EP1348842A2 - Halterungsmaterial für einen katalytischen Umwandler - Google Patents

Halterungsmaterial für einen katalytischen Umwandler Download PDF

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Publication number
EP1348842A2
EP1348842A2 EP03007136A EP03007136A EP1348842A2 EP 1348842 A2 EP1348842 A2 EP 1348842A2 EP 03007136 A EP03007136 A EP 03007136A EP 03007136 A EP03007136 A EP 03007136A EP 1348842 A2 EP1348842 A2 EP 1348842A2
Authority
EP
European Patent Office
Prior art keywords
fiber
holding material
sewing thread
catalyst carrier
organic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP03007136A
Other languages
English (en)
French (fr)
Other versions
EP1348842A3 (de
Inventor
Toshiyuki Anji
Masafumi Tanaka
Tadashi c/o Nichias Corporation Sakane
Takahito c/o Nichias Corporation Mochida
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nichias Corp
Original Assignee
Nichias Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nichias Corp filed Critical Nichias Corp
Publication of EP1348842A2 publication Critical patent/EP1348842A2/de
Publication of EP1348842A3 publication Critical patent/EP1348842A3/de
Withdrawn legal-status Critical Current

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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
    • D04H1/42—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
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/45—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by forming intermeshing loops or stitches from some of the fibres
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/52—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by applying or inserting filamentary binding elements
    • 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
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
    • 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

Definitions

  • the present invention relates to a catalyst carrier holding material used in a catalytic converter, for example, for purging exhaust gas emitted from an automobile.
  • a catalytic converter for purging exhaust gas is loaded in a vehicle such as an automobile in order to remove detrimental components such as carbon monoxide, hydrocarbon and nitrogen oxides from exhaust gas emitted from an engine of the vehicle.
  • the catalytic converter has a catalyst carrier 1 shaped like a cylinder, a metal casing 2 for receiving the catalyst carrier 1, and a holding material 3 interposed in a gap between the catalyst carrier 1 and the casing 2 while mounted on the catalyst carrier 1.
  • the catalyst carrier 1 has a cylindrical honey-comb molded material, for example, made of cordierite, and a precious metal catalyst carried by the molded material. It is therefore necessary that the holding material 3 interposed in a gap between the catalyst carrier 1 and the casing 2 has a function for holding the catalyst carrier 1 safely to prevent the catalyst carrier 1 from being damaged by collision with the casing 2 due to vibration or the like during the running of the automobile, and a function for sealing the catalyst carrier 1 to prevent non-purged exhaust gas from leaking out through the gap between the catalyst carrier 1 and the casing 2.
  • mat type holding material which is constituted by inorganic fiber such as alumina fiber, mullite fiber or other ceramic fiber collected into a predetermined thickness while bound with an organic binder to thereby provide adequate elasticity.
  • the organic binder generally used in the holding material 3 examples include rubber compounds, watersoluble organic high-molecular compounds, thermoplastic resins, and thermosetting resins. It is necessary to make the holding material 3 thin to a certain degree because the holding material 3 can be hardly mounted on the catalyst carrier 1 and hardly attached to the casing 2 if the holding material 3 is too thick. Therefore, the holding material 3 generally used is formed so that the ratio of the amount of the organic binder to the total amount of the holding material is in a range of from 5 % by weight to 10 % by weight or about 12 % by weight at maximum.
  • the catalyst carrier 1 has been however recently heated to about 1,000°C in order to improve purging efficiency. For this reason, the organic binder listed above is decomposed and burned out easily, so that CO 2 , CO and various kinds of organic gases are produced. Particularly, a great deal of gas is produced in an early stage of the start of the catalytic converter. Regulation of exhaust emission control has become more and more rigid. There is a possibility that the amount of exhaust gas may be over a regulated value because of CO 2 , etc. derived from the organic binder.
  • electronic engine control has been recently developed. The presence of CO 2 having no relation to exhaust gas originally may cause malfunctions of exhaust sensors to exert a bad influence on the electronic engine control. To prevent this drawback, a maker carries out a baking process to burn out the organic binder before shipping. The baking process is a heavy burden imposed on the maker. This is a major issue.
  • Reduction in quantity of the organic binder is also conceived.
  • force of binding the inorganic fiber is however weakened in accordance with the reduction in quality of the organic binder. For this reason, it is necessary to make the holding material 3 thick, so that there is a problem that assembling property is worsened.
  • an object of the invention is to provide a holding material for a catalytic converter in which inorganic fiber can be bound well even without use of any organic binder so that the thickness of the holding material can be kept equal to that of a related-art holding material.
  • the present inventors have made eager examination to achieve the foregoing object. As a result, it has been found that the thickness of the holding material can be suppressed without use of any organic binder when continuous inorganic fiber is collected into a mat shape and sewn. Thus, the invention is accomplished.
  • the invention provides a holding material for a catalytic converter having a catalyst carrier, a casing for receiving the catalyst carrier, and a holding material interposed in a gap between the catalyst carrier and the casing while wound on the catalyst carrier, the holding material being constituted by a sewn product of a mat material formed by collection of not smaller than 100 cc/5 g by wet volume of inorganic fiber without use of any binder.
  • the wet volume is an index for providing a fiber length and is calculated by a method having the following steps:
  • the holding material 3 according to the invention is formed in such a manner that a mat material 30 formed by collection of inorganic fiber without use of any binder is sewn with sewing thread 31.
  • the kind of the inorganic fiber for forming the mat material 30 is not limited.
  • alumina fiber, mullite fiber or other ceramic fiber may be used suitably.
  • the material preferably used as the alumina fiber is fiber, for example, containing 90 % by weight or more of Al 2 O 3 (and SiO 2 as a residual component) and having low crystallinity in terms of X-ray crystallography.
  • the material preferably used as the mullite fiber is a mullite composition, for example, having an Al 2 O 3 /SiO 2 weight ratio of about 72/28 to about 80/20 and having low crystallinity in terms of X-ray crystallography.
  • the other ceramic fiber may include silica-alumina fiber, and silica fiber. Any known material used in a holding material in the related art may be used as the other ceramic fiber.
  • glass fiber, rock wool or biodegradable fiber may be mixed with the inorganic fiber.
  • continuous fiber selected from these kinds of inorganic fiber and having a wet volume of not smaller than 100 cc/ 5 g, preferably not smaller than 400 cc/5 g. If inorganic fiber having a wet volume smaller than 100 cc/5 g is used, individual fiber pieces are too short to keep both density and thickness at initial values because fiber pieces are apt to drop out through gaps of the sewing thread 31 according to the sewing pitch (the distance between adjacent portions of sewing thread 31) even in the case where sewing is performed. In addition, because fiber pieces are little intertwined with one another, there is a possibility that delamination may occur to reduce both holding performance and sealing performance when the holding material is mounted in the casing.
  • the upper limit of the wet volume is not particularly provided but is generally selected to be in a range of from 400 cc/5 g to 1,000 cc/5 g.
  • Metal fiber sewing thread, inorganic fiber sewing thread or organic fiber sewing thread can be used as the sewing thread 31.
  • the sewing thread include SUS fiber sewing thread (such as Naslon sewing thread), alumina fiber sewing thread, mullite fiber sewing thread, silica-alumina fiber sewing thread, silica fiber sewing thread, glass fiber sewing thread, rock wool sewing thread, biodegradable fiber sewing thread, carbon fiber sewing thread, cotton thread, acrylic fiber sewing thread, polyethylene fiber sewing thread, polyethylene terephthalate fiber sewing thread, aramid fiber sewing thread, aromatic polyamide fiber sewing thread, and polyoxybenzole fiber sewing thread.
  • Sewing thread made of a mixture of two kinds of fiber selected from the group consisting of metal fiber, inorganic fiber and organic fiber can be also used preferably.
  • the mixed fiber sewing thread is advantageous to both production aspect and functional aspect because strength of metal fiber, elasticity (spring characteristic) of inorganic fiber and flexibility of organic fiber can be mixed synergically.
  • the organic fiber sewing thread is decomposed at a high temperature, the same gas as produced from an organic binder used in a related-art holding material is produced from the organic fiber sewing thread.
  • the amount of the organic fiber sewing thread used for sewing is however considerably small compared with the amount of the binder used, so that the gas produced from the organic fiber sewing thread is practically insignificant.
  • the inorganic fiber also contains a binder, the amount of the binder contained in the inorganic fiber is further smaller. Accordingly, a holding material substantially containing no organic component can be obtained when the holding material is heated after sewing as will be described later. In consideration of the organic component, it may be said that the metal fiber sewing thread is the most preferable.
  • the sewing pitch is determined variously in accordance with the length (wet volume) of the inorganic fiber for forming the mat material 30 and the thickness and density of the resulting holding material but is preferably selected to be in a range of from 3 mm to 20 mm. Particularly when the organic fiber sewing thread is used, the amount of the organic fiber sewing thread used increases as the pitch decreases. Accordingly, it is preferable from the point of view of suppressing the organic component that the pitch is selected to be large to a certain degree.
  • the holding material 3 according to the invention is produced as follows. First, inorganic fiber is collected without use of any binder to thereby produce a mat material 30 having a predetermined thickness. On this occasion, various kinds of additives (except any binder) as mixed with the related-art holding material may be mixed with the mat material 30. Then, the mat material 30 is compressed into a thickness of the finally produced holding material and sewn while the compressed state is kept by temporal tacking with nonwoven fabric or the like if necessary. Thus, the holding material is obtained. Incidentally, when the mat material 30 is sewn with inorganic fiber sewing thread, it is preferable that the whole of the mat material 30 is heated after sewing to remove the binder contained in the fiber.
  • the holding material 3 formed in the aforementioned manner according to the invention is wound on the catalyst carrier 1 and interposed between the gap between the catalyst carrier 1 and the casing 2 in the same manner as in the related art.
  • Alumina fiber having a wet volume of 800 cc/5 g was collected without use of any binder to form a mat material 100 mm in width, 314 mm in length, 20 mm in thickness and 1,000 g/m 2 in grammage (areal density). Then, the mat material was compressed into a thickness of 7.5 mm, temporally tacked with nonwoven fabric and sewn with Naslon sewing thread at intervals of a pitch of 10 mm to obtain a holding material.
  • the holding material was wound on a cordierite catalyst carrier of a cylindrical honey-comb structure having an outer diameter of 100 mm and a length of 120 mm and then mounted in a stainless steel casing to produce a catalytic converter.
  • the produced catalytic converter was connected to an exhaust pipe of a gasoline engine. Exhaust gas was passed through the catalytic converter. Gas emitted from the catalytic converter during the passage of the exhaust gas was analyzed. As a result, CO 2 , CO and organic gas were not detected even just after the passage of the exhaust gas. In addition, non-purged exhaust gas supposed to be derived from leakage of the holding material was not detected even during the passage of the exhaust gas, so that good sealing performance was obtained.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
  • Catalysts (AREA)
EP03007136A 2002-03-29 2003-03-28 Halterungsmaterial für einen katalytischen Umwandler Withdrawn EP1348842A3 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2002095937 2002-03-29
JP2002095937A JP2003293754A (ja) 2002-03-29 2002-03-29 触媒コンバーター用保持材

Publications (2)

Publication Number Publication Date
EP1348842A2 true EP1348842A2 (de) 2003-10-01
EP1348842A3 EP1348842A3 (de) 2005-07-13

Family

ID=27800556

Family Applications (1)

Application Number Title Priority Date Filing Date
EP03007136A Withdrawn EP1348842A3 (de) 2002-03-29 2003-03-28 Halterungsmaterial für einen katalytischen Umwandler

Country Status (3)

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US (1) US20030185723A1 (de)
EP (1) EP1348842A3 (de)
JP (1) JP2003293754A (de)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE202005018611U1 (de) * 2005-11-28 2006-02-16 Schierz, Claus, Dipl.-Ing. Lagerungsmatte für die Lagerung eines Abgaskatalysators
CN102159803B (zh) * 2008-07-18 2014-07-23 阿兰图姆公司 用于净化汽车尾气的过滤装置
JP5386150B2 (ja) * 2008-11-06 2014-01-15 ニチアス株式会社 ディスク材用基材及びその製造方法、並びにディスクロール
US8827883B2 (en) 2008-11-06 2014-09-09 Nichias Corporation Base material for disk, process for producing the same, and disk roll
JP2011214194A (ja) * 2010-03-31 2011-10-27 Ibiden Co Ltd 保持シール材
JP2014208990A (ja) * 2013-03-27 2014-11-06 ニチアス株式会社 気体処理装置用保持材
CN109825946A (zh) * 2019-02-21 2019-05-31 浙江华恒复合材料有限公司 一种干法制备真空隔热板芯材的方法

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS63165562A (ja) * 1986-12-27 1988-07-08 電気化学工業株式会社 耐熱性無機繊維成形体及びその製造方法
US5290522A (en) * 1993-01-07 1994-03-01 Minnesota Mining And Manufacturing Company Catalytic converter mounting mat

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Publication number Publication date
US20030185723A1 (en) 2003-10-02
JP2003293754A (ja) 2003-10-15
EP1348842A3 (de) 2005-07-13

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