Abstract: An exhaust gas treatment device, which includes an outer layer, an inner layer that is at least in part disposed within the outer layer, and a loose-fill insulation disposed in the volume between the outer layer and the inner layer, where a piece of fiber mat is disposed between the outer layer and the inner layer and forms a barrier that at least partially prevents the loss of the loose-fill insulation from the volume between the outer layer and the inner layer and a manufacturing method that includes placing a loose-fill insulation into the volume of space between an inner layer and an outer layer and positioning a piece of fiber mat between the outer layer and the inner layer to form a barrier that at least partially prevents the loss of the loose-fill insulation from the volume of space between the outer and inner layers.

Abstract: An exhaust gas treatment device, which includes an outer layer, an inner layer that is at least in part disposed within the outer layer, and an insulation material disposed in an enclosed space between the outer layer and the inner layer, where at least one reservoir disposed with the insulation material is connected to the enclosed space and in fluid communication therewith and a manufacturing method that includes placing an insulation material into an enclosed space between an inner layer and an outer layer for an exhaust gas treatment device and placing the insulation material into a reservoir connected to the enclosed space and in fluid communication therewith.

Abstract: A method for producing an exhaust gas aftertreatment or acoustic device (20) having a maximum operating temperature TMAX. The method includes the steps of (a) providing a blanket (40) of silica fiber insulation material having a weight percentage of SiO2 greater than 65%; (b) calcining the insulating material by heating the blanket (40) so that all of silica fiber insulation material is raised to a temperature T greater than TMAX (where T is less than the melting temperature of the silica fibers of the blanket); and (c) securing the blanket (40) on the device (20) after the calcining step. The blanket is encapsulated in a covering (50) prior to the calcining step whereby the blanket is batting in the covering, with the covering between the blanket and the device being a selected one of wire mesh or siliconized fiber glass.

Abstract: A method is provided for producing an exhaust gas aftertreatment or acoustic device (20) having a maximum operating temperature TMAX. The method includes the steps of providing a blanket (40) of silica fiber or alumina insulation material having a weight percentage of SiO2 or Al2O3 of greater than 65%; calcining the insulating material by heating the blanket (40) so that all of silica fiber insulation material is raised to a temperature T greater than TMAX; and securing the blanket (40) on the device (20) after the calcining step. The blanket is encapsulated in a covering prior to the securing step, and before or after the calcining step, with the covering between the blanket and the device being a selected one of foil, wire mesh, or siliconized fiber glass.

Abstract: An exhaust gas treatment device, which includes an outer layer, an inner layer that is at least in part disposed within the outer layer, and a loose-fill insulation disposed in the volume between the outer layer and the inner layer, where a piece of fiber mat is disposed between the outer layer and the inner layer and forms a barrier that at least partially prevents the loss of the loose-fill insulation from the volume between the outer layer and the inner layer and a manufacturing method that includes placing a loose-fill insulation into the volume of space between an inner layer and an outer layer and positioning a piece of fiber mat between the outer layer and the inner layer to form a barrier that at least partially prevents the loss of the loose-fill insulation from the volume of space between the outer and inner layers.

Abstract: An exhaust gas treatment device, which includes an outer layer, an inner layer that is at least in part disposed within the outer layer, and a loose-fill insulation disposed in the volume between the outer layer and the inner layer, where a piece of fiber mat is disposed between the outer layer and the inner layer and forms a barrier that at least partially prevents the loss of the loose-fill insulation from the volume between the outer layer and the inner layer and a manufacturing method that includes placing a loose-fill insulation into the volume of space between an inner layer and an outer layer and positioning a piece of fiber mat between the outer layer and the inner layer to form a barrier that at least partially prevents the loss of the loose-fill insulation from the volume of space between the outer and inner layers.

Abstract: A method is provided for installing a multi-layer mat (24) in an exhaust gas aftertreatment or acoustic device. The method includes the steps of wrapping the mat (24) around an inner surface of the device along the same plane for at least a complete wrap around the inner surface; subsequently wrapping the mat (24) around the already completed wrap such that each of the successive wraps of the mat (24) are offset a constant distance from the plane of the previous wrap; a final wrap of the mat (24) wherein the mat is wrapped along a final plane for at least a complete wrap around the catalyst; and installing the mat (24) in the device (18) after the wrapping steps.

Abstract: A method is provided for producing an exhaust gas aftertreatment or acoustic device (20) having a maximum operating temperature TMAX. The method includes the steps of providing a blanket (40) of silica fiber or alumina insulation material having a weight percentage of SiO2 or Al2O3 of greater than 65%; calcining the insulating material by heating the blanket (40) so that all of silica fiber insulation material is raised to a temperature T greater than TMAX; and securing the blanket (40) on the device (20) after the calcining step. The blanket is encapsulated in a covering prior to the securing step, and before or after the calcining step, with the covering between the blanket and the device being a selected one of foil, wire mesh, or siliconized fiber glass.

Abstract: An exhaust treatment device includes an inner shell and an outer shell. Fibrous insulation is positioned within a flexible container. The insulation is compressed 30 to 80 percent by volume. The flexible container is sealed to maintain a compressed state of the insulation. The flexible container and the compressed insulation are positioned between the inner and outer shells of the exhaust treatment device.

Abstract: A method is provided for installing a multi-layer mat (24) in an exhaust gas aftertreatment or acoustic device. The method includes the steps of wrapping the mat (24) around an inner surface of the device along the same plane for at least a complete wrap around the inner surface; subsequently wrapping the mat (24) around the already completed wrap such that each of the successive wraps of the mat (24) are offset a constant distance from the plane of the previous wrap; a final wrap of the mat (24) wherein the mat is wrapped along a final plane for at least a complete wrap around the catalyst; and installing the mat (24) in the device (18) after the wrapping steps.

Abstract: A method is provided for producing an exhaust gas aftertreatment or acoustic device (18) having a maximum operating temperature Tmax. The method includes the steps of providing a blanket (28) of silica fiber insulation material having a weight percentage of SiO2 of greater than 65%; heating the blanket (28) so that all of silica fiber insulation material is raised to a temperature T greater than Tmax; and installing the blanket (28) in the device (18) after the heating step.

Abstract: A monolithic exhaust treatment device on unit (10) is provided for treating an exhaust gas (12) from a combustion process (14), and is part of an exhaust gas treatment system (16), which can include other exhaust gas treatment components (18). The monolithic exhaust treatment unit (10) includes a monolithic structure (20), at least two layers (22) of support mat (24), and at least one layer (26) of metallic foil (28) sandwiched between the two layers (22) of support mat (24).