CN103429865A - 污染控制元件的安装构件、其制造方法以及污染控制装置 - Google Patents

污染控制元件的安装构件、其制造方法以及污染控制装置 Download PDF

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CN103429865A
CN103429865A CN2012800141494A CN201280014149A CN103429865A CN 103429865 A CN103429865 A CN 103429865A CN 2012800141494 A CN2012800141494 A CN 2012800141494A CN 201280014149 A CN201280014149 A CN 201280014149A CN 103429865 A CN103429865 A CN 103429865A
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installation component
pollution control
organic binder
aggregation
control element
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CN103429865B (zh
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酒匈健二
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3M Innovative Properties Co
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3M Innovative Properties Co
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Abstract

本发明涉及一种安装构件，所述安装构件在将污染控制元件装配于壳体中时可充分地抑制无机纤维材料的散射，并且所述安装构件甚至在有机粘结剂已燃耗之后可维持所述壳体的内表面和所述污染控制元件之间的足够高的接触压力。本发明的所述安装构件用于将污染控制元件(30)包装和安装于壳体(20)中，并提供由无机纤维材料制成的垫(1)和含有完全浸渍所述垫(1)的大部分的有机粘结剂和无机细小颗粒的聚集物(5)。

Description

污染控制元件的安装构件、其制造方法以及污染控制装置
技术领域
本发明涉及一种污染控制元件(诸如催化剂载体或过滤元件)的安装构件，并且涉及其制造方法。此外，本发明涉及一种污染控制装置，其中污染控制元件通过安装构件安装于壳体内。
背景技术
利用陶瓷催化转化器的废气清洁系统已知作为用于清除包含在汽车发动机的废气中的一氧化碳(CO)、碳氢化合物(HC)和氮氧化物(NOx)等的手段。基本上，陶瓷催化转化器通常将具有蜂窝形状等的陶瓷催化剂载体储存于金属壳体内。
存在有多种类型的陶瓷催化转化器，但是一般形式设置有催化剂载体、储存催化剂载体的壳体和热绝缘构件，该热绝缘构件填充催化剂载体的外表面和壳体的内表面之间的间隙。热绝缘构件安装催化剂载体并预防由于不注意地施加至催化剂载体的冲击和振动等而造成的机械震动。因此，催化剂载体的移动和破坏可进行充分地抑制，并且从而可在长时间期限内提供所需的效果。这种类型的热绝缘构件常常也称为安装构件，因为该构件具有安装污染控制元件(诸如催化剂载体)的功能。
日本未审查专利申请公开号No.S57-61686和2002-66331提出，正常地，从提供优异的热绝缘和耐热性的前景来看，安装构件主要由无机纤维制成。然而，在污染控制元件装配于壳体中时，无机纤维可散射破碎的片或粉末等(下文也称为“纤维片”)，并且存在对周围环境具有负面影响的可能性。因此，通常已存在对将有机粘结剂浸渍或施加至由无机纤维制成的垫上以防止纤维片的散射的研究。例如，日本未审查专利申请公开No.2006-223920描述了一种安装构件，其中至少两种类型的具有不同玻璃化转变温度(Tg)的有机粘结剂浸渍入由纤维材料制成的垫中。
发明内容
附带地讲，在清洁汽车发动机的废气的工艺过程中，该室内部的温度可达到约900℃。通常，在已开始污染控制装置的使用之后，包含于安装构件中的有机粘结剂燃烧并从壳体内部消除。甚至在有机粘结剂已燃烧之后，要求安装构件维持高接触压力以便该安装材料充分地表现出防止污染控制元件的破坏和移动的功能。
本发明的目标是提供一种安装构件，该安装构件在污染控制元件装配于壳体中时可抑制无机纤维材料的散射，并且甚至在有机粘结剂已燃烧之后可维持所需的接触压力以将污染控制元件保持在壳体中。
根据本发明的一个方面的安装构件用于将污染控制元件包装和安装于壳体内，并且提供了由无机纤维材料制成的垫，其中大部分的垫以包含有机粘结剂和无机细小颗粒的聚集物浸渍。
根据本发明的另一个方面的污染控制装置设置有壳体、安装于壳体中的污染控制元件，和设置于壳体和污染控制元件之间的上述安装构件。
根据本发明的另一个方面的制造用于将污染控制元件包装和安装于壳体内部的安装构件的方法提供了以下步骤：制备液体，其中含有有机粘结剂和无机细小颗粒的聚集物已沉淀；将聚集物浸渍入由无机纤维材料制成的垫中。
本发明的效果
根据本发明，含有有机粘结剂和无机细小颗粒的聚集物完全浸渍垫的大部分，并且因此无机纤维材料的散射在将污染控制元件装配入壳体时可通过有机粘结剂抑制，并且甚至在有机粘结剂已燃烧之后，用于将污染控制元件安装于壳体中的所需接触压力可通过剩余的无机细小颗粒来维持。
附图说明
图1为示出本发明的安装构件的一个实施例的透视图。
图2为示出其中聚集物在本发明的安装构件暴露于高温条件之前已附着至无机纤维的状况的示意图。
图3为示出其中烧结无机细小颗粒在本发明的安装构件已暴露于高温条件之后附着至无机纤维的状况的示意图。
图4为示出根据本发明的污染控制装置的一个实施例的剖视图。
图5为示出受热安装构件的接触压力随时间变化的曲线图。
具体实施方式
根据本发明的一个方面的安装构件用于将污染控制元件包装和安装于壳体中，并且提供了由以含有有机粘结剂和无机细小颗粒的聚集物浸渍的无机纤维材料制成的垫。
利用这种安装构件，将有机粘结剂和细小颗粒整合为聚集物，并且浸渍入垫中，并且因此两种组分分散入整个垫中并附着至垫中的无机纤维，并且从而可有效地表现出各种功能。有机粘结剂在制造污染控制装置的工艺过程中抑制纤维片的散射，此外，无机细小颗粒在有机粘结剂已燃烧之后留在垫中，并且表现出维持壳体的内表面和污染控制元件之间的充分高的接触压力的效果。
无机细小颗粒连同有机粘结剂一起作为聚集物浸渍入垫中，并且因此在对安装构件加热之前，无机细小颗粒将连同有机粘结剂一起附着至无机纤维的表面和交点。此后，在安装构件暴露于其中有机粘结剂将燃烧的高温条件时，无机细小颗粒的烧结将继续进行，并且已附着至无机纤维材料的表面的无机细小颗粒将附连至无机纤维，从而增加无机纤维的表面的粗糙度并可能对抑制无机纤维共同的滑动起作用。另一方面，附连至无机纤维的交点的无机细小颗粒将约束交点，并且据认为对维持无机纤维的三维形状起作用。据认为，安装构件在厚度方向上不容易压缩，并且充分高的接触压力可通过这些无机细小颗粒的作用来维持。
无机细小颗粒的实例包括由至少一种类型的材料制成的颗粒，该至少一种类型的材料选自金属氧化物、氮化物、碳化物，和它们的复合材料。此外，如果使用具有1μm或更小的平均直径的无机细小颗粒，那么表面能将是高的，所以烧结性质将会增强(换句话说，烧结将更容易发生)，并且因此对无机纤维的附连性质可以更强。
此外，无机细小颗粒可表现出维持如上所述的接触压力的效果，所以浸渍入垫中的有机粘结剂的量可相对减少。这些优点对高度先进的汽车发动机的控制系统是特别有用的。这是因为如果过量的有机粘结剂包含在安装构件中，那么存在有控制系统传感器的与燃烧相关联的无意启动的可能性。具体地讲，如果具有15℃或更低的玻璃化转变温度的丙烯酸胶乳用作有机粘结剂，那么有机粘结剂在室温(装配工作在该室温下执行)下将具有相对于无机纤维的足够高的润湿性质，并且因此无机纤维的散射可有效地抑制。即使有机粘结剂的含量基于安装构件中的材料的总量计为(例如)5重量％或更小，纤维片的散射可有效地抑制。
本发明的污染控制装置具有壳体、提供于壳体中的污染控制元件，和置于壳体和污染控制元件之间的本实施例的安装构件。通过使用用于安装污染控制元件的本发明的安装构件，无机纤维材料的散射在制造工艺过程中可有效地抑制，并且甚至在有机粘结剂已燃烧之后，充分高的接触压力可维持于壳体的内表面和污染控制元件之间。
此外，本发明的安装构件的制造方法包括(a)制备溶液的步骤，该溶液具有沉淀的含有有机粘结剂和无机细小颗粒的聚集物，和(b)将聚集物浸渍入由无机纤维材料制成的垫中。
利用上述的制造方法，含有有机粘结剂和无机细小颗粒的聚集物首先沉淀，并且随后聚集物浸渍入垫中。因此，无机细小颗粒连同有机粘结剂可以更均匀的分散性附连遍及大部分的垫，该分散性通过独立地浸渍有机粘结剂和无机细小颗粒是不能容易地获得的。
上述步骤(a)优选地包括制备溶液的步骤，该溶液具有从含有有机粘结剂和分散有有机细小颗粒的胶体溶液的共混物沉淀的聚集物。使用胶体溶液具有优点如下：含有具有充分均匀尺寸的聚集物的溶液可容易地生产。
本发明的优选实施例在下文中参照附图详细地描述。
图1为示出本实施例的安装构件的一个实例的透视图。在相同图中示出的安装构件10用于以环状圆柱体或椭圆圆柱体外部形状包装污染控制元件30并安装于壳体20中(参照图4)。安装构件10具有对应于污染控制元件30的外周长的长度的长度。安装构件10在一端具有凸部10a，在另一端具有凹部10b，并且在安装构件10环绕污染控制元件30包装时，凸部10a插入凹部10b中。注意，安装构件10并非必需地具有凸部10a和凹部10b。
安装构件10包括由无机纤维材料制成的垫1，和浸渍入垫1中的含有有机粘结剂和无机细小颗粒的聚集物5。如图2的示意图所示，在安装构件10暴露于高温条件之前，聚集物5包含有机粘结剂3和无机细小颗粒4，并且附连至组成垫1的无机纤维1a。有机粘结剂3覆盖至少一部分的有机纤维1a的表面，并且防止纤维片的散射。注意，图2为概念性示意图，用于辅助理解聚集物5和垫1中的无机纤维1a的结构实例。组成安装构件10的垫1、有机粘结剂和无机细小颗粒在下文中描述。
垫1由无机纤维材料制成，并且优选地由含有氧化铝纤维的无机纤维材料制成。无机纤维材料可掺混两种或两种以上类型的氧化铝纤维，并且如果需要，氧化铝纤维也可掺混其它无机材料。也可使用的无机材料并不限于下述材料，并且可包括硅纤维、玻璃纤维、膨润土、蛭石和石墨，等等。这些无机材料可单独地使用，或者两种或两种以上类型可以进行结合和一起使用。
形成垫1的无机纤维并不限于特定厚度(平均直径)，而且平均直径优选地为从约2μm至7μm。如果无机纤维具有小于约2μm的平均直径，那么无机纤维将往往易碎和缺乏强度，但是另一方面，如果平均直径大于约7μm，形成安装构件将往往是困难的。
此外，类似于厚度，无机纤维的长度也并没有特定地限制。然而，无机纤维优选地具有从约0.5mm至50mm的平均长度。如果无机纤维的平均长度小于约0.5mm，那么使用有机纤维来形成安装构件的效果等不能被表现出来，反之，如果平均长度大于约50mm，那么处理性质将是劣等的，并且因此制造安装构件的工艺将不容易顺畅地进行。
垫1可为主要由多层片材的氧化铝纤维制成的氧化铝纤维垫。氧化铝纤维垫中的氧化铝纤维的平均长度优选地处于从约20mm至200mm的范围内，并且该纤维的厚度(平均直径)优选地处于从约1μm至40μm的范围内。此外，氧化铝纤维优选地以Al2O3／SiO2(Al2O3／SiO2)=约70／30至74／26的重量比率由莫来石制成。
例如，氧化铝纤维垫可利用由共混物制成的纺丝原液来制造，该共混物包含作为铝源的氧氯化铝等、作为硅源的硅溶胶等、作为有机粘结剂的聚乙烯醇等，和水。换句话讲，上述垫可通过以下步骤制造，叠加纺丝氧化铝纤维前体以形成片材，和随后在通常从约1000摄氏度至1300摄氏度的高温下熔结。注意，针刺也可在形成的片材上进行。
在制造这种类型的氧化铝纤维垫时，其它陶瓷纤维和无机溶胀材料也可补充地添加至氧化铝纤维。在这种情况下，添加的材料可均匀地共混入垫中，但是成本可减少，同时通过局部提供来维持添加剂材料的性能，同时避免特别受热区域。陶瓷纤维可为硅纤维或玻璃纤维等，并且无机溶胀材料可为膨润土、溶胀蛭石或溶胀石墨等。
如图2的示意图所示，有机粘结剂附着至无机纤维1a并抑制纤维片的散射。有机粘结剂3的合适实例包括天然和合成的聚合物材料(诸如树脂材料，例如丁二烯-苯乙烯树脂、聚苯乙烯树脂、聚醋酸乙烯树脂和丙烯酸类树脂等)或有机材料(诸如聚乙烯醇等)。有机粘结剂优选地为丙烯酸类胶乳。
丙烯酸类胶乳可为多个类型，但是优选地选自从安装构件10组合物和污染控制元件30的所需性质的角度来看具有有利的玻璃化转变温度(Tg)的那些。已知丙烯酸类胶乳具有正常处于从约-70℃至50℃的范围内的玻璃化转变温度，并且根据本实施例，具有15℃或更小的Tg的胶乳是优选的，但是具有1℃或更小或具有10℃或更小的Tg的胶乳也可使用。如果使用具有15℃或更低的Tg的丙烯酸类胶乳，那么在标准工作温度(25℃)下可向无机纤维表明足够高的润湿性，并且因此纤维片的散射可有效地抑制，其中污染控制元件30在该标准工作温度下被安装于壳体20中。
本实施例所使用的有机粘结剂可为多种类型的丙烯酸类胶乳，只要对安装构件10等的性质不存在负面影响，并且如果优选的，丙烯酸类胶乳可照原样从商业采购和使用，或者可以随意地修改以匹配其中将使用安装构件的环境。合适的丙烯酸类胶乳为通过将丙烯酸类树脂分散于水性介质或其它介质而获得的胶态分散体。
有机粘结剂3在安装构件10中的含量优选地为5质量％或更小，例如4质量％或更小、3质量％或更小，或2质量％或更小，基于安装构件10的总质量计。通过抑制有机粘结剂的含量，汽车控制系统由于其燃烧等而导致的意外传感器作用等的风险可消除。从防止纤维片的散射的角度来看，有机粘结剂含量的下限优选地为0.1质量％。
无机细小细心颗粒4连同有机粘结剂3组成聚集物5。无机细小颗粒4不独立地浸渍入安装构件中，而是作为具有有机粘结剂3的聚集物5浸渍入垫中，因此如图2所示，无机细小颗粒4连同有机粘结剂附连至垫中的无机纤维的表面和交点。换句话讲，有机细小颗粒以有利地分散的状况存在遍及大部分的垫，该状况在独立地浸渍无机颗粒时难以获得。
甚至在有机粘结剂3燃烧之后，安装构件10有助于在壳体20的内表面和污染控制元件30之间维持足够高的接触压力。在将安装构件10储存于壳体20中并暴露于高温条件以使得有机粘结剂燃烧时，具有高表面能的无机细小颗粒4将被烧结。此时，如图3的示意图所示，附着至无机纤维1a的表面的无机细小颗粒4将形成烧结团粒5a并附连至无机纤维1a，并且将增加无机纤维1a的表面的粗糙度。另一方面，附着至无机纤维1a的交点的无机细小颗粒4将形成烧结团粒5b并将约束无机纤维1a在交点处的移动。因此，安装构件10在厚度方向(图3中的箭头T的方向)上将不容易压缩，并且从而可维持足够高的接触压力。注意，类似于图2，图3也是概念性示意图，用以辅助理解垫中的无机纤维1a和无机细小颗粒4在有机粘结剂的燃烧之后的结构实例。
无机细小颗粒4可为可附连至无机纤维1a的颗粒，但是优选的具体实例包括由金属氧化物、氮化物、碳化物和它们的复合材料制成的细小颗粒。这些细小颗粒可作为单一类型单独地使用，或两种或两种以上类型可结合使用。如果垫1包含氧化铝纤维，那么从与氧化铝纤维的反应性的角度来看，无机细小颗粒4优选地选自硅细小颗粒、氧化铝细小颗粒、二氧化钛细小颗粒和氧化锆细小颗粒。
注意，在本实施例中，无机细小颗粒的尺寸和形状不特别地限制，只要该颗粒连同有机粘结剂形成聚集物、浸渍入安装构件中，和附连至无机纤维，并且如果将该安装构件使用于污染控制装置中，那么无机细小颗粒甚至在有机粘结剂已燃烧之后可留在垫中。然而，从烧结性质的角度来看，无机细小颗粒4的平均直径优选地为1μm或更小，并且更优选地为500nm或更小。从处理性质和采购的容易性来看，无机细小颗粒4的平均粒径的下限优选地为1nm，并且更优选地为4nm。注意，平均粒径通常可使用(例如)BET方法测量。
安装构件10中的无机细小颗粒4的含量优选地为10质量％或更小、更优选地为5质量％或更小，基于安装构件10的总质量计。例如，如果将20质量％以上的无机细小颗粒4添加至安装构件10，那么将存在有机粘结剂的必要量增加的趋势。另一方面，如果无机细小颗粒4的含量小于0.1质量％，那么维持接触压力将可能是不足的。
含有无机细小颗粒4和有机粘结剂3的聚集物5优选地均匀分散遍及整个安装构件10。另一方面，如果通过厚度观察安装构件10，那么聚集物5优选地基本上均匀分散在安装构件10的厚度方向上。
接下来，描述安装构件10的制造方法。根据本实施例的制造方法提供了(a)制备液体的步骤，该液体具有沉淀的含有有机粘结剂和无机细小颗粒的聚集物；和(b)将聚集物浸渍入垫1中的步骤。
步骤(a)优选地包括制备溶液的步骤，该溶液具有从含有有机粘结剂和分散有无机细小颗粒的胶体溶液的共混物沉淀的聚集物。上述材料可用作有机粘结剂和无机细小颗粒。其中分散有无机细小颗粒(无机溶胶)的胶体溶液的优选实例包括硅溶胶、氧化铝溶胶、二氧化钛溶胶和氧化锆溶胶，等等。例如，硅溶胶可为商用Snowtex(注册商标，日产化工株式会社(Nissan Chemical Industries，Ltd.))等。使用胶体溶液具有优点如下：含有具有充分均匀尺寸的聚集物的溶液可容易地生产。
为了将聚集物充分地沉淀于步骤(a)中的液体中，溶液的pH值优选地在将有机粘结剂和胶体溶液添加至液体之前或之后调整。换句话讲，将诸如硫酸铝这样的电解质添加至水并且混合以将水的pH值调整为从4至6。聚集物可以通过以下步骤充分地沉淀：将所需量的有机粘结剂和胶体溶液添加和混合入该液体中，并且随后添加絮凝剂，诸如有机絮凝剂，例如聚丙烯酰胺或铝酸盐。
液体中的聚集物的直径可通过pH值调整或通过在混合有机粘结剂和胶体溶液之后添加的絮凝剂的类型和量进行调整。注意，在溶液中，沉淀的聚集物利用滴管滴落到制剂上并且随后利用光学显微镜以20至200倍的放大系数获取放大的相片，20个聚集物颗粒的最大直径被从相片测量，并且液体中的聚集物的平均直径可根据这个平均值确定。无机颗粒自身是极其小的，所以在以液体浸渍时，滑动将容易地发生于垫的无机纤维之间，并且甚至不容易附连至垫的内部的材料通过提供作为聚集物也将容易地留在垫的无机纤维之间。具体地讲，如果液体中的聚集物的平均粒径为约20μm或更大和100μm或更小，那么聚集物在将液体浸渍入垫中时将更容易地留在垫中。此外，如果聚集物的平均粒径为约2mm或更小或约1mm或更小，那么垫中聚集物的分散可更均匀地执行。
步骤(b)的浸渍方法并非特别地限制，只要聚集物可充分地附连至形成垫1的无机纤维1a。例如，垫1可浸入具有沉淀的聚集物的液体，或者通过将液体过滤透过垫1可使得聚集物附连至垫1。
利用该制造方法，含有有机粘结剂和无机细小颗粒的聚集物首先沉淀，随后聚集物被浸渍入垫中，并且因此无机细小颗粒连同有机粘结剂可以更均匀的分散性附连遍及大部分的垫，这点通过独立地浸渍有机粘结剂和无机细小颗粒或在不形成聚集物的情况下是不容易获得的。包含有机粘结剂和无机细小颗粒的聚集物以良好的分散性附着至无机纤维的表面和交点，并留在垫中。
附着至垫中无机纤维的聚集物的平均直径可通过以下步骤确定：放大约500倍和利用SEM装置摄制垫形状的安装构件的横截面，随意地提取相片中已附着至纤维表面的聚集物的20个颗粒，读取每个聚集物的最大直径，并确定尺寸的平均值。附连至垫的聚集物将具有略小于在浸入溶液中因干燥已溶胀的聚集物的尺寸。关于平均直径，具有约1μm或更大或者约5μm或更大的直径的聚集物将容易地留在垫中，并且如果直径为约50μm或更小或者约30μm或更小，那么聚集物将往往更均匀地分散于整个垫中。
在执行步骤(a)和步骤(b)之后，将水从垫1移除并且将垫干燥以获得安装构件。所获得的安装构件可以利用剪刀或切割器等在使用之前被切割成所需的尺寸和形状。
如图4所示，安装构件10用于将污染控制元件30安装于污染控制装置50中。污染控制元件30的一个具体实例为用于清洁发动机的废气的催化剂载体或过滤元件等。污染控制装置50的一个具体实例为催化转化器或排气清洁装置(诸如柴油机颗粒过滤装置)。
图4中示出的污染控制装置50具有壳体20、设置于壳体20中的污染控制元件30，和设置于壳体20的内表面和污染控制元件30的外表面之间的安装构件10。污染控制装置50还提供了气体流入口21和气体流出口22，气体流入口21将废气引入至污染控制元件30，气体流出口22排出已穿过污染控制元件30的废气。
从减少所使用的安装构件10的量和确保密封性的角度来看，壳体20的内表面和污染控制元件30的外表面之间的间隙的宽度优选地从约1.5mm至15mm。安装构件10优选地处于适当压缩状况以提供壳体20和污染控制元件30之间的合适堆密度。如上文所述，利用安装构件10，甚至在有机粘结剂3已燃烧之后仍然可维持足够高的接触压力，所以在装配过程中的堆密度可设定为低于常规的堆密度，并且因此所使用的相对昂贵的无机纤维材料的量可减少。
用于压缩和装配安装构件10的手段包括翻盖压缩(clamshellcompression)、填料压缩和绞压器压缩(tourniquet compression)，等等。安装构件10在以所谓的压接构造制造催化转化器时可有利地使用，其中将安装构件在压力下(诸如，例如以填料压缩)按压入(例如)圆形圆柱体形状的壳体20。
例如，对于其中污染控制装置50为催化转化器的情况，催化转化器优选地为所谓的整体型催化转化器，其中该催化转化器具有整体形状的催化剂元件。催化转化器由具有带有蜂窝横截面的小通道的催化剂元件制成，并且因此尺寸小于常规的球粒型催化转化器。此外，关于废气的接触表面积可充分地确保，所以排气抵抗性可最小化，并且废气可更有效地处理。该催化转化器可有利地结合各种类型的内燃发动机使用来处理废气。具体地讲，在将这种构造的催化转化器安装于汽车(诸如乘用车、公交或卡车，等等)的排气系统中时，可充分地表明优异的效果。
由催化剂载体支承的催化剂通常为金属(诸如铂、钌、锇、铑、铱、镍，或钯，等等)或金属氧化物(诸如五氧化二钒或二氧化钛，等等)，并且优选地以涂层形式使用。
实例
本发明参考工作实例来进行描述。注意，自然地，本发明不限于这些工作实例。
实例1
添加6g的硫酸铝并将其与10L的水混合。获得的水溶液的pH值为4.5。将2.6g的下述有机粘结剂和10g的硅溶胶添加至水溶液以获得分散体。将3.5g的下述液体铝酸钠添加至该分散体以制备具有沉淀的含有有机粘结剂和无机细小颗粒的聚集物的溶液。
有机粘结剂：Nipol LX874(产品名称)，由日本瑞翁株式会社(JapanZeon Corporation)制造，Tg：-31℃；
硅溶胶：Snowtex O(产品名称)，由日产化学工业株式会社(NissanChemical Industries，Ltd.)制造，平均粒径：10nm至20nm；
液体铝酸钠：Nalco2372(产品名称)，由纳尔科化学公司(NalcoChemical Company)制造。
将针刺氧化铝纤维毯(Maftec MLS-2毯(产品名称)，由三菱塑料株式会社(Mitsubishi Plastics Inc.)制造)切割成25cm正方形，并且置于正方形造纸机中的网片上。将上述溶液倾倒于毯的顶部上并使其透过该毯。在毯下方回收滤液。在将聚集物以这种方式浸渍入毯中之后，将该毯在设定为120℃温度的暖空气烘干机中干燥60分钟以获得安装构件。
实例2
将安装构件类似于实例1来制备，不同的是，添加1g的硫酸铝并将其与10L的水混合以获得pH值为6.2的水溶液，以及通过将1g的液体铝酸钠添加至含有有机粘结剂(2.6g)和无机细小颗粒的分散体来制备具有沉淀的有机粘结剂和无机细小颗粒的聚集物的溶液。
实例3
将安装构件类似于实例1来制备，不同的是，使用具有-13℃的Tg的有机粘结剂(Nipol LX821(产品名称)，由日本瑞翁株式会社制造)取代具有-31℃的Tg的有机粘结剂。制剂量等示出于表1中。
实例4
将安装构件类似于实例1来制备，不同的是，使用具有+1℃的Tg的有机粘结剂(Nipol LX811H(产品名称)，由日本瑞翁株式会社制造)取代具有-31℃的Tg的有机粘结剂。制剂量等示出于表1中。
实例5
将安装构件类似于实例1来制备，不同的是，使用具有+25℃的Tg的有机粘结剂(Nipol LX814(产品名称)，由日本瑞翁株式会社制造)取代具有-31℃的Tg的有机粘结剂。制剂量等示出于表1中。
实例6
将安装构件类似于实例1来制备，不同的是，硅溶胶(Snowtex O(产品名称)，由日产化学工业株式会社制造)的制剂量从10g变为5g。制剂量等示出于表1中。
实例7
将安装构件类似于实例1来制备，不同的是，硅溶胶(Snowtex O(产品名称)，由日产化学工业株式会社制造)的制剂量从10g变为40g。制剂量等示出于表1中。
比较例1
将安装构件类似于实例4制备，不同的是，仅将有机粘结剂(Tg：+1℃)添加至含有硫酸铝的水溶液，并且不添加硅溶胶。制剂量等示出于表2中。在该对比例中，聚集物通过液体穿过毯而沉淀，但是结果示出，样品的环境温度接触压力小于工作实例等。
比较例2
将安装构件类似于实例1制备，不同的是，液体铝酸钠不被添加至含有有机粘结剂和无机细小颗粒的分散体。制剂量等示出于表2中。对于该比较例，在穿过毯的液体中未观察到聚集物的沉淀，并且因此几乎没有有机粘结剂和无机细小颗粒附连至藉此加工的样品。
比较例3
将安装构件类似于实例1制备，不同的是，硫酸铝不被添加至10L的水。制剂量等示出于表2中。在该比较例中，在穿过毯的液体中未观察到聚集物的沉淀，并且几乎没有有机粘结剂和无机细小颗粒附连。
评估测试
对根据下述方法如上文所述加工的每个安装构件确定有机粘结剂含量、纤维片的散射比率，和在环境温度(室温)下的接触压力。
有机粘结剂含量的测量
将从每个安装构件切割的25mm×25mm样品在烘箱中于110℃下干燥1小时，然后测量包含有机粘结剂的样品的重量(W0)。接下来，将样品在烘箱中于900℃下加热1小时，并测量有机粘结剂已燃烧之后的重量(W1)。在加热过程中对应于垫中有机粘结剂的含量的重量减少(LOI)通过下述等式计算。
由于加热导致的重量减少(LOI)重量％=(W0-W1)／W0×100
纤维片的散射比率的测量
冲击测试器根据日本工业标准(JIS K-6830)制造，并且随后冲击测试根据该标准中的指令执行。
(1)测试片(尺寸：100mm×100mm)利用冲切模具从安装构件(尺寸：250mm×250mm)制备，并且随后测量质量。
（2）如JIS K-6830所示，将测试片放置于冲击测试器中，并且随后从30°的角度施加冲击力。
(3)在测试之后，将测试片从冲击测试器移除并且再次测量质量。
(4)纤维片的散射的量根据测试片在测试之前和之后的变化计算。
安装构件在环境温度下的接触压力的测量
(1)圆形测试片(直径：45mm)利用冲切模具从安装构件(尺寸：250mm×250mm)制备，随后测量质量。
(2)将提供0.3g／cm3的支柱密度的垫厚度根据质量的测量值计算。
(3)将测试片放置于压缩测试器(由岛津公司(ShimadzuCorporation)制造的“Autograph AG-I”型号)的压缩板的中心上，并且随后以20mm／分钟的速度压缩，直至实现由上述计算所确定的垫厚度。将峰处的压力(接触压力)取为在环境温度下的接触压力(kPa)。
[表1]
Figure BDA0000384136380000141
[表2]
Figure BDA0000384136380000151
加热的安装构件接触压力的测量
(1)类似于实例1，一种圆形测试片(直径：45mm)利用冲切模具从安装构件(尺寸：250mm×250mm)制备，并且随后测量该质量。
(2)垫厚度由质量的测量值计算，其中填料密度为0.23g/cm3(不包括燃烧的组分，诸如有机组分)。
(3)测试片被夹紧于压缩测试仪(由岛津公司(ShimadzuCorporation)制造的“Autograph AG-I”型号)的2个(不锈钢)板之间，并且随后以20mm／分钟的速度压缩直至实现通过上述计算确定的垫厚度。
(4)在压缩测试片时，这两个板之一被加热至900℃，同时另一个板被加热至650℃。为了观察接触压力随时间的变化，在这两个板已分别达到900℃和650℃之后(测试开始时间)，每30分钟测量接触压力，共20小时。结果示出于表3和图5中。注意，接触压力的变化可通过下述等式近似计算，并且10年之后的接触压力可由该近似公式计算。
Y＝aXb
在公式中，X表示时间(hr)；Y表示接触压力(kPa)；和a、b表示系数。
测试片由以类似于比较例1的方式生产的安装构件加工，并且除了提供测量结果，还测量接触压力，如上文所述。结果示出于表3和图5中。
[表3]
Figure BDA0000384136380000161

Claims (13)

1.一种用于将污染控制元件包装和安装于壳体内的安装构件，包括：
具有无机纤维材料的垫；和
含有有机粘结剂和无机颗粒的聚集物，所述聚集物完全浸渍所述垫的大部分。
2.根据权利要求1所述的安装构件，其中所述有机粘结剂为具有15℃或更小的玻璃化转变温度(Tg)的丙烯酸胶乳。
3.根据权利要求1或2所述的安装构件，其中所述垫中所述有机粘结剂的总含量在大于0至小于等于5重量％的范围内。
4.根据权利要求1至3中的任一项所述的安装构件，其中所述无机颗粒为选自金属的氧化物、氮化物、碳化物以及它们的组合的至少一种材料。
5.根据权利要求1至4中的任一项所述的安装构件，其中所述无机细小颗粒具有1微米或更小的平均粒径。
6.根据权利要求1至5中的任一项所述的安装构件，其中所述聚集物具有1微米或更大的平均粒径。
7.一种污染控制装置，包括：
壳体，
设置于所述壳体内的污染控制元件，和
布置于所述壳体和所述污染控制元件之间的安装构件，
其中所述安装构件为根据权利要求1至5中任一项所述的安装构件。
8.根据权利要求7所述的污染控制装置，其中所述污染控制元件为催化剂载体或过滤元件。
9.一种制造用于将污染控制元件包装和安装于污染控制装置的壳体内的安装构件的方法，所述方法包括如下步骤：
制备其中沉淀含有有机粘结剂和无机细小颗粒的聚集物的液体，和
将所述聚集物浸渍入含有无机纤维的垫中。
10.根据权利要求9所述的方法，其中制备所述液体的所述步骤包括下列步骤：在混合物液体中制备其中沉淀聚集物的液体，所述混合物液体含有有机粘结剂和其中分散有无机细小颗粒的胶体溶液。
11.根据权利要求9或10所述的方法，其中所述有机粘结剂为具有15℃或更小的玻璃化转变温度(Tg)的丙烯酸胶乳。
12.根据权利要求9至11中的任一项所述的方法，其中所述无机颗粒具有1微米或更小的平均粒径。
13.根据权利要求9至12中的任一项所述的方法，其中沉淀于所述液体中的所述聚集物具有在从20微米或更大至2mm或更小的范围内的平均直径。
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US20130305697A1 (en) 2013-11-21
KR20140005275A (ko) 2014-01-14
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