Compositions containing biosoluble inorganic fibers and micaceous binders

Abstract

Compositions that include a mixture of biosoluble inorganic fibers and a micaceous binder are described. The compositions can be prepared free of refractory ceramic fibers that are respirable but durable in a physiological medium. The compositions are typically in the form of a sheet material or a paste and can be used, for example, as a protective packing material around the pollution control element or as an insulating material in the end cone region in a pollution control device. Sheet materials formed from the compositions have an area of a X-Y plane that decrease less than about 6 percent when heated to about 900° C.

1 . A composition comprising:
 a) a non-intumescent crushed micaceous mineral in an amount of about 5 to about 80 weight percent on a dry weight basis; and   b) biosoluble inorganic fibers in an amount of about 5 to about 90 weight percent on a dry weight basis.   
     
     
         2 . The composition of  claim 1 , wherein said composition is in the form of a paste or a sheet material. 
     
     
         3 . The composition of  claim 1 , wherein the composition is in a form suitable (a) for use in a pollution control device, (b) as a heat barrier, (c) as a fire barrier, or (d) as a protective packing material. 
     
     
         4 . The composition of  claim 1 , wherein the composition is in a form suitable for use as a mounting mat, or as an insulating material in an end cone region, of a pollution control device. 
     
     
         5 . (canceled) 
     
     
         6 . (canceled) 
     
     
         7 . The composition of  claim 1 , wherein the composition is in the form of a sheet material having an area in a X-Y plane, the area decreasing less than about 6 percent when said sheet material is heated to about 900° C. 
     
     
         8 . The composition of  claim 1 , wherein said biosoluble inorganic fibers comprise about 45 to about 90 weight percent SiO 2 , up to about 45 weight percent CaO, up to about 35 weight percent MgO, and less than 10 weight percent Al 2 O 3  based on the weight of the biosoluble inorganic fibers. 
     
     
         9 . The composition of  claim 1 , wherein said crushed micaceous mineral has a particle size less than about 150 micrometers. 
     
     
         10 . The composition of  claim 9 , wherein said micaceous mineral comprises vermiculite. 
     
     
         11 . (canceled) 
     
     
         12 . The composition of  claim 1 , further comprising non-respirable inorganic fiber. 
     
     
         13 . The composition of  claim 1 , wherein said composition is an intumescent material. 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . The composition of  claim 1 , further comprising a polymeric binder in an amount of about 0.1 to about 15 weight percent on a dry weight basis. 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . The composition of  claim 1 , wherein said composition is in the form of a sheet material having a multilayered construction or in the form of a sheet material comprising an edge protector. 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . A pollution control device comprising:
 a) a housing;   b) a pollution control element disposed in the housing; and   c) a protective material disposed in a gap between at least a portion of the housing and a portion of the pollution control element, said protective material comprising the composition of  claim 1 .   
     
     
         25 . The pollution control device of  claim 24 , wherein the protective material is in the form of a sheet material or a paste. 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . The pollution control device of  claim 24 , wherein said micaceous mineral comprises vermiculite. 
     
     
         29 . The pollution control device of  claim 24 , wherein said protective material further comprises an intumescent material in an amount up to about 80 weight percent on a dry weight basis. 
     
     
         30 . The pollution control device of  claim 24 , wherein said a protective material further comprises non-respirable inorganic fibers. 
     
     
         31 . (canceled) 
     
     
         32 . A pollution control device comprising a housing and insulating material disposed in said housing, said insulting material comprising the composition of  claim 1 . 
     
     
         33 . (canceled) 
     
     
         34 . (canceled) 
     
     
         35 . (canceled) 
     
     
         36 . (canceled) 
     
     
         37 . A method of making a pollution control device comprising
 providing a housing and a pollution control element;   forming a protective packing material comprising the composition of  claim 1 ;   disposing the pollution control element in the housing; and   positioning the protective packing material between at least of portion of pollution control element and the housing.   
     
     
         38 . (canceled) 
     
     
         39 . (canceled) 
     
     
         40 . A method of making a sheet material comprising:
 forming an aqueous slurry comprising the composition of  claim 1 ;   adding a coagulating agent to form a coagulated slurry; and   removing water from the coagulated slurry to form a sheet material.