Repositionable Adhesive for Ceramic Monoliths
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Solution Overview
Problem
Ceramic monoliths in pollution control devices are fragile and prone to damage due to thermal expansion differences with metal housings, and conventional repositionable adhesives often fail or cause adhesive transfer during assembly, complicating the 'canning' process.
Innovation Solution
A repositionable mounting material with inorganic fibers and a layer of pressure-sensitive adhesive comprising adhesive microspheres and binder particles, optimized in particle size distribution and ratio, which is repositionably adherable to ceramic monoliths without damaging the material or causing adhesive transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional repositionable adhesives are used to secure the mounting material to the monolith, then the mounting material can be repositioned during assembly, but the adhesive fails or causes adhesive transfer during assembly
Solution Approach 1:
The patent applies composite materials by combining adhesive microspheres (30-70 wt%) with binder particles (30-70 wt%) to create a hybrid adhesive layer. The adhesive microspheres provide repositionability through their microsphere structure, while the binder particles provide structural integrity and prevent adhesive transfer. This composite approach resolves the contradiction by integrating the beneficial properties of both material types to achieve both repositionability and reliable adhesion without failure or transfer.
2Area of stationary object
If the mounting material is made with thin walls to provide large surface area, then the surface area increases for better adhesion, but the monolith becomes fragile and susceptible to breakage
Solution Approach 1:
The patent applies local quality by creating a differentiated structure where the monolith maintains thin walls for large surface area in the bulk, while the outer surface receives a specialized adhesive coating. This coating is applied locally to the surface where adhesion is needed, allowing the monolith to have both high surface area for adhesion and sufficient mechanical strength through the thin-wall design, without compromising overall fragility.
3Reliability
If ceramic mat or intumescent sheet materials are disposed between the ceramic monolith and the metal housing, then thermal expansion differences are compensated, but the adhesion of the mounting mat to the ceramic monolith becomes difficult to maintain
Solution Approach 1:
The patent applies composite materials by formulating an adhesive coating that combines adhesive microspheres with binder particles. The binder particles provide strong bonding to the ceramic monolith surface, while the adhesive microspheres maintain repositionability and accommodate thermal expansion differences. This composite adhesive layer resolves the contradiction by providing both secure adhesion and flexibility to handle thermal expansion between the ceramic monolith and metal housing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the repositionability and adhesion of the mounting material to ceramic monoliths, reducing damage and adhesive transfer, thereby improving the assembly process of pollution control devices.
Implementation Method 1
a layer of repositionable pressure-sensitive adhesive inwardly disposed along at least a portion of the first major surface, wherein the layer of repositionable pressure-sensitive adhesive comprises: adhesive microspheres and binder particles
Data Source
Figure 1~2
Figure 3
AI summary
A repositionable mounting material comprises a mounting material having a major surface and comprising inorganic fibers. A layer of repositionable pressure-sensitive adhesive inwardly disposed along at least a portion of the first major surface. The layer of repositionable pressure-sensitive adhesive comprises: adhesive microspheres having a first particle size distribution with at least one mode, each of which has a D50 of at least 30 micrometers; and binder particles having a second particle size distribution with at least one mode, wherein each mode has a D50 that is less than 10 micrometers, and wherein at least one of the at least one modes has a D50 below one micrometer. The repositionable mounting material is useful in manufacture of pollution control devices. Methods of making the foregoing are also disclosed.