CN100585138C - 污染控制设备中的系统 - Google Patents

污染控制设备中的系统 Download PDF

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CN100585138C
CN100585138C CN200480003290A CN200480003290A CN100585138C CN 100585138 C CN100585138 C CN 100585138C CN 200480003290 A CN200480003290 A CN 200480003290A CN 200480003290 A CN200480003290 A CN 200480003290A CN 100585138 C CN100585138 C CN 100585138C
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pollution control
adhesive
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control equipment
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CN1745229A (zh
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约瑟夫·C·派泽特
凯文·卡乔雷克
伊恩·R·哈丁
卡尔·J·布劳恩赖特
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3M Innovative Properties Co
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Abstract

薄壁结构(例如，端锥绝热器(12)和/或安装垫)(12)包括适于污染控制设备(16)的绝热部分(例如，端锥)的绝热材料和/或适于将污染控制元件安装在污染控制设备(16)(例如，催化式排气净化器的催化元件、柴油发动机或者汽油发动机的排气过滤器的过滤元件等)中的安装材料。所述薄壁结构可包括例如以板、垫(12)或者三维薄壁结构(例如，单段或者多段三维端锥绝热器(12))的形式绝热材料和/或安装材料。媒介胶(18)(例如，热活化胶、热熔胶和/或胶状的热塑性材料)粘合在所述薄壁结构的至少一个主表面上，以便涂在所述的至少一个主表面上并渗入所述的至少一个主表面。所述媒介胶(18)至少机械地粘合在所述薄壁结构上。压敏胶(20)粘合在所述媒介胶(18)上，该压敏胶用于将所述薄壁结构固定在所述污染控制设备(16)中适当的位置上。

Description

污染控制设备中的系统
技术领域
本发明涉及在内燃机排气系统中使用的污染控制系统，更具体涉及用于将污染控制元件安装在所述的污染控制设备中和/或使污染控制元件在所述的污染控制设备中绝热的系统，并进一步具体涉及用于在组装所述的污染控制设备中将这些安装和/或绝热系统的部分或者全部固定在适当的位置上的结构和技术。本发明还涉及组装包括使用这些结构和/或技术的污染控制设备的方法。
背景技术
现有的污染控制设备(例如，催化式排气净化器、排气过滤器等)用在诸如例如在各种交通工具(例如，汽车、船只、航空器等)中使用的发动机的内燃机、发电机等的排气系统中。这些污染控制设备一般采用多种绝热材料和安装材料。这些材料一般是用陶瓷纤维、发泡颗粒或者它们的组合物制成的。这些材料以像PCT申请No.PCT/US97/15864(公开号No.WO 98/50688)所公开的端锥(end cone)绝热器的形式、或者以像美国专利No.4,305,992、4,999，168和6,245,301所公开的安装垫(mat)的形式使用。除了使用多种材料外，还采用了许多技术来将这些绝热器和安装垫组装进污染控制设备。
有继续改进用于组装污染控制设备的方法的需要。
发明内容
一种已确定的这样的需要是：在污染控制设备的组装中，用更好的方法将绝热材料和/或安装材料固定在适当的位置上。本发明至少在部分上直接满足了这个需要。能要求的是，将这些现有的绝热材料、或者安装材料固定在污染控制设备内所要求的位置上。在使用压敏胶(PSA)将这些材料固定在污染控制设备内时，PSA和绝热材料或者安装材料之间的粘结可能不足以将材料保持在适当的位置上。已发现的是，在绝热材料或者安装材料包括有纤维时，这种不足的粘结较多可能是在使用非常短的纤维(例如，大约5mm以下)和/或使用低量的有机粘合剂、或者未使用有机粘合剂时形成的。还已经发现的是，在长缠绕纤维与较大量的有机粘合剂结合使用时，就不易出现这种不足的粘结的情况。
还已经发现是，通过在绝热材料或者安装材料和PSA之间用中间的热活化胶或者热熔胶、或者胶状的热塑材料，能够避免这个问题。
在本发明的一个方面中，提供有薄壁结构(例如，端锥绝热器和/或安装垫)，该薄壁结构包括有适于污染控制设备绝热部分(例如，端锥)的绝热材料和/或适于将污染控制元件安装在污染控制设备(例如，催化式排气净化器、柴油或者汽油发动机排气过滤器中的过滤元件等)中的安装材料。所述薄壁结构能包括例如以板、垫或者三维薄壁结构(例如，单段或者多段三维端锥绝热器)形式的绝热材料和/或安装材料。媒介胶(例如，热活化胶、热熔胶和/或胶状的热塑材料)粘合在所述薄壁结构的至少一个主表面上，以便涂在所述至少一个主表面上并渗入所述至少一个主表面。所述媒介胶至少机械地粘合在所述薄壁结构上。对于该媒介胶，除了机械地粘合，还能要求的是，化学地粘合在所述薄壁结构上，或者代替机械地粘合。压敏胶则粘合在该媒介胶上。
绝热材料和/或安装材料可包括发泡材料和/或非发泡材料。例如，所述非发泡材料一般包括诸如陶瓷纤维的无机纤维。该陶瓷纤维可以是耐火陶瓷材料。例如，发泡材料一般包括蛭石和其它这样的材料。有机粘合剂可用来将无机纤维保持在一起并使所述薄壁结构(例如，端锥绝热器)维持高密度且薄的状态。
在本发明的另一个方面中，提供有污染控制设备，该污染控制设备包括有端锥绝热器和/或安装垫，该端锥绝热器和/或安装垫包括上述的薄壁结构。
在本发明的又一个方面中，与内燃机一起或者独立于内燃机提供用于内燃机的排气系统，该排气系统包括上述的污染控制设备。
在本发明的又一个方面中，提供有制造污染控制设备的方法，该方法包括使用上述的端锥绝热器和/或安装垫，并包括：通过使用中间的热活化胶或者热熔胶、或者胶状的热塑材料，将所述端锥绝热器和/或安装垫固定在所述污染控制设备中的端锥绝热器、安装垫或者其它薄壁结构和压敏胶之间，所述PSA用来将端锥绝热器和/或安装垫粘合在该污染控制设备中适当的位置上。
附图说明
图1是用在根据本发明的污染控制设备中的示例固定系统的示意性的截面图。
具体实施方式
尽管在这根据具体实施例来描述本发明，但是对于本领域的技术人员而言，能够容易明显地在不背离本发明要旨的情况下作出各种改变、重新布置和替换。
参照图1，显示了根据本发明的示例固定系统10，该固定系统能够用来将端锥绝热器12固定在内燃机(例如，汽车、发电机、船只、航空器等使用的发动机)的排气系统中使用的污染控制设备16(例如，催化式排气净化器、发动机排气过滤器等)的内端锥壳体14和外端锥壳体22之间。尽管不是专有的，但对将两段的每段端锥绝热器12(例如，蛤形的两半)固定在内壳体14和外壳体22中的一个或者另一个适当的位置上而言，特别是在所述端锥绝热器12是不对称(例如，关于通过端锥的排气流的轴线不对称)的时，该固定系统10是特别有用的。在所述端锥绝热器12是不对称的时(即在所述端锥壳体14和22是不对称的时)，所述端锥绝热器12在所述壳体14和22内的定位对于保证污染控制设备的端锥部分适当地组装而言可能是关键性的。端锥绝热器12和端锥壳体14和22之间的未对准会导致不得不重新组装污染控制设备的端锥部分，或者在某些情况下会导致报废。
例如，所述固定系统10能用来将安装垫12固定在壳体22(例如，蛤形的壳体)的内表面适当的位置上，使得允许将污染控制元件14(例如，催化元件、柴油发动机或者汽油发动机的过滤元件等)安装在控制系统装置16中，安装垫12处于所述壳体22和所述污染控制元件14之间。
所述固定系统10包括一层或者多层粘合在所述端锥绝热器和/或安装垫12的至少一个主表面上的媒介胶18(例如，热活化胶、热熔胶和/或胶状的热塑材料)，使得完全地、或者至少基本涂在所述至少一个主表面上并渗入所述端锥绝热器或者安装垫12。热熔胶可以是压敏胶或者热活化胶，即室温下不粘的胶。热熔胶也可以是热塑(即可再熔)或者热固合成物。一层或者多层压敏胶(PSA)20粘合在媒介胶18上，在压敏胶层和媒介胶之间或者在PSA层20的顶部，有或者没有膜、沙罩、织物或者无纺布织物等。如果膜、沙罩、织物或者无纺布织物处于PSA层20的顶部，那么，例如，通过使PSA20粘合在所述装置16的壳体(例如，金属罐)部分22的内表面上，一层或者多层其它的PSA层20用来将所述端锥绝热器或者安装垫12固定在所述污染控制设备16中。聚合沙罩、织物或者无纺布织物或者膜可以由例如聚乙烯、聚酯、尼龙等制成。
所述端锥绝热器和/或安装垫12可包括以板、垫或者其它这样的薄壁结构形式的非发泡材料(例如，无机纤维)和/或发泡材料。无机纤维可以是陶瓷纤维。该陶瓷纤维可以是耐火陶瓷纤维。有机粘合剂可用来将无机纤维保持在一起并使所述的端锥绝热器或者安装垫12维持高密度且薄的状态。无机纤维的实例包括适于在污染控制设备16中的绝热和/或安装应用中使用的板，所述板包括，例如，美国专利No.5,380,580和4,863,700以及PCT公开专利申请No.WO 00/75496A1所公开和教导的陶瓷纤维板或者层，它们每一个都通过参考全部结合在此。
在PCT申请No.PCT/US97/15864(公开号No.WO 98/50688)中可以找到端锥绝热器的实例，该申请通过参考全部粘合在此。在美国专利No.4,305,992、4,999,168和6,245,301中可以找到安装垫的实例，它们通过参考也全部结合在此。
媒介胶可以是任何适于涂在安装垫或者端锥绝热器并渗入安装垫或者端锥绝热器的类型的胶。压敏胶可以是任何适于固定在所述污染控制设备的应用表面上的类型的胶(例如，所述设备壳体的处于该设备端部或者邻近所述污染控制元件的内表面处，或者在所述污染控制元件的外表面上)。压敏胶(PSA)的实例包括丙烯酸PSA、黏性嵌段共聚PSA、聚亚安酯PSA、乙酸乙烯PSA等。适合的压敏胶可包括有水基胶，例如乳胶，以及溶剂胶。可以将媒介胶喷在所述安装垫或者端锥绝热器上，或者另外涂敷在所述安装垫或者端锥绝热器上(例如，刷在安装垫或者端锥绝热器上)，或者以膜、织物或者非织物网等提供，并将该媒介胶层压在所述安装垫或者端锥绝热器上。所述PSA可以喷在媒介胶上，或者以转移胶或者双面涂层带提供，并将该PSA层压在所述中间胶上。转移胶带可从商业名称为3MTM的3M公司得到，产品编号为诸如转移胶带468MP、转移胶带468MPF、转移胶带966等。
具有粘合在绝热材料和/或安装材料一面上的聚合物膜、沙罩或者其它的涂敷层会有许多优点。以下示例优点中的一个或者多个能够实施：改进绝热材料和/或安装材料的处理强度；改进绝热材料和/或安装材料的抗扯性；减少摩擦系数以便更容易地装配和安装所述污染控制元件以及组装所述污染控制设备；改进将压敏胶(PSA)带涂敷在绝热材料和/或安装材料表面上的能力(例如，使端锥绝热材料的板材保持端锥或者圆锥形)。
实例1
本发明的一个实例可以使用含纤维的绝热板材料(例如，由3M公司制造的900HT纤维板材料)制造，流延(cast)聚丙烯膜的主表面通过媒介胶层粘合在纤维板材料的主表面上，该媒介胶层由Bostik制造的、产品名称为PE-65的非织物热塑网提供。媒介胶层被夹在纤维板材料的主表面和聚合物膜的主表面之间，并粘合在所述两个主表面上。加热该胶层，使得它渗入纤维板材料的主表面。在制造该结构中，将纤维板材料放置在底部，将PE-65放置在中间，并将聚合物膜放置在顶部。然后，该结构通过热辊层合机，在不损害聚合物膜的情况下用充足的热量来使热塑网熔化。造成的层压结构具有坚固的膜，以使粘合绝热。使所述膜与所述绝热器分开的180度剥离试验显示出，与使用PSA将聚合物膜粘合在纤维板材料相比，有4到5倍的提高。
实例2
除所述聚合物膜外，与实例1结构相同的结构的背面有很好地粘合在Bostik PE-65上的PSA，并用粘合在所述媒介胶层上的所述膜的PSA面来层压该结构。
实例3
本发明的另一个实例可以使用作为中间胶的热熔胶(Bostik公司的Bostik聚合105胶网)作成。该胶网被放置在现有的陶瓷纤维基的安装垫上，并加热，使胶处于大约110-140℃之间。纺成的粗尼龙非织物的沙罩具有大约0.1mm的厚度和85盎司/码2的基本重量(可从商业名称为Cerex的公司得到)，用压送辊将该沙罩层压在加热的胶网上，以在安装垫上提供用于使压敏胶定位的表面。将压敏胶转移带粘附在尼龙沙罩上，以提供根据本发明的绝热垫。
实例4
本发明的又一个实例可以使用含纤维的材料(例如，由3M公司制造的900HT陶瓷纤维板材料)制造，具有流延聚丙烯膜的主表面，背面有低粘附的衬背，通过媒介胶层粘合在所述纤维板材料的主表面上，该媒介胶由Bostik制造的、产品名称为PE-65-50(具有50g/m2的基本重量)的非织物热塑网提供。该媒介胶层被夹在纤维板材料的主表面和聚合物膜的主表面之间，并粘合在所述两个主表面上。加热该胶层，使得它渗入纤维板材料的主表面。在制造该结构中，将纤维板材料放置在底部，使PE-65-50Bostik胶处于中间，聚合物膜处于顶部。然后，该结构通过热辊层合机，在不损害聚合物膜的情况下用充足热量来使热塑网熔化。然后，将3M公司制造的、产品名称为9671LE并适于粘附在含油/不含油的金属表面上的300LSE高强度双面转移胶带的一个胶面(即主表面)涂敷并粘合在所述聚合物膜上。用纸剥离衬里(paperrelease liner)来保护转移带的另一个胶面(即主表面)。为了使所述含纤维的板材料粘附在污染控制设备壳体的内表面上，将所述纸剥离衬里除去，从而将另一个胶面涂敷在壳体的内表面上。

Claims (17)

1.一种用在污染控制设备中的组合，所述组合包括：
薄壁结构，包括含纤维的绝热材料，所述绝热材料适于使该污染控制设备的一部分绝热；以及
媒介胶，粘合在所述薄壁结构的至少一个主表面上，以便涂在至少一个主表面上并渗入所述绝热材料，使得该媒介胶至少机械地粘合在所述薄壁结构上；和
压敏胶，粘合在所述媒介胶的与所述薄壁结构相反的一侧上，其中，所述组合是用在污染控制设备中的绝热器。
2.根据权利要求1所述的组合，其中，所述材料还包括发泡材料。
3.根据权利要求1所述的组合，其中，所述材料是非发泡材料。
4.根据权利要求1所述的组合，其中，所述媒介胶是热活化胶、热熔胶、胶状的热塑材料或者它们的组合物中的一种或者多种。
5.根据权利要求1所述的组合，其中，所述压敏胶粘合到所述媒介胶，膜、纱罩、织物或者无纺布织物被夹在所述压敏胶和所述媒介胶之间，或者处于所述压敏胶的顶部。
6.如权利要求1所述的组合，其中，所述材料包括具有5mm或5mm以下长度的纤维。
7.一种用在污染控制设备中的组合，所述组合包括：
薄壁结构，包括含纤维的安装材料，所述安装材料适于在该污染控制设备中安装污染控制元件；以及
媒介胶，粘合在所述薄壁结构的至少一个主表面上，以便涂在至少一个主表面上并渗入所述安装材料，使得该媒介胶至少机械地粘合在所述薄壁结构上；和
压敏胶，粘合在所述媒介胶的与所述薄壁结构相反的一侧上，其中，所述组合是用在污染控制设备中的安装垫。
8.根据权利要求7所述的组合，其中，所述材料还包括发泡材料。
9.根据权利要求7所述的组合，其中，所述材料是非发泡材料。
10.根据权利要求7所述的组合，其中，所述媒介胶是热活化胶、热熔胶、胶状的热塑材料或者它们的组合物中的一种或者多种。
11.根据权利要求7所述的组合，其中，所述压敏胶粘合到所述媒介胶，膜、纱罩、织物或者无纺布织物被夹在所述压敏胶和所述媒介胶之间，或者处于所述压敏胶的顶部。
12.如权利要求7所述的组合，其中，所述材料包括具有5mm或5mm以下长度的纤维。
13.一种污染控制设备，包括根据权利要求1-12中的任一项所述的组合。
14.一种用于内燃机的排气系统，所述排气系统包括根据权利要求13所述的污染控制设备。
15.一种内燃机，包括根据权利要求14所述的排气系统。
16.一种交通工具，包括根据权利要求15所述的内燃机。
17.一种制造污染控制设备的方法，包括以下步骤：
提供根据权利要求1-12中的任一项所述的组合；
提供用于所述污染控制设备的壳体；以及
通过使用所述压敏胶，将所述组合粘合在所述壳体的内表面上，从而在该污染控制设备中将所述组合固定到位。
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US7820117B2 (en) 2010-10-26
CN1745229A (zh) 2006-03-08
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JP4870548B2 (ja) 2012-02-08
US20060286014A1 (en) 2006-12-21
BRPI0407126B1 (pt) 2016-01-26
JP2006516699A (ja) 2006-07-06
ZA200506956B (en) 2006-11-29
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CA2514754A1 (en) 2004-08-19
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