US20160069246A1 - Method of producing an insulated exhaust device - Google Patents
Method of producing an insulated exhaust device Download PDFInfo
- Publication number
- US20160069246A1 US20160069246A1 US14/941,961 US201514941961A US2016069246A1 US 20160069246 A1 US20160069246 A1 US 20160069246A1 US 201514941961 A US201514941961 A US 201514941961A US 2016069246 A1 US2016069246 A1 US 2016069246A1
- Authority
- US
- United States
- Prior art keywords
- blanket
- max
- exhaust gas
- covering
- insulation material
- 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.)
- Abandoned
Links
Images
Classifications
-
- 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
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/14—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having thermal insulation
- F01N13/148—Multiple layers of insulating material
-
- 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
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/18—Construction facilitating manufacture, assembly, or disassembly
-
- 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
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/14—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having thermal insulation
-
- 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
- F01N2310/02—Mineral wool, e.g. glass wool, rock wool, asbestos or the like
-
- 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
- Y10T29/49826—Assembling or joining
Definitions
- This invention relates to exhaust gas aftertreatment and/or acoustic systems and the devices used therein that utilize external insulation blankets.
- Heat insulating batts and blankets are utilized in exhaust gas systems in order to provide heat insulation for acoustic and aftertreatment devices of the system to control the heat exchange to and from the devices. It is known, for example, to place heat insulating blankets between adjacent wall surfaces of such devices with the material of the heat insulation blanket being compressed to provide a desired installed density for the material to help maintain the heat insulating blanket in its mounted position via frictional forces between the blanket and the adjacent wall surfaces.
- Such a structure is shown in U.S. Ser. No. 12/696,347, filed Jan. 29, 2010 by Keith Olivier et al., entitled “Method of Producing an Insulated Exhaust Device”, the disclosure of which is hereby incorporated by reference.
- the present invention is directed to overcoming one or more of the problems set forth above.
- a method of providing external insulation for an exhaust gas aftertreatment or acoustic device having a maximum operating temperature T MAX includes (a) providing a blanket of silica fiber insulation material having a weight percentage of SiO 2 of greater than 65%, (b) calcining the blanket by heating all of the silica fiber insulation material to a temperature T greater than T MAX , wherein T is less than a melting temperature of the silica fibers of the blanket, (c) encapsulating the blanket in a covering before the calcining step whereby the blanket is batting in the covering, and (d) securing the blanket around an outermost surface of the exhaust gas aftertreatment or acoustic device after the calcining step, wherein the covering between the blanket and the exhaust gas aftertreatment or acoustic device is a selected one of wire mesh or high temperature textile.
- T is at least 1.05 ⁇ T MAX .
- the high temperature textile is a selected one of siliconized fiber glass or straight woven glass fiber.
- the blanket is an uncompressed state.
- T MAX is within the range of 300° C. to 1100° C.
- the securing step comprises installing the blanket so that the blanket encircles a core of the device through which the exhaust gas passes.
- a method of providing external insulation for an exhaust gas aftertreatment or acoustic device having a maximum operating temperature T MAX includes (a) providing a blanket of silica fiber insulation material having a weight percentage of SiO 2 of greater than 95%, (b) calcining the blanket by heating all of the silica fiber insulation material to a temperature T greater than T MAX , wherein T is less than a melting temperature of the silica fibers of the blanket, (c) encapsulating the blanket in a covering before the calcining step whereby the blanket is batting in the covering, and (d) securing the blanket around an outermost surface of the exhaust gas aftertreatment or acoustic device after the calcining step, wherein the covering between the blanket and the exhaust gas aftertreatment or acoustic device is a selected one of wire mesh or high temperature textile.
- the high temperature textile is a selected one of siliconized fiber glass or straight woven glass fiber.
- the blanket is an uncompressed state.
- T MAX is within the range of 300° C. to 1100° C.
- the securing step comprises installing the blanket so that the blanket encircles a core of the device through which the exhaust gas passes.
- a method of providing external insulation for an exhaust gas aftertreatment or acoustic device having a maximum operating temperature T MAX includes (a) providing a blanket of silica fiber insulation material having a weight percentage of SiO 2 of greater than 65%, (b) calcining the blanket in an uncompressed state by heating all of the silica fiber insulation material to a temperature T greater than T MAX , wherein T is less than a melting temperature of the silica fibers of the blanket and is at least 1.05 ⁇ T MAX and T MAX is within a range of 300° C.
- the high temperature textile is a selected one of siliconized fiber glass or straight woven glass fiber.
- the securing step comprises installing the blanket so that the blanket encircles a core of the device through which the exhaust gas passes.
- FIG. 1 is a section view of an exhaust system component employing the invention.
- FIG. 2 is a section view of a portion of the external blanket of the present invention encapsulated in a covering.
- the present invention may be used, for example, in an exhaust gas system such as a diesel exhaust gas aftertreatment system to treat the exhaust from a diesel combustion process (e.g., a diesel compression engine).
- the exhaust will typically contain oxides of nitrogen (NO x ) such as nitric oxide (NO) and nitrogen dioxide (NO 2 ) among others, particulate matter (PM), hydrocarbons, carbon monoxide (CO), and other combustion by-products.
- the system may include one or more exhaust gas acoustic and/or aftertreatment devices or components.
- Examples of such devices include catalytic converters, diesel oxidation catalysts, diesel particulate filters, gas particulate filters, lean NO x traps, selective catalytic reduction monoliths, burners, manifolds, connecting pipes, mufflers, resonators, tail pipes, emission control system enclosure boxes, insulation rings, insulated end cones, insulated end caps, insulated inlet pipes, and insulated outlet pipes, all of any cross-sectional geometry, many of which are known.
- some of the foregoing devices may be strictly metallic components with a central core through which the exhaust flows, and other of the devices may include a core in the form of a ceramic monolithic structure and/or a woven metal structure through which the exhaust flows.
- These devices are conventionally used in motor vehicles (diesel or gasoline), construction equipment, locomotive engine applications (diesel or gasoline), marine engine applications (diesel or gasoline), small internal combustion engines (diesel or gasoline), and stationary power generation (diesel or gasoline).
- FIG. 1 shows one example of such a device for use in a system such as described above, in the form of a catalytic unit 20 such as shown in Olivier et al. U.S. Ser. No. 12/696,347, the disclosure of which was heretofore incorporated by reference.
- the catalytic unit 20 has a catalytic core 22 , a mount mat 24 , a cylindrical inner housing or can 26 , and heat insulating blanket or batt 28 , and a cylindrical outer housing or jacket 30 .
- the core 22 may typically be a ceramic substrate having a monolithic structure with a catalyst coated thereon and will typically have an oval or circular cross section.
- the mounting mat 24 is sandwiched between the core 22 and the can 26 to help protect the core 22 from shock and vibrational forces that can be transmitted from the can 26 to the core 22 .
- the mounting mat 24 is made of a heat resistant and shock absorbing-type material, such as a mat of glass fibers or rock wool and is compressed between the can and the carrier in order to generate a desired holding force.
- the heat insulating blanket 28 located inside the catalytic unit outer housing 30 may be made of a silica fiber insulation material having a weight percentage of SiO 2 of greater than 65%, and in preferred embodiments greater than 95%, and in highly preferred embodiments greater than 98%.
- a silica fiber insulation material having a weight percentage of SiO 2 of greater than 65%, and in preferred embodiments greater than 95%, and in highly preferred embodiments greater than 98%.
- an external blanket 40 is wrapped around the unit outer housing 30 so as to substantially encapsulate the housing 30 .
- the external blanket 40 may be advantageously made of a silica fiber insulation material having a weight percentage of SiO 2 of greater than 65%, and in preferred embodiments greater than 95%, and in highly preferred embodiments greater than 98%.
- a silica fiber insulation material having a weight percentage of SiO 2 of greater than 65%, and in preferred embodiments greater than 95%, and in highly preferred embodiments greater than 98%.
- Such material is known and commercially available, with one suitable example being supplied by BGF Industries, Inc. under the trade name SilcoSoft®, and another suitable example being supplied by ASGLAWO technofibre GmbH under the trade name Asglasil®.
- Such material is typically supplied in rolls, with the individual blankets 40 being die cut to the appropriate length and width for the corresponding device 20 after the material has been taken from the roll.
- the blanket 40 may have an average installed density of 0.18 grams/cubic centimeter to 0.30 grams/cubic centimeter of the silica fiber insulation material of the blanket 40 .
- the blanket 28 is heat treated to achieve calcination of the silica fiber insulation material.
- the blanket 40 is heated so that all of the silica fiber insulation material in the blanket 28 is raised to a temperature T greater than the maximum operating temperature T MAX of the device 20 .
- This heat treatment improves the resiliency and erosion resistance of the silica fiber insulation material and also eliminates the potential for a “thermoset” failure mode that can result if the silica fiber material were calcinated in-situ in the device 20 during operation of the system.
- this heat treatment takes place with the blanket 40 in an uncompressed or free state wherein there are no compressive forces being applied to the silica fiber insulation material of the blanket 40 .
- the temperature T preferably has some margin of safety above the maximum operating temperature T MAX of the device 18 , with one preferred margin of safety being 1.05 ⁇ T MAX .
- This heat treatment improves the resiliency and erosion resistance of the silica fiber insulation material and also eliminates the potential for a “thermoset” failure mode that could result if the silica fiber material were to be calcinated in-situ on the device during operation of the system.
- heat treatment takes place with the external blanket 40 in an uncompressed or free state wherein there are no compressive forces being applied to the silica fiber insulation material of the external blanket 40 .
- the temperature T preferably has some margin of safety above the maximum operating temperature T MAX of the device 18 , with one preferred margin of safety being 1.05 ⁇ T MAX .
- the heat treated blanket can maintain suitable frictional engagement with the unit outer housing 30 over the desired life of the device because the silica fiber insulation material of the blanket 40 maintains its resiliency and does not take on a “thermoset” from the max operation temperature T MAX of the device.
- the heat treatment may advantageously be accomplished using an in-line oven wherein the silica fiber heat insulation material is unrolled from a supply roll of the material and passed fiat through an oven on a conveyor so that the external blanket 40 is planar during the heat treatment to reduce or prevent differential heating of the material of the blanket 40 and variation in thickness of the material in the blanket 40 .
- individual blankets 40 can be die cut to the desired length and width before installing on a device.
- a complete supply roll of the silica fiber heat insulation material can be heat treated, with or without rotation of the roll in an oven, whereby individual blankets 40 can be die cut to the desired length and width after heat treatment and before installing on the device.
- the silica fiber insulation material can be die cut before heat treatment, with the blanket being slightly oversized in length and width to account for shrinkage during heat treatment, and with the die cut blankets then heat treated in an oven while laying flat on a planar surface.
- the external blanket 40 may also advantageously be a high alumina blanket.
- the external blanket 40 may be advantageously made of an alumina insulation material having a weight percentage of Al 2 O 3 of greater than 65%, and in preferred embodiments greater than 95%, and in highly preferred embodiments greater than 98%.
- Such blankets are known and commercially available, with one suitable example being supplied by Sell Ltd. of Cheshire, U.K. under the LDM trade name, and another suitable example being supplied by Mitsubishi under the MLS-2 trade name.
- these high alumina blankets 40 are also heat treated to achieve calcination prior to placement on the device 20 .
- the calcined external blanket 40 of either embodiment is advantageously used as batting encapsulated in a covering 50 prior to placement on the device 20 , as illustrated in FIG. 2 . Calcination of the blanket 40 may be accomplished before encapsulating the blanket 40 in the covering 50 . However, calcination may also be accomplished in the covering 50 where the covering 50 will not be adversely impacted by the temperatures used in the calcinations.
- the side of the covering facing the heat side may advantageously be foil, wire mesh or a high temperature textile, such as siliconized fiber glass or straight woven glass fiber.
- devices in exhaust gas systems having external blankets according to the present invention substantially reduce damage and cracking when removing and replacing insulation, damage due to exposure to vibration, damage due to loose or otherwise inappropriate fit due to thermal set, and/or loss of insulation properties due to loose or otherwise inappropriate fit, and/or loss of insulation material.
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Exhaust Silencers (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
- This application is a divisional of Ser. No. 13/277,663, filed Oct. 20, 2011, the disclosure of which is hereby incorporated by reference.
- Not Applicable.
- Not Applicable.
- This invention relates to exhaust gas aftertreatment and/or acoustic systems and the devices used therein that utilize external insulation blankets.
- Heat insulating batts and blankets are utilized in exhaust gas systems in order to provide heat insulation for acoustic and aftertreatment devices of the system to control the heat exchange to and from the devices. It is known, for example, to place heat insulating blankets between adjacent wall surfaces of such devices with the material of the heat insulation blanket being compressed to provide a desired installed density for the material to help maintain the heat insulating blanket in its mounted position via frictional forces between the blanket and the adjacent wall surfaces. Such a structure is shown in U.S. Ser. No. 12/696,347, filed Jan. 29, 2010 by Keith Olivier et al., entitled “Method of Producing an Insulated Exhaust Device”, the disclosure of which is hereby incorporated by reference.
- It is also known to provide heat insulation blankets around the exterior of such exhaust gas system devices. However, such blankets have been found to encounter a variety of failure modes, including damage and cracking when removing and replacing insulation, damage due to exposure to vibration, damage due to loose or otherwise inappropriate fit due to thermal set, loss of insulation properties due to loose or otherwise inappropriate fit, and/or loss of insulation material.
- The present invention is directed to overcoming one or more of the problems set forth above.
- In one aspect of the invention, a method of providing external insulation for an exhaust gas aftertreatment or acoustic device having a maximum operating temperature TMAX is provided, where the method includes (a) providing a blanket of silica fiber insulation material having a weight percentage of SiO2 of greater than 65%, (b) calcining the blanket by heating all of the silica fiber insulation material to a temperature T greater than TMAX, wherein T is less than a melting temperature of the silica fibers of the blanket, (c) encapsulating the blanket in a covering before the calcining step whereby the blanket is batting in the covering, and (d) securing the blanket around an outermost surface of the exhaust gas aftertreatment or acoustic device after the calcining step, wherein the covering between the blanket and the exhaust gas aftertreatment or acoustic device is a selected one of wire mesh or high temperature textile.
- In one form of this aspect of the invention, T is at least 1.05×TMAX.
- In another form of this aspect of the invention, the high temperature textile is a selected one of siliconized fiber glass or straight woven glass fiber.
- In yet another form of this aspect of the present invention, during the calcining step the blanket is an uncompressed state.
- In another form of this aspect of the present invention, TMAX is within the range of 300° C. to 1100° C.
- In still another form, the securing step comprises installing the blanket so that the blanket encircles a core of the device through which the exhaust gas passes.
- In another aspect of the invention, a method of providing external insulation for an exhaust gas aftertreatment or acoustic device having a maximum operating temperature TMAX is provided, where the method includes (a) providing a blanket of silica fiber insulation material having a weight percentage of SiO2 of greater than 95%, (b) calcining the blanket by heating all of the silica fiber insulation material to a temperature T greater than TMAX, wherein T is less than a melting temperature of the silica fibers of the blanket, (c) encapsulating the blanket in a covering before the calcining step whereby the blanket is batting in the covering, and (d) securing the blanket around an outermost surface of the exhaust gas aftertreatment or acoustic device after the calcining step, wherein the covering between the blanket and the exhaust gas aftertreatment or acoustic device is a selected one of wire mesh or high temperature textile.
- In one form of this aspect of the invention, T is at least 1.05×TMAX.
- In another form of this aspect of the invention, the high temperature textile is a selected one of siliconized fiber glass or straight woven glass fiber.
- In yet another form of this aspect of the present invention, during the calcining step the blanket is an uncompressed state.
- In another form of this aspect of the present invention, TMAX is within the range of 300° C. to 1100° C.
- In still another form, the securing step comprises installing the blanket so that the blanket encircles a core of the device through which the exhaust gas passes.
- In still another aspect of the invention, a method of providing external insulation for an exhaust gas aftertreatment or acoustic device having a maximum operating temperature TMAX is provided, where the method includes (a) providing a blanket of silica fiber insulation material having a weight percentage of SiO2 of greater than 65%, (b) calcining the blanket in an uncompressed state by heating all of the silica fiber insulation material to a temperature T greater than TMAX, wherein T is less than a melting temperature of the silica fibers of the blanket and is at least 1.05×TMAX and TMAX is within a range of 300° C. to 1100° C., (c) encapsulating the blanket in a covering before the calcining step whereby the blanket is batting in the covering, and (d) securing the blanket around an outermost surface of the exhaust gas aftertreatment or acoustic device after the encapsulating step, wherein the covering between the blanket and the exhaust gas aftertreatment or acoustic device is a selected one of wire mesh or high temperature textile.
- In one form of this aspect of the invention, the high temperature textile is a selected one of siliconized fiber glass or straight woven glass fiber.
- In another form, the securing step comprises installing the blanket so that the blanket encircles a core of the device through which the exhaust gas passes.
- Other objects, features, and advantages of the invention will become apparent from a review of the entire specification, including the appended claims and drawings.
-
FIG. 1 is a section view of an exhaust system component employing the invention; and -
FIG. 2 is a section view of a portion of the external blanket of the present invention encapsulated in a covering. - The present invention may be used, for example, in an exhaust gas system such as a diesel exhaust gas aftertreatment system to treat the exhaust from a diesel combustion process (e.g., a diesel compression engine). The exhaust will typically contain oxides of nitrogen (NOx) such as nitric oxide (NO) and nitrogen dioxide (NO2) among others, particulate matter (PM), hydrocarbons, carbon monoxide (CO), and other combustion by-products. The system may include one or more exhaust gas acoustic and/or aftertreatment devices or components. Examples of such devices include catalytic converters, diesel oxidation catalysts, diesel particulate filters, gas particulate filters, lean NOx traps, selective catalytic reduction monoliths, burners, manifolds, connecting pipes, mufflers, resonators, tail pipes, emission control system enclosure boxes, insulation rings, insulated end cones, insulated end caps, insulated inlet pipes, and insulated outlet pipes, all of any cross-sectional geometry, many of which are known.
- As those skilled in the art will appreciate, some of the foregoing devices may be strictly metallic components with a central core through which the exhaust flows, and other of the devices may include a core in the form of a ceramic monolithic structure and/or a woven metal structure through which the exhaust flows. These devices are conventionally used in motor vehicles (diesel or gasoline), construction equipment, locomotive engine applications (diesel or gasoline), marine engine applications (diesel or gasoline), small internal combustion engines (diesel or gasoline), and stationary power generation (diesel or gasoline).
-
FIG. 1 shows one example of such a device for use in a system such as described above, in the form of acatalytic unit 20 such as shown in Olivier et al. U.S. Ser. No. 12/696,347, the disclosure of which was heretofore incorporated by reference. - The
catalytic unit 20 has acatalytic core 22, amount mat 24, a cylindrical inner housing or can 26, and heat insulating blanket orbatt 28, and a cylindrical outer housing orjacket 30. - The
core 22 may typically be a ceramic substrate having a monolithic structure with a catalyst coated thereon and will typically have an oval or circular cross section. - The mounting
mat 24 is sandwiched between thecore 22 and thecan 26 to help protect thecore 22 from shock and vibrational forces that can be transmitted from thecan 26 to thecore 22. Typically themounting mat 24 is made of a heat resistant and shock absorbing-type material, such as a mat of glass fibers or rock wool and is compressed between the can and the carrier in order to generate a desired holding force. - The
heat insulating blanket 28 located inside the catalytic unitouter housing 30 may be made of a silica fiber insulation material having a weight percentage of SiO2 of greater than 65%, and in preferred embodiments greater than 95%, and in highly preferred embodiments greater than 98%. Such material is known and commercially available, with one suitable example being supplied by BGF Industries, Inc. under the trade name SilcoSoft®, and another suitable example being supplied by ASGLAWO technofibre GmbH under the trade name Asglasil®. Such material is typically supplied in rolls, with theindividual blankets 28 being die cut to the appropriate length and width for the corresponding device 18 after the material has been taken from the roll. - In accordance with the present invention, an
external blanket 40 is wrapped around the unitouter housing 30 so as to substantially encapsulate thehousing 30. - In one embodiment, the
external blanket 40 may be advantageously made of a silica fiber insulation material having a weight percentage of SiO2 of greater than 65%, and in preferred embodiments greater than 95%, and in highly preferred embodiments greater than 98%. Such material is known and commercially available, with one suitable example being supplied by BGF Industries, Inc. under the trade name SilcoSoft®, and another suitable example being supplied by ASGLAWO technofibre GmbH under the trade name Asglasil®. Such material is typically supplied in rolls, with theindividual blankets 40 being die cut to the appropriate length and width for thecorresponding device 20 after the material has been taken from the roll. In one preferred form, theblanket 40 may have an average installed density of 0.18 grams/cubic centimeter to 0.30 grams/cubic centimeter of the silica fiber insulation material of theblanket 40. - According to the invention, before the
blanket 40 is installed into the device 18, theblanket 28 is heat treated to achieve calcination of the silica fiber insulation material. In this regard, theblanket 40 is heated so that all of the silica fiber insulation material in theblanket 28 is raised to a temperature T greater than the maximum operating temperature TMAX of thedevice 20. This heat treatment improves the resiliency and erosion resistance of the silica fiber insulation material and also eliminates the potential for a “thermoset” failure mode that can result if the silica fiber material were calcinated in-situ in thedevice 20 during operation of the system. Preferably, this heat treatment takes place with theblanket 40 in an uncompressed or free state wherein there are no compressive forces being applied to the silica fiber insulation material of theblanket 40. The temperature T preferably has some margin of safety above the maximum operating temperature TMAX of the device 18, with one preferred margin of safety being 1.05×TMAX. - This heat treatment improves the resiliency and erosion resistance of the silica fiber insulation material and also eliminates the potential for a “thermoset” failure mode that could result if the silica fiber material were to be calcinated in-situ on the device during operation of the system. Preferably, such heat treatment takes place with the
external blanket 40 in an uncompressed or free state wherein there are no compressive forces being applied to the silica fiber insulation material of theexternal blanket 40. The temperature T preferably has some margin of safety above the maximum operating temperature TMAX of the device 18, with one preferred margin of safety being 1.05×TMAX. - By heat treating the silica fiber heat insulation material to the temperature T greater than TMAX before the
external blanket 40 is installed on the device, the heat treated blanket can maintain suitable frictional engagement with the unitouter housing 30 over the desired life of the device because the silica fiber insulation material of theblanket 40 maintains its resiliency and does not take on a “thermoset” from the max operation temperature TMAX of the device. - The heat treatment may advantageously be accomplished using an in-line oven wherein the silica fiber heat insulation material is unrolled from a supply roll of the material and passed fiat through an oven on a conveyor so that the
external blanket 40 is planar during the heat treatment to reduce or prevent differential heating of the material of theblanket 40 and variation in thickness of the material in theblanket 40. After heat treatment,individual blankets 40 can be die cut to the desired length and width before installing on a device. Alternatively, however, a complete supply roll of the silica fiber heat insulation material can be heat treated, with or without rotation of the roll in an oven, wherebyindividual blankets 40 can be die cut to the desired length and width after heat treatment and before installing on the device. As yet an another alternative, the silica fiber insulation material can be die cut before heat treatment, with the blanket being slightly oversized in length and width to account for shrinkage during heat treatment, and with the die cut blankets then heat treated in an oven while laying flat on a planar surface. - In accordance with a second embodiment, the
external blanket 40 may also advantageously be a high alumina blanket. In one embodiment, theexternal blanket 40 may be advantageously made of an alumina insulation material having a weight percentage of Al2O3 of greater than 65%, and in preferred embodiments greater than 95%, and in highly preferred embodiments greater than 98%. Such blankets are known and commercially available, with one suitable example being supplied by Sell Ltd. of Cheshire, U.K. under the LDM trade name, and another suitable example being supplied by Mitsubishi under the MLS-2 trade name. In accordance with the present invention, thesehigh alumina blankets 40 are also heat treated to achieve calcination prior to placement on thedevice 20. - The calcined
external blanket 40 of either embodiment is advantageously used as batting encapsulated in a covering 50 prior to placement on thedevice 20, as illustrated inFIG. 2 . Calcination of theblanket 40 may be accomplished before encapsulating theblanket 40 in thecovering 50. However, calcination may also be accomplished in the covering 50 where the covering 50 will not be adversely impacted by the temperatures used in the calcinations. When installed on thedevice 20, the side of the covering facing the heat side (e.g., the device 20) may advantageously be foil, wire mesh or a high temperature textile, such as siliconized fiber glass or straight woven glass fiber. - It should be appreciated that devices in exhaust gas systems having external blankets according to the present invention substantially reduce damage and cracking when removing and replacing insulation, damage due to exposure to vibration, damage due to loose or otherwise inappropriate fit due to thermal set, and/or loss of insulation properties due to loose or otherwise inappropriate fit, and/or loss of insulation material.
- It should also be appreciated that while the invention has been described herein in connection with a diesel combustion process in the form of, for example, a diesel compression engine, the invention may find use in devices that are utilized in exhaust gas systems for other types of combustion processes, including other types of internal combustion engines, including, for example, internal combustion engines that use gasoline or other alternative fuels.
Claims (15)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/941,961 US20160069246A1 (en) | 2011-10-20 | 2015-11-16 | Method of producing an insulated exhaust device |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/277,663 US9217357B2 (en) | 2011-10-20 | 2011-10-20 | Method of producing an insulated exhaust device |
US14/941,961 US20160069246A1 (en) | 2011-10-20 | 2015-11-16 | Method of producing an insulated exhaust device |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/277,663 Division US9217357B2 (en) | 2011-10-20 | 2011-10-20 | Method of producing an insulated exhaust device |
Publications (1)
Publication Number | Publication Date |
---|---|
US20160069246A1 true US20160069246A1 (en) | 2016-03-10 |
Family
ID=48134746
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/277,663 Active 2033-11-17 US9217357B2 (en) | 2011-10-20 | 2011-10-20 | Method of producing an insulated exhaust device |
US14/941,961 Abandoned US20160069246A1 (en) | 2011-10-20 | 2015-11-16 | Method of producing an insulated exhaust device |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/277,663 Active 2033-11-17 US9217357B2 (en) | 2011-10-20 | 2011-10-20 | Method of producing an insulated exhaust device |
Country Status (4)
Country | Link |
---|---|
US (2) | US9217357B2 (en) |
CN (1) | CN104039552A (en) |
DE (1) | DE112012004349T5 (en) |
WO (1) | WO2013058840A1 (en) |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9976687B2 (en) * | 2012-05-18 | 2018-05-22 | Saprex, Llc | Breathable multi-component exhaust insulation system |
US9388515B2 (en) | 2012-09-28 | 2016-07-12 | Saprex, Llc | Heat curable composite textile |
PL3443254T3 (en) | 2016-04-15 | 2024-05-20 | Saprex, Llc | Composite insulation system |
EP3541601A4 (en) | 2016-11-18 | 2020-08-19 | Saprex, LLC | Composite insulation system |
JP6769308B2 (en) * | 2017-01-11 | 2020-10-14 | 株式会社豊田自動織機 | Exhaust gas purification device |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4428999A (en) | 1981-08-20 | 1984-01-31 | Textured Products | Refractory coated and vapor barrier coated flame resistant insulating fabric composition |
US6383623B1 (en) | 1999-08-06 | 2002-05-07 | Tex Tech Industries Inc. | High performance insulations |
CA2500380C (en) | 2002-09-30 | 2008-10-14 | Unifrax Corporation | Exhaust gas treatment device and method for making the same |
US8652599B2 (en) * | 2003-01-22 | 2014-02-18 | 3M Innovative Properties Company | Molded three-dimensional insulator |
KR20100076942A (en) * | 2007-08-31 | 2010-07-06 | 유니프랙스 아이 엘엘씨 | Substrate mounting system |
JP2011089420A (en) * | 2009-10-20 | 2011-05-06 | Nakagawa Sangyo Kk | Heat insulating body for vehicle exhaust pipe, and method for manufacturing the same |
US20110185575A1 (en) | 2010-01-29 | 2011-08-04 | Keith Olivier | Method of Producing an Insulated Exhaust Gas Device |
-
2011
- 2011-10-20 US US13/277,663 patent/US9217357B2/en active Active
-
2012
- 2012-06-28 DE DE112012004349.9T patent/DE112012004349T5/en not_active Withdrawn
- 2012-06-28 CN CN201280050971.6A patent/CN104039552A/en active Pending
- 2012-06-28 WO PCT/US2012/044494 patent/WO2013058840A1/en active Application Filing
-
2015
- 2015-11-16 US US14/941,961 patent/US20160069246A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
DE112012004349T5 (en) | 2014-07-31 |
US9217357B2 (en) | 2015-12-22 |
US20130097839A1 (en) | 2013-04-25 |
WO2013058840A1 (en) | 2013-04-25 |
CN104039552A (en) | 2014-09-10 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20160069246A1 (en) | Method of producing an insulated exhaust device | |
JP4557976B2 (en) | Contamination control element holding material and contamination control device | |
JP2006516043A5 (en) | Pollution control device for diesel engine exhaust gas system and mat for mounting pollution control element in pollution control device | |
KR101414693B1 (en) | Monolithic exhaust treatment unit for treating an exhaust gas | |
US8505203B2 (en) | Method of installing a longitudinally offset multi-layer mat in an exhaust gas aftertreatment or acoustic device | |
US20120144652A1 (en) | Method of installing a multi-layer batt, blanket or mat in an exhaust gas aftertreatment or acoustic device | |
US8747510B2 (en) | Method of installing a multi-layer batt, blanket or mat in an exhaust gas aftertreatment or acoustic device | |
US20110185575A1 (en) | Method of Producing an Insulated Exhaust Gas Device | |
US8100315B1 (en) | Method of insulating an exhaust device | |
EP1308607B1 (en) | End cones for exhaust emission control devices and methods of making | |
US20130032274A1 (en) | Method of wrapping a batt, blanket or mat in an exhaust gas aftertreatment or acoustic device |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: TENNECO AUTOMOTIVE OPERATING COMPANY INC., ILLINOI Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:LATHAM, RUTH;ALCINI, WILLIAM;FREIS, STEVEN;SIGNING DATES FROM 20110827 TO 20111013;REEL/FRAME:037049/0555 |
|
AS | Assignment |
Owner name: JPMORGAN CHASE BANK, N.A., AS ADMINISTRATIVE AGENT, ILLINOIS Free format text: GRANT OF SECURITY INTEREST IN PATENT RIGHTS;ASSIGNOR:TENNECO AUTOMOTIVE OPERATING COMPANY INC.;REEL/FRAME:042809/0515 Effective date: 20170512 Owner name: JPMORGAN CHASE BANK, N.A., AS ADMINISTRATIVE AGENT Free format text: GRANT OF SECURITY INTEREST IN PATENT RIGHTS;ASSIGNOR:TENNECO AUTOMOTIVE OPERATING COMPANY INC.;REEL/FRAME:042809/0515 Effective date: 20170512 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |
|
AS | Assignment |
Owner name: TENNECO AUTOMOTIVE OPERATING COMPANY INC., ILLINOIS Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:JPMORGAN CHASE BANK, N.A.;REEL/FRAME:048099/0716 Effective date: 20181001 Owner name: TENNECO AUTOMOTIVE OPERATING COMPANY INC., ILLINOI Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:JPMORGAN CHASE BANK, N.A.;REEL/FRAME:048099/0716 Effective date: 20181001 |