within this size range had a projected size of only slightly over 10 m. When the Fibre Loss Test described herein was performed on a sample of this material, a weight loss of 0.99% was measured. These results were entered into Table 1 as Comparative Example 3.

(34) It is noted that the water spray resulted in a mat having inferior shedding properties, compared to the mat of FIG. 7, which was treated using the same laser settings, but without water spray.

EXAMPLES

(35) Samples of mats were prepared from an alumina-silica fibre sheet denominated Maftec MLS2 from Mitsubishi Plastics Inc. The sheet had a base weight of 2150 g/m.sup.2 and a thickness of about 12.5 mm. The fibres had a nominal average diameter of 5.5 m. The sheet was spray impregnated with a slurry of organic binder (Acronal A273 S from BASF) and inorganic particles (Boehmite powder available under the name Dispal 23n4-80 from company Sasol). Fifteen square-shaped samples, each sized 50 mm50 mm, were cut out of the sheet using a die and grouped into five sample groups, each containing three samples.

(36) Samples in sample group 5 were sprayed with water prior to heat treatment, in order to obtain fewer and larger fusion volumes.

(37) All four edge surfaces of the samples of sample groups 1-5 were heat-fused using a laser beam of 9.7 m wavelength, generated in a 300 W CO.sub.2 laser of Rofin-Baasel GmbH&Co. KG. The laser beam was oriented orthogonal to the edge surface and scanned the edge surface in a pattern of parallel vertical lines being separated by a horizontal spacing referred to as grid space, with a linear speed in a direction along the vertical lines of 1 m/s.

(38) In order to obtain different sizes of fusion volumes and different size distributions, different laser settings for focus distance and grid space were used:

Example 1

(39) Sample group 1, focus distance=60 mm, grid space=0.8 mm;

Example 2

(40) Sample group 2, focus distance=40 mm, grid space=0.8 mm;

Comparative Example 1

(41) Sample group 3, focus distance=10 mm, grid space=0.8 mm;

Comparative Example 2

(42) Sample group 4, focus distance=60 mm, grid space 0.6 mm;

Comparative Example 3

(43) Sample group 5, focus distance=40 mm, grid space=0.8 mm.

(44) After heat fusion, the heat-treated edge surfaces of all samples within a sample group looked generally similar and rather uniform. A portion of an edge surface of one sample of each sample group was analyzed by taking microphotographs using an electron microscope TM3000 from Hitachi. To avoid image distortions, the imaging direction of the microscope was set orthogonal to the edge surface in the middle of the photographed portion of the edge surface. For each fusion volume shown in a portion of the microphotographs corresponding to a 1 mm1 mm area on the edge surface, the projected size was determined by measuring the length of the longest geometric extension of the fusion volume in the microphotograph, applying the scaling factor of the photo, and thereby obtaining the real projected size of each fusion volume, as projected in the photographic parallel projection onto the edge surface. The process of measuring the length of the longest geometric extension was done by a human on a computerized version of the microphotograph, using available tools for measuring length in image processing software. Only those features were considered fusion volumes and were taken into account that had a projected size of more than 7.5 m. The projected size of each fusion volume was rounded to the closest integer number, which was entered into a list.

(45) The average number of fusion volumes per square millimetre of the edge plane was determined by counting the number of entries in the list.

(46) The ratio of fusion volumes having a projected size of between 10 m and 100 m was determined by dividing the number of those fusion volumes in the 1 mm1 mm area having a projected size of between 10 m and 100 m (including those fusion volumes having a projected size of exactly 10 or exactly 100 m) by the number of all fusion volumes in the 1 mm1 mm area. The percentage was obtained by multiplying this ratio number with 100.

(47) Fibre shedding performance of sample groups 1-5 was then evaluated using the fibre loss test described below. Each sample of each sample group was tested in the fibre loss test. Each sample yielded a shedding percentage, expressed as weight loss in percent. The higher the weight loss, the higher the amount of fibre dust exiting the sample, so that a higher weight loss corresponds to a less desired shedding performance. The weight loss percentage of the three samples of a sample group were added and divided by three to yield a shedding performance for the sample group. Table 1 summarizes the results.

(48) TABLE-US-00001 TABLE 1 Percentage of Average fusion volumes number of per mm.sup.2 Shedding Sample fusion volumes having projected weight group per mm.sup.2 size 1-10 m loss Example 1 1 109 92% 0.21% Example 2 2 104 98% 0.28% Comparative 3 40 35% 0.45% Example 1 Comparative 4 101 74% 0.35% Example 2 Comparative 5 12 92% 0.99% Example 3

(49) The table confirms that samples having an average of at least 100 fusion volumes per mm.sup.2 of the edge plane and, simultaneously, of which fusion volumes at least 80% have a projected size of between 10 m and 100 m exhibit a superior shedding performance of less than 0.30%. Based on this data, it is believed that heat treatment of edge surfaces of mounting mats according to the present disclosure will result in a lower amount of fibre dust loss when the mats are handled during a pollution control device assembly operation, as compared to untreated mounting mats.

(50) Test Method Fibre Loss Test

(51) The fibre loss test is used to determine the amount of fibre shedding, that is the percentage, by weight, of fibre that is lost by a fibre material comprising inorganic fibres on impact due to fibre shedding. The test fixture is the device according to the Japanese Standard JIS K-6830-1996, as revised 1996-04-01. This device has a fixed vertical frame connected by hinges at the top to a second frame having approximately the same dimensions as the fixed frame. The second frame can be pivoted about the hinges with respect to the fixed frame, whereby it moves outwardly at the bottom to form an angle with the fixed frame at the top that is defined by the fixed frame and the second frame.

(52) A test sample of fibre material measuring 50 mm by 50 mm is weighed, and then clamped onto a mounting plate attached to the bottom of the second frame, with one of the edge surfaces facing downward. The mounting plate is even with the bottom of the second frame so that the mat and plate do not extend beyond the peripheral edges of second frame.

(53) To perform the test, the second frame is pivoted upward to form a 45 degree angle with the fixed frame and released so that it strikes the fixed frame. The impact of the plate striking the frame causes any fibre dust and other debris to fall off of the sample. The sample is removed and weighed, and test results are reported in percent weight loss as follows:
[(Tared weightWeight after striking frame)/(Tared weight)]100=Percent Fibre Loss,

(54) wherein tared weight is the weight of the sample prior to being clamped onto the mounting plate of the second frame.