Methods of making a catalytic converter or diesel...

F - Mech Eng,Light,Heat,Weapons – 01 – N

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F01N 3/28 (2006.01) B28B 1/20 (2006.01) B28B 19/00 (2006.01) C04B 14/02 (2006.01) C04B 14/20 (2006.01) F01N 3/021 (2006.01)

Patent

CA 2225811

The invention provides a method of making a catalytic converter for automotive exhaust gases comprising: (a) placing a catalytic converter element in a mold; (b) injecting a sufficient amount of a flowable mounting material into the mold to form a seamless continuous coating around a portion of the element, the flowable mounting material comprising 2 to 90 dry weight percent of at least one unexpanded intumescent material, 10 to 98 dry weight percent of binder, 0 to 25 dry weight percent fibers, 0 to 70 dry weight percent of one or more fillers, and a liquid; and (c) removing the catalytic converter element from the mold. In a preferred embodiment the catalytic converter element is heated to a temperature from about 60 ~C to about 150 ~C after step (c) and then said catalytic element is disposed in a housing. Analogous methods of making diesel particulate filters and high temperature rigid filters are also described.

L'invention se rapporte à un procédé de fabrication d'un convertisseur catalytique pour gaz d'échappement d'automobiles, ce procédé consistant à: (a) placer un élément de convertisseur catalytique dans un moule; (b) injecter une quantité suffisante d'un matériau de fixation fluide dans le moule pour former un revêtement continu sans jointure autour d'une partie de l'élément, le matériau de fixation fluide comprenant de 2 à 90 % en poids sec d'au moins un matériau intumescent non dilaté, de 10 à 98 % en poids sec de liant, de 0 à 25 % en poids sec de fibres, de 0 à 70 % en poids sec d'au moins une charge de remplissage et un liquide; et (c) retirer du moule l'élément de convertisseur catalytique. Selon un mode préféré de réalisation, l'élément de convertisseur catalytique est chauffé à une température comprise entre environ 60 ·C et environ 150 ·C après l'étape (c), et l'élément catalytique est déposé dans un logement. Des procédés analogues de fabrication de filtres particulaires Diesel et de filtres rigides haute température sont également décrits.

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