New Mounting Materials For Catalytic Converters to Meet Stricter Emission Requirements 2003-01-3554

This paper discusses trends in environmental regulations to achieve tighter emission standards for vehicles, which is reflected in the design and components of catalytic converters. Catalytic converters are being located closer to the engine to achieve faster catalyst activity and quicker emission reduction. The ceramic monoliths are also changing to provide a higher number of cells per area resulting in reduced mass, wall thickness and mechanical strength. These designs are demanding new mounting materials that can provide broader temperature capability, while maintaining the ability to hold the ceramic monolith inside the can without damage to the ceramic monolith. New reduced vermiculite intumescent materials, non-intumescent materials and combinations of intumescent and non-intumescent materials are discussed to address the compatibility with the new monoliths and broader operating temperatures. They are evaluated in mechanical tests to quantify the performance of these new mount systems. Performance data for these new mat materials will be presented demonstrating proper operating parameters and application compatibility.