Abstract: The invention relates to a process for hot application of an adhesive composition (80) on a support (96), by means of a system comprising: a nozzle (50) for applying the adhesive composition (80), a line (88) for supplying the nozzle (50) with the adhesive composition (80) to be applied in fluid form, a mixer (30) positioned in the line (88) for the homogeneous mixture of the main components of the adhesive composition before its application; the applied adhesive composition (80) including as main components: a silylated prepolymer, a compatible tackifying resin; the adhesive composition comprising a cross-linking catalyst; the process comprising: supplying the line (88) with the silylated prepolymer separated from the cross-linking catalyst, the mixing of the cross-linking catalyst with the main components by means of the mixer (30), the hot application of the mixed adhesive composition (80) onto a support (96).

Abstract: A process for hot application of an adhesive composition (80) on a support (96), by means of a nozzle (50) applying the adhesive composition (80), a line (88) supplying the nozzle (50) with the adhesive composition (80) to be applied in fluid form, a mixer (30) positioned in the line (88) for the homogeneous mixture of the main components of the adhesive composition before its application; the applied adhesive composition (80) including a silylated prepolymer, a compatible tackifying resin; the adhesive composition having a cross-linking catalyst; the process involving: supplying the line (88) with the silylated prepolymer separated from the cross-linking catalyst, the mixing of the cross-linking catalyst with the main components by the mixer (30), the hot application of the mixed adhesive composition (80) onto a support (96).

Abstract: Gravity-laid inorganic fiber webs and methods of making and using are disclosed. The gravity-laying process comprises mechanically separating inorganic fibers and collecting the fibers as a web, and may comprise blending of multiple types of inorganic fibers and/or blending of inorganic particulate additives with the fibers.

Abstract: The present invention relates to a mounting mat for mounting a pollution control device in a catalytic converter, the mounting mat comprising a non-woven mat of inorganic fibers having distributed therein inorganic particles having an average diameter of 1 nm to 100 nm and wherein the mounting mat is free of organic binder or contains organic binder in an amount of not more than 5% by weight, based on the total weight of the mounting mat. The invention further relates to a pollution control device including the mounting mat and to a method of making the mounting mat.

Abstract: A method of making mounting mats comprising the steps of: (i) supplying inorganic fibers through an inlet of a forming box having an open bottom positioned over a forming wire to form a mat of fibers on the forming wire, the forming box having rollers for breaking apart clumps of fibers and an endless belt screen; (ii) capturing clumps of fibers on the endless belt; (iii) conveying captured clumps of fibers on the endless belt so as to enable captured clumps to release from the belt and be broken apart by the rollers; (iv) transporting the mat of fibers out of the forming box by the forming wire; and (v) compressing and restraining the mat of fibers to thereby obtain a mounting mat having a desired thickness suitable for mounting a pollution control element in a pollution control device.

Abstract: Nonwoven fibrous webs including randomly oriented discrete fibers defining a multiplicity of non-hollow projections extending from a major surface of the nonwoven fibrous web (as considered without the projections), and a plurality of substantially planar land areas formed between each adjoining projection in a plane defined by and substantially parallel with the major surface. In some exemplary embodiments, the randomly oriented discrete fibers include multi-component fibers having at least a first region having a first melting temperature and a second region having a second melting temperature, wherein the first melting temperature is less than the second melting temperature. At least a portion of the oriented discrete fibers are bonded together at a plurality of intersection points with the first region of the multi-component fibers. In certain embodiments, the patterned air-laid nonwoven fibrous webs include particulates.

Abstract: The present invention relates to a mounting mat for mounting a pollution control device in a catalytic converter, the mounting mat comprising a non-woven mat of inorganic fibers having distributed therein inorganic particles having an average diameter of 1 nm to 100 nm and wherein the mounting mat is free of organic binder or contains organic binder in an amount of not more than 5% by weight, based on the total weight of the mounting mat. The invention further relates to a pollution control device including the mounting mat and to a method of making the mounting mat.

Abstract: Nonwoven fibrous webs including a multiplicity of randomly oriented discrete fibers and a multiplicity of chemically active particulates secured to the web, and methods of making and using same. In some embodiments, more than 0% and less than 10% wt. of the nonwoven fibrous web is made of multi-component fibers having at least a first region exhibiting a first melting temperature and a second region exhibiting a second melting temperature greater than the first melting temperature. In other embodiments, the discrete fibers include a first population of monocomponent thermoplastic fibers having a first melting temperature, and a second population of monocomponent fibers having a second melting temperature greater than the first melting temperature. In certain embodiments, at least some of the particulates are bonded to the fibers. In other embodiments, at least some of the particulates are secured within interstices of the fibrous web, without substantial bonding to the fibers.

Abstract: The present invention relates to a mounting mat for mounting a pollution control device in a catalytic converter, the mounting mat comprising a non-woven mat of inorganic fibers having distributed therein inorganic particles having an average diameter of 1 nm to 100 nm and wherein the mounting mat is free of organic binder or contains organic binder in an amount of not more than 5% by weight, based on the total weight of the mounting mat. The invention further relates to a pollution control device including the mounting mat and to a method of making the mounting mat.

Abstract: Monolithic gravity-laid inorganic fiber webs that are greater than about 5 cm in thickness are disclosed. Methods of making and using such webs are also disclosed. The gravity-laying process comprises mechanically separating inorganic fibers and collecting the fibers as a monolithic thick web, and may comprise blending of multiple types of inorganic fibers and/or blending of inorganic particulate additives with the fibers.

Abstract: Non-woven mat including basalt and amorphous refractory ceramic fibers, bio-soluble ceramic fibers, and/or heat-treated silica fibers. Embodiments of the non-woven mat surprisingly have a Resiliency Value after three thermal cycles from 25° C. to 700° C./400° C. of the Real Condition Fixture Test at least 1.1 times greater than the Resiliency Value of a comparable non-woven mat consisting of any individual type of fibers of the non-woven mat. The non-woven mats are useful, for example, in pollution control devices and other thermal insulation applications.

Abstract: The invention relates to a process for hot application of an adhesive composition (80) on a support (96), by means of a system comprising: a nozzle (50) for applying the adhesive composition (80), a line (88) for supplying the nozzle (50) with the adhesive composition (80) to be applied in fluid form, a mixer (30) positioned in the line (88) for the homogeneous mixture of the main components of the adhesive composition before its application; the applied adhesive composition (80) including as main components: a silylated prepolymer, a compatible tackifying resin; the adhesive composition comprising a cross-linking catalyst; the process comprising: supplying the line (88) with the silylated prepolymer separated from the cross-linking catalyst, the mixing of the cross-linking catalyst with the main components by means of the mixer (30), the hot application of the mixed adhesive composition (80) onto a support (96).

Abstract: Non-woven mat including magnesium aluminum silicate glass fibers and amorphous refractory ceramic fibers, bio-soluble ceramic fibers, and/or heat-treated silica fibers. Embodiments of the nonwoven mat surprisingly have a Resiliency Value after three thermal cycles from 25° C. to 700° C./400° C. of the Real Condition Fixture Test at least 1.1 times greater than the Resiliency Value of a comparable non-woven mat consisting of any individual type of fibers of the non-woven mat. The non-woven mats are useful, for example, in pollution control devices and other thermal insulation applications.

Abstract: Monolithic gravity-laid inorganic fiber webs that are greater than about 5 cm in thickness are disclosed. Methods of making and using such webs are also disclosed. The gravity-laying process comprises mechanically separating inorganic fibers and collecting the fibers as a monolithic thick web, and may comprise blending of multiple types of inorganic fibers and/or blending of inorganic particulate additives with the fibers.

Abstract: Gravity-laid inorganic fiber webs and methods of making and using are disclosed. The gravity-laying process comprises mechanically separating inorganic fibers and collecting the fibers as a web, and may comprise blending of multiple types of inorganic fibers and/or blending of inorganic particulate additives with the fibers.

Abstract: Monolithic gravity-laid inorganic fiber webs that are greater than about 5 cm in thickness are disclosed. Methods of making and using such webs are also disclosed. The gravity-laying process comprises mechanically separating inorganic fibers and collecting the fibers as a monolithic thick web, and may comprise blending of multiple types of inorganic fibers and/or blending of inorganic particulate additives with the fibers.

Abstract: Gravity-laid inorganic fiber webs and methods of making and using are disclosed. The gravity-laying process comprises mechanically separating inorganic fibers and collecting the fibers as a web, and may comprise blending of multiple types of inorganic fibers and/or blending of inorganic particulate additives with the fibers.

Abstract: Porous supported articles and methods of making are disclosed. Multicomponent polymeric fibers are introduced into a forming chamber and are infilled at least into the interior void spaces of a support web. At least some of the infilled multicomponent component fibers are self-bonded to each other to form a porous web that is embedded within the support web. The porous embedded web may contain particles that are bonded to the multicomponent fibers of the web. The optional particles in the porous embedded web may be e.g. abrasive, absorbent, etc.

Abstract: The present invention relates to a mat for mounting one or more pollution control elements in a pollution control device for the treatment of exhaust gases, said mat comprising heat-treated glass fibers containing Al2O3 in an amount of 10 to 30% by weight and SiO2 in an amount of 52 to 65% by weight based on the total weight of the glass fibers.

Abstract: Methods are disclosed in which two or more forming chambers are used to process inorganic fibers by gravity-laying methods. The methods may comprise using a first forming chamber to open inorganic fibers and using a second forming chamber to process the opened inorganic fibers, optionally to blend the opened inorganic fibers with additional inorganic fibers and/or with particulate additives, and to collect the inorganic fibers as a mat. The methods may comprise using a first forming chamber to form a first inorganic fiber layer and a second forming chamber to form a second inorganic fiber layer, and consolidating the first and second inorganic fiber layers so as to provide a multilayer gravity-laid inorganic fiber web.