CN107250500B - 保持材料、其制造方法以及使用其的气体处理装置 - Google Patents
保持材料、其制造方法以及使用其的气体处理装置 Download PDFInfo
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- CN107250500B CN107250500B CN201680012257.6A CN201680012257A CN107250500B CN 107250500 B CN107250500 B CN 107250500B CN 201680012257 A CN201680012257 A CN 201680012257A CN 107250500 B CN107250500 B CN 107250500B
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- 239000000463 material Substances 0.000 title claims abstract description 35
- 238000004519 manufacturing process Methods 0.000 title claims description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 40
- 229920002401 polyacrylamide Polymers 0.000 claims abstract description 28
- 238000012545 processing Methods 0.000 claims description 29
- 239000012784 inorganic fiber Substances 0.000 claims description 27
- 239000011230 binding agent Substances 0.000 claims description 17
- 239000002002 slurry Substances 0.000 claims description 11
- 239000003054 catalyst Substances 0.000 claims description 9
- 238000012360 testing method Methods 0.000 claims description 3
- 238000000465 moulding Methods 0.000 claims description 2
- 238000012856 packing Methods 0.000 claims description 2
- 239000000203 mixture Substances 0.000 abstract description 3
- 239000007789 gas Substances 0.000 description 31
- 238000000034 method Methods 0.000 description 15
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 11
- 239000000835 fiber Substances 0.000 description 7
- 239000000377 silicon dioxide Substances 0.000 description 6
- 238000004804 winding Methods 0.000 description 5
- 239000004925 Acrylic resin Substances 0.000 description 4
- 229920000178 Acrylic resin Polymers 0.000 description 4
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 238000004090 dissolution Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000011049 filling Methods 0.000 description 3
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 125000005396 acrylic acid ester group Chemical group 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 230000003197 catalytic effect Effects 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 125000005397 methacrylic acid ester group Chemical group 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 238000000746 purification Methods 0.000 description 2
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
- 229920001893 acrylonitrile styrene Polymers 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 238000003763 carbonization Methods 0.000 description 1
- 239000000701 coagulant Substances 0.000 description 1
- 230000015271 coagulation Effects 0.000 description 1
- 238000005345 coagulation Methods 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- SCUZVMOVTVSBLE-UHFFFAOYSA-N prop-2-enenitrile;styrene Chemical compound C=CC#N.C=CC1=CC=CC=C1 SCUZVMOVTVSBLE-UHFFFAOYSA-N 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
- 239000010455 vermiculite Substances 0.000 description 1
- 229910052902 vermiculite Inorganic materials 0.000 description 1
- 235000019354 vermiculite Nutrition 0.000 description 1
Classifications
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- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/36—Inorganic fibres or flakes
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/20—Macromolecular organic compounds
- D21H17/33—Synthetic macromolecular compounds
- D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H17/37—Polymers of unsaturated acids or derivatives thereof, e.g. polyacrylates
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/0211—Arrangements for mounting filtering elements in housing, e.g. with means for compensating thermal expansion or vibration
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
- F01N3/2825—Ceramics
- F01N3/2828—Ceramic multi-channel monoliths, e.g. honeycombs
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
- F01N3/2835—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support fibrous
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
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- F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
- F01N3/2871—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing the mats or gaskets having an additional, e.g. non-insulating or non-cushioning layer, a metal foil or an adhesive layer
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- F01N2350/02—Fitting ceramic monoliths in a metallic housing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
- F01N2450/02—Fitting monolithic blocks into the housing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Textile Engineering (AREA)
- Ceramic Engineering (AREA)
- Inorganic Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Exhaust Gas After Treatment (AREA)
- Catalysts (AREA)
- Solid-Sorbent Or Filter-Aiding Compositions (AREA)
- Nonwoven Fabrics (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (AREA)
Abstract
一种保持材料,其包含:含有70重量%以上的氧化铝成分的无机纤维;表面带负电的、聚丙烯酰胺以外的有机粘合剂;氧化铝溶胶;和重均分子量为300万~600万的聚丙烯酰胺,在将上述无机纤维计为100重量份时,上述氧化铝溶胶的量为2~8重量份,在将上述无机纤维计为100重量份时,上述聚丙烯酰胺的量为0.01~1.0重量份。
Description
技术领域
本发明涉及用于例如汽车等的排气净化用气体处理装置的处理结构体的保持材料。
背景技术
在汽车等车辆中,为了除去其发动机的排气中所含的一氧化碳、碳氢化合物、氮氧化物等有害成分,搭载有排气净化用气体处理装置。这样的气体处理装置一般由被形成为筒状的催化剂载体等处理结构体、收纳处理结构体的金属制的壳体、和安装在处理结构体并且介入安装在处理结构体与壳体的间隙的保持材料构成。
对于介入安装在处理结构体与壳体的间隙的保持材料,要求兼备:安全地保持处理结构体的功能,从而在汽车行驶中不会由于振动等而导致处理结构体与壳体发生冲突遭破损;和密封功能,从而使得未净化的排气不会从处理结构体与壳体的间隙泄露。为了安全地保持处理结构体,需要以规定的表面压力保持处理结构体,但是由于重复地受到伴随加热的压缩,而存在表面压力下降的问题。
例如,专利文献1中,公开了组合二氧化硅纤维和氧化铝溶胶而得到的表面压力高的保持材料。
现有技术文献
专利文献
专利文献1:日本特开2013-148072号公报
发明内容
本发明的目的在于,提供表面压力高且能够以良好的生产率进行制造的保持材料以及使用该保持材料的气体处理装置。
本发明的发明者们经过深入研究的结果,发现以规定配合量包含规定分子量的聚丙烯酰胺和氧化铝溶胶时,能够得到表面压力高且制造性良好的保持材料,从而完成了本发明。
根据本发明,提供以下的保持材料和气体处理装置等。
1.一种保持材料,其中,
包含:
含有70重量%以上的氧化铝成分的无机纤维;
表面带负电的、聚丙烯酰胺以外的有机粘合剂;
氧化铝溶胶;和
重均分子量为300万~600万的聚丙烯酰胺,
在将上述无机纤维计为100重量份时,上述氧化铝溶胶的量为2~8重量份,
在将上述无机纤维计为100重量份时,上述聚丙烯酰胺的量为0.01~1.0重量份。
2.1所记载的保持材料,其中,以填充密度0.5g/cm3、缝隙开放率12%进行2500次重复试验的结果,自初期开放时表面压力的表面压力残存率为24%以上。
3.1或2所记载的保持材料,其中,上述无机纤维的交点之中,氧化铝溶胶以短径500nm以上的块附着的交点为15%以上。
4.一种保持材料的制造方法,其中,
以成为如下组成的方式混合并制备水性浆料,
将上述水性浆料脱水成形,制作湿润成形体,
将上述湿润成形体干燥,
其中,
上述水性浆料包含:
含有70重量%以上的氧化铝成分的无机纤维;
表面带负电的、聚丙烯酰胺以外的有机粘合剂;
氧化铝溶胶;和
重均分子量为300万~600万的聚丙烯酰胺,
在将上述无机纤维计为100重量份时,上述氧化铝溶胶的量为2~8重量份,
在将上述无机纤维计为100重量份时,上述聚丙烯酰胺的量为0.01~1.0重量份。
5.一种气体处理装置,其中,
具备:
被形成为筒状的处理结构体;
收纳上述处理结构体的壳体;和
介入安装在上述处理结构体与上述壳体的间隙的1~3中任一项所记载的保持材料。
6.5所记载的气体处理装置,其中,
上述处理结构体为催化剂载体或排气过滤器。
根据本发明,能够提供表面压力高且能够以良好的生产率进行制造的保持材料和使用该保持材料的气体处理装置。
附图说明
图1是表示安装有本发明的一种实施方式的保持材料的气体处理装置的截面图。
图2是表示对实施例3所得到的保持材料测定表面压力的结果的图。
具体实施方式
以下,对本发明的保持材料进行详细说明。
图1是示意地表示安装有本发明的保持材料的气体处理装置的一种实施方式的截面图。所图示的气体处理装置10由被形成为筒状的处理结构体1、收纳处理结构体1的壳体2、和安装在处理结构体1且介入安装在处理结构体1与壳体2的间隙的保持材料3构成。保持材料3通常为片状,卷绕在处理结构体1上,但也可以设计为筒状。
气体处理装置10用于除去气体中所含的有害物质和/或颗粒。气体处理装置10为例如在汽车等车辆中除去从内燃机(汽油发动机、柴油发动机等)排出的排气中所含的有害物质和/或颗粒的排气处理装置。
具体而言,气体处理装置10为例如用于除去汽油发动机的排气中所含的有害物质的催化转化器、或用于除去柴油发动机的排气中所含的颗粒的DPF(柴油颗粒过滤器,Diesel Particulate Filter)。
处理结构体1为具有处理气体的功能的结构体。气体处理装置10为催化转化器时,处理结构体1是催化剂载体,其具有用于净化气体的催化剂和载持该催化剂的载体。
另外,气体处理装置10为DPF时,处理结构体1是具有捕获该气体中的该颗粒的过滤器的结构体。此时,处理结构体1也可以包含催化剂。
壳体2例如为不锈钢、铁和铝等的金属制。壳体2也可以被划分为多个部分。
保持材料3用于在壳体2内保持处理结构体1。即,保持材料3以被压缩的状态配置在处理结构体1与壳体2的间隙中,由此,在该壳体2内稳定地保持该处理结构体1。
本发明的保持材料包含:含有70重量%以上的氧化铝成分的无机纤维;表面带负电的、聚丙烯酰胺以外的有机粘合剂;氧化铝溶胶;和重均分子量为300万~600万的聚丙烯酰胺。
本发明中使用的无机纤维通常含有70~100重量%的氧化铝成分、0~30重量%的二氧化硅成分。优选含有72~98重量%的氧化铝成分、2~28重量%的二氧化硅成分。例如,可以使用含有90~98重量%的氧化铝成分、2~10重量%的二氧化硅成分的无机纤维。
另外,优选含有98重量%以上或100重量%(其中,包含不可避免的杂质)的氧化铝成分和二氧化硅成分。
在将无机纤维计为100重量份时,氧化铝溶胶的量为2~8重量份。优选为2.5~7重量份、更优选为3~6重量份。小于2重量份时,耐久后的表面压力值得不到提高。超过8重量份时,存在卷绕时垫发生破裂的担忧。另外,增加氧化铝溶胶的量时,耐风蚀性得到提高。
作为表面带负电的、聚丙烯酰胺以外的有机粘合剂,可以使用公知的粘合剂,可以使用橡胶类、水溶性有机高分子化合物、热塑性树脂、热固性树脂等。优选为丙烯酸树脂。作为丙烯酸树脂的示例,可以列举丙烯酸、丙烯酸酯、丙烯腈、甲基丙烯酸、甲基丙烯酸酯等的均聚物和共聚物、丙烯腈-苯乙烯共聚物、丙烯腈-丁二烯-苯乙烯共聚物等。
在将无机纤维计为100重量份时,有机粘合剂的量通常为0.01~20重量份。优选为0.1~15重量份、更优选为2~12重量份、特别优选为5~11重量份。包含大量有机粘合剂时,虽然对催化剂载体的卷绕性得到提高,但是在有机粘合剂分解时,容易因有机粘合剂的碳化而引起表面压力的下降。
本发明中使用的聚丙烯酰胺的重均分子量为300万~600万,例如为400万~500万。小于300万时,有无法赋予粘合力的担忧。超过600万时,有制造性变差的担忧。
在将无机纤维计为100重量份时,聚丙烯酰胺的量为0.01~1.0重量份。优选为0.05~0.8重量份、更优选为0.1~0.5重量份。小于0.01重量份时,有凝聚效果下降而无法赋予粘合力的担忧。超过1.0重量份时,电荷的平衡被破坏,凝聚效果反而下降,从而有无法赋予粘合力的担忧。
本发明的保持材料中,除了包含无机纤维、氧化铝溶胶、聚丙烯酰胺、和有机粘合剂以外,还能够包含纸浆等的有机纤维、蛭石等的膨胀材料等。本发明的保持材料中无需包含淀粉。
本发明的保持材料中包含的无机纤维、氧化铝溶胶、聚丙烯酰胺、和有机粘合剂的合计含量可以是90重量%以上、95重量%以上、或98重量%以上或100重量%(包含不可避免的杂质)。本发明的保持材料例如可以通过烧成而使有机粘合剂烧尽。
在本发明中,对保持材料的厚度没有限定,通常为6mm~20mm。对于密度没有限定,通常为0.10g/cm3~0.25g/cm3。
本发明的保持材料优选为,以填充密度0.5g/cm3、缝隙开放率(Gap开放率)12%进行2500次重复试验的结果,自初期开放时表面压力的表面压力残存率为24%以上,更优选为26%以上。
在保持材料中,无机纤维互相缠绕,在纤维的周围以及交点附着有氧化铝溶胶。优选在无机纤维的交点之中,氧化铝溶胶以短径500nm以上的块附着的交点为15%以上。该交点比例大时,有表面压力残存率变高的倾向。该交点比例更优选为20%以上。
对于本发明的保持材料的制造方法没有限制,例如可以采用如下的方法。
将水、上述无机纤维、有机粘合剂、氧化铝溶胶和聚丙烯酰胺混合,制备水性浆料。将该水性浆料脱水成形,制作湿润成形体。之后,将湿润成形体干燥,得到保持材料。
在制备水性浆料时,在将无机纤维计为100重量份时,将氧化铝溶胶的量设为2~8重量份,并将聚丙烯酰胺的量设为0.01~1.0重量份。
实施例
以下,通过实施例对本发明进行详细说明,但本发明并不限定于该实施例。
实施例1,2
(1)保持体的制造
将氧化铝纤维(96.0重量%的Al2O3成分和4.0重量%的SiO2成分)、丙烯酸树脂(丙烯酸酯和甲基丙烯酸酯的共聚物)(有机粘合剂)、氧化铝溶胶和聚丙烯酰胺A(重均分子量(分子量)450万)分散在水中,制备水性浆料。将各成分的配合量示于表1中。表中所示的配合量是将氧化铝纤维计为100重量份时的重量份。
接着,使水性浆料流入到具有金属丝网的脱水成形模中,进行脱水成形,得到氧化铝纤维制湿润成形体。进一步,一边对湿润成形体进行压缩、一边以100℃进行干燥,从而得到保持体。密度为0.165g/cm3。
此外,重均分子量是通过使用HLC-8120作为柱、以流速1ml/分钟、利用GPC法进行测定的。
(2)保持体的评价
通过以下方法评价保持体的特性。
(i)凝聚状态
通过目视观察凝聚状态。凝聚状态为蓬松的凝聚时,物性稳定,因而优选。
(ii)表面平滑性
通过目视观察表面平滑性。表面平滑时,不容易在卷绕时以表面的凹凸为基点在垫发生破裂、裂纹,因而优选。将卷绕时垫上没有破裂、裂纹的例记为良好(○),将卷绕时以表面凹凸部为起点在垫上发生破裂、裂纹的例记为差(×)。
(iii)制造性
将凝聚剂投入到以300rpm搅拌的10℃的水中,使其成为0.5%浓度,测量到完全溶解为止的时间。将在1小时以内溶解的例记为良好(○),溶解需要1小时以上时记为差(×)。
(iv)表面压力残存率
通过以下方法测定表面压力残存率。
表面压力的测定使用岛津株式会社制的万能试验机Autograph进行。将压缩夹具的圆盘(直径100mm、厚度25mm)安装在上下,将上下压盘的间隔成为10mm的位置设为零点。接着,将上述制作的垫配置在下压盘,从零点位置以10mm/分钟的压缩速度将垫以成为0.5g/cm3的填充密度的方式压缩后、开放至12%(填充密度0.446g/cm3)的开放率为止,并将此操作重复2500循环后,进行测定。此时得到的就是自初期开放时表面压力的第2500循环次的开放时表面压力的表面压力残存率。
(v)卷绕性
将保持材料卷绕在直径70mm的催化剂载体上,观察卷绕性。垫上没有破裂、裂纹时,记为良好(○);垫发生了破裂、裂纹时,记为差(×)。
(vi)交点比例
利用显微镜观察,测定无机纤维的交点之中,氧化铝溶胶无机粘合剂以短径500nm以上的块附着的交点的交点比例。
比较例1~5
按照表1所示的成分和配合量,与实施例1同样地进行操作,制造保持体,进行评价。将结果示于表1中。
此外,比较例4中,作为凝聚剂,使用重均分子量为900万的聚丙烯酰胺B。
实施例3
对于实施例1中使用的氧化铝纤维100重量份、丙烯酸树脂10重量份、聚丙烯酰胺A0.3重量份,将氧化铝溶胶的量从0.5重量份改变为6.5重量份,与实施例1同样地进行操作,制造保持材料。与实施例1同样地进行操作,测定2500次后的开放时表面压力。将结果示于图2中。
产业上的利用的可能性
本发明的保持材料能够用于汽车等的排气净化用气体处理装置等中。
以上详细说明了本发明的实施方式和/或实施例的几种,但对本领域技术人员而言,在实质上不脱离本发明的新颖的启示和效果的情况下,对这些作为例示的实施方式和/或实施例添加多种变更是容易的。因此,这些多种变更包含在本发明的范围内。
在此援用该说明书所记载的文献和成为本申请的巴黎公约优先权的基础的日本申请说明书的内容的全部。
Claims (5)
1.一种保持材料,其中,
包含:
含有70重量%以上的氧化铝成分的无机纤维;
表面带负电的、聚丙烯酰胺以外的有机粘合剂;
氧化铝溶胶;和
重均分子量为300万~600万的聚丙烯酰胺,
在将所述无机纤维计为100重量份时,所述氧化铝溶胶的量为2~8重量份,
在将所述无机纤维计为100重量份时,所述聚丙烯酰胺的量为0.01~1.0重量份,
所述无机纤维的交点之中,氧化铝溶胶以短径500nm以上的块附着的交点为15%以上。
2.如权利要求1所述的保持材料,其中,
以填充密度0.5g/cm3、缝隙开放率12%进行2500次重复试验的结果,自初期开放时表面压力的表面压力残存率为24%以上。
3.一种保持材料的制造方法,该保持材料是权利要求1所述的保持材料,其中,
以成为如下组成的方式混合并制备水性浆料,
将所述水性浆料脱水成形,制作湿润成形体,
将所述湿润成形体干燥,
其中,
所述水性浆料包含:
含有70重量%以上的氧化铝成分的无机纤维;
表面带负电的、聚丙烯酰胺以外的有机粘合剂;
氧化铝溶胶;和
重均分子量为300万~600万的聚丙烯酰胺,
在将所述无机纤维计为100重量份时,所述氧化铝溶胶的量为2~8重量份,
在将所述无机纤维计为100重量份时,所述聚丙烯酰胺的量为0.01~1.0重量份。
4.一种气体处理装置,其中,
具备:
被形成为筒状的处理结构体;
收纳所述处理结构体的壳体;和
介入安装在所述处理结构体与所述壳体的间隙的权利要求1或2所述的保持材料。
5.如权利要求4所述的气体处理装置,其中,
所述处理结构体为催化剂载体或排气过滤器。
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EP3263860A1 (en) | 2018-01-03 |
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US10422060B2 (en) | 2019-09-24 |
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