CN1259500C - 净化废气用催化剂转换器的保持密封材料 - Google Patents
净化废气用催化剂转换器的保持密封材料 Download PDFInfo
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Abstract
本发明的目的在于提供能够防止无机纤维从表面飞散并能良好地保持在组装时的作业环境的净化废气用催化剂转换器的保持密封材料。在本发明中,在设置于净化废气用催化剂转换器中的催化剂载体和覆盖其外侧的壳体之间的保持密封材料中,保持密封材料在以垫层状设置无机纤维构成的垫层状材料中添加有重量百分比为0.5~20%的有机粘合剂或无机粘合剂构成的粘合剂,同时,将组装后的填充密度调整至0.1~0.6g/cm3的范围内,且在沿上述垫层状材料的厚度方向三等分为上部、中部、下部来测定添加至垫层状材料的粘合剂的固体成分的分布率时,上述上部以及下部中的上述分布率比上述中部高。
Description
技术领域
本发明涉及用于净化从内燃机等发动机排放出的废气的净化废气用催化剂转换器,特别涉及其保持密封材料。
背景技术
如图6所示,以往,为了净化从内燃机等发动机92排放出的废气而使用了净化废气用催化剂转换器90。净化废气用催化剂转换器90具有催化剂载体1和覆盖其外侧的金属材料壳体95,设置在这两者之间的保持密封材料91。所述保持密封材料91能够防止从催化剂载体1和金属材料壳体95之间排放的气体的泄漏,并能够防止催化剂载体1与金属材料壳体95接触而造成损伤。
另外,在制造上述净化废气用催化剂转换器90时,应将保持密封材料91卷绕在催化剂载体1上,将进行所述卷绕形成的一体件装配在壳体95内。之后,通过焊接分别使入口连接部97、出口连接部98结合至所述壳体95的两端。以此方式制造的净化废气用催化剂转换器90设置在从发动机92排出的排气管道99的中点。
但是,在上述以往的净化废气用催化剂转换器90中的保持密封材料91具有以下问题。
即,上述保持密封材料91由呈线状体且比重比较轻的无机纤维制成。因此,在将该保持密封材料91组装在上述催化剂载体1以及壳体95上时,上述无机纤维会从保持密封材料91的表面放散至空中。因此,可能导致进行上述组装作业的工作区中作业环境恶化,在进行上述组装作业时,例如,工人必须佩戴防尘面具等进行作业。
针对以往的问题,本发明提供的净化废气用催化剂转换器的保持密封材料能够防止无机纤维从表面飞散,并在组装时良好地保持作业环境。
发明内容
本发明提供了一种净化废气用催化剂转换器的保持密封材料,其设置在净化废气用催化剂转换器中的催化剂载体和覆盖其外侧的壳体之间,其特征在于:
所述保持密封材料在以垫层状设置无机纤维构成的垫层状材料中添加有由重量百分比为0.5~20%的有机粘合剂或无机粘合剂构成的粘合剂,同时,将组装后的填充密度调整至0.1~0.6g/cm3的范围内,
并且,在沿上述垫层状材料的厚度方向三等分为上部、中部、下部来测定添加至上述垫层状材料的上述粘合剂的固体成分的分布率时,上述上部以及下部中的上述分布率比上述中部高,
对于上述上部、中部、下部中的上述粘合剂的固体成分的分布率而言,上部的重量百分比为35~50%,中部的重量百分比为0~30%,下部的重量百分比为35~50%。
本发明最关注的问题是:在如上述那样测定上述粘合剂的固体成分的分布率时,上述上部以及下部中的上述分布率比上述中部高。
此处,所谓重量百分比为0.5~10%的粘合剂表示粘合剂在整个垫层状材料中的含量。
下面,对本发明的作用效果进行说明。
在本发明中,上述粘合剂集中添加在作为上述保持密封材料表面中暴露部分的上部和下部。即,保持密封材料中暴露至外界的表面由上述粘合剂的固体成分覆盖。因此,能够防止呈线状体且比重比较轻的无机纤维从保持密封材料的表面飞散至空中。所以,在将保持密封材料组装在上述催化剂载体以及壳体上时,由于无机纤维难以飞散,因此,即使操作者不使用防尘面罩等装置,也能够进行舒适的作业。所以,能够良好地保持进行上述组装作业的工作区的工作环境。
附图说明
图1为立体图,其显示了在实施例1中,将保持密封材料组装在催化剂载体以及壳体上的状态;
图2(A)为立体图,其显示了在实施例1中,将保持密封材料卷绕在催化剂载体之前的状态;
图2(B)为立体图,其显示了在实施例1中,将保持密封材料卷绕在催化剂载体的状态;
图3为立体图,其显示了在实施例1中,使由将保持密封材料卷绕在催化剂载体上所形成的一体件装配在壳体上的状态;
图4为说明图,其显示了在实施例1中将装有保持密封材料的净化废气用催化剂转换器设置在发动机排气管中点处的状态;
图5为显示实施例1中针刺装置(ニ-ドルパンチング)的说明图;
图6为说明图,其显示了以往例子中,将装有保持密封材料的净化废气用催化剂转换器设置在发动机排气管中点处的状态。
具体实施方式
在本发明中,在上述粘合剂的含有量的重量百分比不足0.5%时,不能防止上述无机纤维的飞散。另一方面,在粘合剂的含有量的重量百分比超过20%时,将有机粘合剂用作所述粘合剂的情况与将无机粘合剂用作所述粘合剂的情况有所不同。即,存在以下危险性:在使用有机粘合剂时,在将上述保持密封材料装配在上述催化剂载体以及壳体上以便用作净化废气用催化剂转换器时,粘合剂成为有机气体并与废气混合,从而会增加废气的浓度。另外,在使用无机粘合剂时,会降低保持密封材料的柔韧性,从而难以将保持密封材料装配在催化剂载体上。
另外,在上述保持密封材料装配后的填充密度不足0.1g/cm3的情况下,在装配了保持密封材料后,保持密封材料和催化剂载体或保持密封材料和壳体的接触压力较小,因此存在它们会沿轴向移动的危险性。另一方面,在填充密度超过0.6g/cm3的情况下,在进行上述装配时,压破保持密封材料的量较大,从而存在压坏保持密封材料、使保持密封材料的耐久性恶化的危险性。
在上述上部、中部、下部中上述粘合剂的固体成分的分布率最好为:上部为35~50%(重量百分比),中部为0~30%(重量百分比),下部为35~50%(重量百分比)。因此,能够容易地防止无机纤维从上述保持密封材料表面飞散。
另外,在上述上部以及下部的上述分布率不足35%(重量百分比)的情况下,粘合剂的固体成分不会充分固定在上述保持密封材料的表面上,从而存在不能充分防止保持密封材料的无机纤维从其表面飞散至空气中的危险性。
另一方面,在上部或下部中任意一个的上述分布率超过50%(重量百分比)时以及在上述中部的上述分布率超过30%(重量百分比)时,粘合剂中固体成分的分布会偏向上部或下部,从而存在不能充分防止保持密封材料的无机纤维从其表面飞散至空中的危险性。
构成上述垫层状材料的上述无机纤维最好是从结晶铝纤维、硅铝纤维、硅纤维中选择的1种或2种以上的纤维。因此,能够确保防止元机纤维从上述保持密封材料的表面飞散。
对于上述保持密封材料而言,进行从500mm高落下10次的下落试验后的重量减少率最好小于0.2%(重量百分比)。因此,能够确保防止无机纤维从上述保持密封材料的表面飞散。
另外,将落下前的保持密封材料的重量作为W0,将落下后的保持密封材料的重量作为W,该重量减少率α[%]为由α=((W0-W)/W0)×100[%]表示的量。
下面,虽然利用实施例对本发明作了更详细的说明,但是本发明不应局限于此。
实施例1
利用图1~图5对本发明实施例中净化废气用催化剂转换器的保持密封材料进行说明。
如图1所示,本实施例中的保持密封材料2在净化废气用催化剂转换器10中,是被设置在催化剂载体1以及覆盖其外侧的壳体95之间来使用的。另外,将由重量百分比为0.5~20%的有机粘合剂或无机粘合剂构成的粘合剂添加在以垫层状设置无机纤维制成的垫层状材料21(参见图2(A),图2(B))以构成保持密封材料2,同时,将组装后的填充密度调整至0.1~0.6g/cm3的范围内。
并且,在上述保持密封材料2中:在沿上述垫层状材料21的厚度方向三等分出上部211、中部212、下部213以测定添加在上述垫层状材料21的上述粘合剂的固体部分的分布率时,上述上部211以及下部213中的上述分布率比上述中部212高。
具体来说,上述保持密封材料2组装后的填充密度为0.5g/cm3,上述垫层状材料21组装前的厚度为25mm。另外,对于上述粘合剂的分布率而言,上部为45%(重量百分比),中部为10%(重量百分比),下部为45%(重量百分比)。
下面,对其进行详细说明。
在上述催化剂载体1中,使用了以蜂窝状形成其剖面的堇青石载体。在这种催化剂载体1中,沿其轴向设有多个矩形孔11。另外,在这些矩形孔11之间形成作为其隔壁的多个蜂窝壁12(参见图1)。另外,在催化剂载体1中,装载有以白金或钯作为主要成分的催化剂。
另外,在构成上述垫层状材料21的上述无机纤维中使用了结晶铝纤维,这种纤维为不会因热而过份膨胀的无膨胀性纤维。另外,在上述粘合剂中,使用了作为有机粘合剂的乳胶。
下面,对将上述粘合剂添加在垫层状材料21的方法进行说明。
首先,将粘合剂溶液喷射至垫层状材料21的表面,使粘合剂从该表面渗透。之后,使所述垫层状材料21干燥,在该垫层状材料21中添加粘合剂的固体成分。以此方式,进行粘合剂的添加。通过调节上述粘合剂的喷射强度,能够调节粘合剂在上部、中部、下部中的含量。
下面,对上述保持密封材料的组装方法进行说明。
首先,将上述粘合剂添加至上述垫层状材料21,形成保持密封材料。另外,同时,使上述催化剂装载在上述保持密封材料2上。
接着,在催化剂的载体1上卷绕保持密封材料2以在外周侧构成其上部211(参见图2(A),图2(B)),在壳体95的内部设置进行所述卷绕的一体件20(参见图3)。以此方式,进行保持材料2的组装,通过焊接分别使熔接入口连接部97,出口连接部98连接在壳体95的两端(参见图4)。
另外,将以此方式制造的净化废气用催化剂转换器10设置在发动机92排出的排气管99的中部。
在这种情况下,如图5所示,在添加粘合剂之前,对上述垫层状材料21实施针刺处理。所述针刺处理是通过可沿穿刺方向往复运动的针板51和针刺装置5进行的,其中,所述针刺装置具有支承进行所述处理的垫层状材料21内外两个表面的一对支承板52。
在针板51上固定有用于穿刺垫层状材料21的多根针53。针53以大约500个的密度固定在针板中100cm2的区域中。另外,在支承板52中设有针的通过孔520。
在使垫层状材料21在一对支承板52之间通过的同时,使针板51往复运动时,使针53刺穿垫层状材料21,从而在垫层状材料21内的无机纤维之间形成编织。
下面说明本实施例的作用效果。
在本实施例中,上述粘合剂的添加在作为上述保持密封材料2表面的露出部分的上述上部211和下部213集中进行。即,保持密封材料2中暴露于外部的表面由上述粘合剂的固体成分覆盖。因此,能够防止呈丝状条且比重较轻的无机纤维从保持密封材料2表面飞散至空中。因此,由于在将保持密封材料2组装在上述催化剂载体1以及壳体95上时,无机纤维很难飞散,所以,即使操作者不使用防尘面罩等装置,也能够进行舒适的作业。因此,能够良好地保持进行上述组装作业的工作区的工作环境。
另外,虽然改善柔性能够容易地将进行针刺处理的垫层状材料21卷绕在上述催化剂载体1上,但另一方面,在垫层状材料21的表面会残留弯曲且较短的无机纤维。随后,在进行上述垫层状材料21的组装时,所述残留的较短的无机纤维易于飞散至空中。
因此,在进行针刺处理时,如上所述,通过在垫层状材料21中添加粘合剂,所形成的保持密封材料2在使柔性优化的同时,能够防止上述残留的较短无机纤维飞散至空中。
实施例2
在本实施例中,为了确保在上述垫层状材料21中所含的无机纤维难以飞散至空中,进行了以下的下落试验。
即,在该下落试验中,使用了添加了不同粘合剂的垫层状材料21(发明制品1,2)以及未添加粘合剂的垫层状材料21(比较制品),使它们从500mm高度落下10次。之后,通过检测下落后的垫层状材料21的重量减少率,能够测定垫层状材料21中的无机纤维向空中的飞散。
(发明制品1)
在组装前的自由状态下,在由松密度0.05g/cm3、厚度25mm的结晶铝纤维制成的垫层状材料21中,作为粘合剂,添加占垫层状材料21整体量的1%(重量百分比)的乳胶。另外,所述粘合剂的分布率为上部45%(重量百分比),中部10%(重量百分比),下部45%(重量百分比)。之后,在对所述垫层状材料21进行上述下落试验,测定上述重量减少率时,所述重量减少率为0.002%。
将落下前的垫层状材料21的重量作为W0,将落下后的垫层状材料21的重量作为W,该重量减少率α[%]为由α=((W0-W)/W0)×100[%]表示的量。
(发明制品2)
在与上述发明制品1相同的结晶铝纤维的垫层状材料21中,作为粘合剂,添加占垫层状材料21整体量的1%(重量百分比)的铝溶胶。另外,所述粘合剂的分布率与发明制品1相同。之后,在对所述垫层状材料21进行上述下落试验,测定上述重量减少率时,所述重量减少率为0.003%。
(比较制品)
在与上述发明制品1相同的结晶铝纤维的垫层状材料21中,不添加粘合剂而进行上述下落试验。之后,在测定这种情况下的上述重量减少率时,所述重量减少率为0.312%。
由以此方式进行的上述下落试验的结果可知,通过在上述保持密封材料2中的垫层状材料21的上部211以及下部213集中添加上述粘合剂,能够显著降低上述重量减少率。另外,若所述重量减少率小于0.2%(重量百分比),则能够有效地防止保持密封材料2中的无机纤维向空中飞散。
工业可利用性
如上所述,本发明提供的净化废气用催化剂转换器能够防止无机纤维从表面飞散,并在组装时良好地保持作业环境。
Claims (3)
1.一种净化废气用催化剂转换器中的保持密封材料,其设置在净化废气用催化剂转换器中的催化剂载体和覆盖其外侧的壳体之间,其特征在于:
所述保持密封材料在以垫层状设置无机纤维构成的垫层状材料中添加由重量百分比为0.5~20%的有机粘合剂或无机粘合剂构成的粘合剂,同时,将组装后的填充密度调整至0.1~0.6g/cm3的范围内,
并且,在沿上述垫层状材料的厚度方向三等分为上部、中部、下部来测定添加至上述垫层状材料的上述粘合剂的固体成分的分布率时,上述上部以及下部中的上述分布率比上述中部高,
对于上述上部、中部、下部中的上述粘合剂的固体成分的分布率而言,上部的重量百分比为35~50%,中部的重量百分比为0~30%,下部的重量百分比为35~50%。
2.根据权利要求1所述的净化废气用催化剂转换器中的保持密封材料,其特征在于:构成上述垫层状材料的上述无机纤维为从结晶铝纤维、硅铝纤维、硅纤维中选择的1种或2种以上的纤维。
3.根据权利要求1所述的净化废气用催化剂转换器中的保持密封材料,其特征在于:对于所述保持密封材料而言,进行从500mm高处落下10次的下落试验后的重量减少率为重量百分比0.2%以下。
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EP1296030A1 (en) | 2003-03-26 |
JP4042305B2 (ja) | 2008-02-06 |
KR20030015282A (ko) | 2003-02-20 |
DE60109035T2 (de) | 2006-04-13 |
US20030104189A1 (en) | 2003-06-05 |
KR100545467B1 (ko) | 2006-01-24 |
CN1437677A (zh) | 2003-08-20 |
JP2002004848A (ja) | 2002-01-09 |
EP1296030B1 (en) | 2005-02-23 |
EP1296030A4 (en) | 2004-04-21 |
DE60109035D1 (de) | 2005-03-31 |
WO2001098640A1 (fr) | 2001-12-27 |
US6960386B2 (en) | 2005-11-01 |
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