JP2002302859A - Method for manufacturing heat-resisting mat - Google Patents
Method for manufacturing heat-resisting matInfo
- Publication number
- JP2002302859A JP2002302859A JP2001103370A JP2001103370A JP2002302859A JP 2002302859 A JP2002302859 A JP 2002302859A JP 2001103370 A JP2001103370 A JP 2001103370A JP 2001103370 A JP2001103370 A JP 2001103370A JP 2002302859 A JP2002302859 A JP 2002302859A
- Authority
- JP
- Japan
- Prior art keywords
- organic binder
- mat
- heat
- thickness
- alumina fiber
- 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.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 238000000034 method Methods 0.000 title claims abstract description 16
- 239000000835 fiber Substances 0.000 claims abstract description 61
- 239000011230 binding agent Substances 0.000 claims abstract description 55
- 239000007788 liquid Substances 0.000 claims abstract description 28
- 239000006185 dispersion Substances 0.000 claims abstract description 13
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 42
- 229920000178 Acrylic resin Polymers 0.000 claims description 3
- 239000004925 Acrylic resin Substances 0.000 claims description 3
- 238000000197 pyrolysis Methods 0.000 abstract 1
- 239000000463 material Substances 0.000 description 15
- 230000003197 catalytic effect Effects 0.000 description 8
- 229920001577 copolymer Polymers 0.000 description 7
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 6
- 239000004816 latex Substances 0.000 description 6
- 229920000126 latex Polymers 0.000 description 6
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 5
- 238000005470 impregnation Methods 0.000 description 5
- 229910052863 mullite Inorganic materials 0.000 description 5
- 238000004080 punching Methods 0.000 description 5
- 229920005989 resin Polymers 0.000 description 5
- 239000011347 resin Substances 0.000 description 5
- 238000005979 thermal decomposition reaction Methods 0.000 description 5
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 4
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 4
- 229910004298 SiO 2 Inorganic materials 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 3
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Natural products C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 2
- 229920000459 Nitrile rubber Polymers 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 229920001971 elastomer Polymers 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000012856 packing Methods 0.000 description 2
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 239000002243 precursor Substances 0.000 description 2
- 239000005060 rubber Substances 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- DNJRKFKAFWSXSE-UHFFFAOYSA-N 1-chloro-2-ethenoxyethane Chemical compound ClCCOC=C DNJRKFKAFWSXSE-UHFFFAOYSA-N 0.000 description 1
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- HRPVXLWXLXDGHG-UHFFFAOYSA-N Acrylamide Chemical compound NC(=O)C=C HRPVXLWXLXDGHG-UHFFFAOYSA-N 0.000 description 1
- 101100325793 Arabidopsis thaliana BCA2 gene Proteins 0.000 description 1
- 229930185605 Bisphenol Natural products 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 241000196324 Embryophyta Species 0.000 description 1
- 244000043261 Hevea brasiliensis Species 0.000 description 1
- 101000777301 Homo sapiens Uteroglobin Proteins 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 102100031083 Uteroglobin Human genes 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- 125000005396 acrylic acid ester group Chemical group 0.000 description 1
- 229920000800 acrylic rubber Polymers 0.000 description 1
- 239000004480 active ingredient Substances 0.000 description 1
- -1 aluminum oxychloride Chemical compound 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 1
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 125000005397 methacrylic acid ester group Chemical group 0.000 description 1
- 125000005395 methacrylic acid group Chemical group 0.000 description 1
- 229920003052 natural elastomer Polymers 0.000 description 1
- 229920001194 natural rubber Polymers 0.000 description 1
- 229920003986 novolac Polymers 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000004094 surface-active agent Substances 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
Landscapes
- Exhaust Gas After Treatment (AREA)
- Catalysts (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は耐熱性マットの製造
方法に関する。[0001] The present invention relates to a method for producing a heat-resistant mat.
【０００２】[0002]
【従来の技術】従来より、厚さ方向に圧縮されたアルミ
ナ質繊維マット中に熱分解によって消失する有機バイン
ダーが含有されて成る耐熱性マットが知られている（例
えば特許第３０２５４３３号公報など）。この耐熱性マ
ットは、アルミナ質繊維マットに有機バインダー液を含
浸させる第１工程、有機バインダー液が含浸されたアル
ミナ質繊維マットを厚さ方向に圧縮する第２工程、圧縮
されたアルミナ質繊維マットの厚さを維持したまま有機
バインダー液の媒体液を除去する第３工程を包含する方
法で製造される（同上）。2. Description of the Related Art Hitherto, a heat-resistant mat in which an organic binder which disappears by thermal decomposition is contained in an alumina fiber mat compressed in a thickness direction has been known (for example, Japanese Patent No. 3025433). . The heat-resistant mat comprises a first step of impregnating the alumina fiber mat with an organic binder liquid, a second step of compressing the alumina fiber mat impregnated with the organic binder liquid in the thickness direction, and a step of compressing the compressed alumina fiber mat. Is produced by a method including a third step of removing the medium liquid of the organic binder liquid while maintaining the thickness (see above).
【０００３】上記の耐熱性マットは、排気ガス浄化用触
媒コンバータにおいてモノリス（触媒保持体）と当該モ
ノリスの外側を覆う金属性シェル（キャン）との間に挿
入配置されるモノリス保持材として優れている（同
上）。また、その他の分野における各種の耐熱性パッキ
ング材としても有用である。The above-mentioned heat-resistant mat is excellent as a monolith holding material inserted and disposed between a monolith (catalyst holding body) and a metal shell (can) covering the outside of the monolith in a catalytic converter for purifying exhaust gas. (Id.) It is also useful as various heat-resistant packing materials in other fields.
【０００４】しかしながら、上記の製造方法による場合
は、時として、耐熱性マット中に有機バインダーが偏在
し、厚さが不均一になることがある。その結果、熱分解
によって有機バインダーが消失した際に発生する耐熱性
マットの面圧にバラツキが生じ、しかも、厚さの不均一
性の程度によっては金属性シェル等の適用場所への装着
が困難になる場合がある。[0004] However, in the case of the above-mentioned manufacturing method, the organic binder is sometimes unevenly distributed in the heat-resistant mat, and the thickness becomes non-uniform. As a result, the surface pressure of the heat-resistant mat generated when the organic binder is lost due to thermal decomposition varies, and depending on the degree of non-uniformity of the thickness, it is difficult to attach the metal shell to an application place. May be.
【０００５】[0005]
【発明が解決しようとする課題】本発明は、上記実情に
鑑みなされたものであり、その目的は、厚さ方向に圧縮
されたアルミナ質繊維マット中に熱分解によって消失す
る有機バインダーが含有されて成る耐熱性マットの製造
方法であって、有機バインダーが実質的に均一に存在し
て厚さが実質的に均一な耐熱性マットが得られる様に改
良された製造方法を提供することにある。SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object of the present invention is to contain an organic binder which disappears by thermal decomposition in an alumina fiber mat compressed in a thickness direction. To provide an improved method for producing a heat-resistant mat comprising an organic binder present substantially uniformly and having a substantially uniform thickness. .
【０００６】[0006]
【課題を解決するための手段】本発明者は、鋭意検討を
重ねた結果、有機バインダー液として、有機溶剤を使用
せずに、有機バインダー水分散液を使用する工業的に有
利な製造方法においては、使用する水分散液の液物性に
より、アルミナ質繊維マットに対する水分散液の含浸の
均一性が著しく異るとの知見を得た。Means for Solving the Problems As a result of intensive studies, the present inventor has found that an industrially advantageous production method using an organic binder aqueous dispersion without using an organic solvent as the organic binder liquid. Obtained that the uniformity of impregnation of the aqueous dispersion with the alumina fiber mat was significantly different depending on the physical properties of the aqueous dispersion used.
【０００７】本発明は、上記の知見を基に更に検討を重
ねて完成されたものであり、その要旨は、アルミナ質繊
維マットに有機バインダー液を含浸させる第１工程、有
機バインダー液が含浸されたアルミナ質繊維マットを厚
さ方向に圧縮する第２工程、圧縮されたアルミナ質繊維
マットの厚さを維持したまま有機バインダー液の媒体液
を除去する第３工程を包含する耐熱性マットの製造方法
において、有機バインダー液として、２５℃で測定した
表面張力が２５ｄｙｎ／ｃｍ以上の有機バインダー水分
散液を使用することを特徴とする耐熱性マットの製造方
法に存する。The present invention has been completed by further study based on the above findings. The gist of the present invention is that a first step of impregnating an alumina fiber mat with an organic binder liquid is performed. Production of a heat-resistant mat including a second step of compressing the alumina fiber mat in the thickness direction, and a third step of removing a medium liquid of the organic binder liquid while maintaining the thickness of the compressed alumina fiber mat. In the method, there is provided a method for producing a heat-resistant mat, characterized in that a water dispersion of an organic binder having a surface tension measured at 25 ° C of 25 dyn / cm or more is used as the organic binder liquid.
【０００８】[0008]
【発明の実施の形態】以下本発明について詳細に説明す
る。本発明においては、基材マットとして、主としてア
ルミナ繊維の積層シートから成るアルミナ質繊維マット
を使用する。アルミナ繊維の繊維長は、通常２０〜２０
０ｍｍ、繊維径は通常１〜４０μｍ、好ましくは２〜２
０μｍである。アルミナ繊維は、Ａｌ2Ｏ3／ＳｉＯ2重
量比（以下、Ａｌ2Ｏ3／ＳｉＯ2という）＝７０／３０
〜７４／２６のムライト組成であることが好ましい。Ａ
ｌ2Ｏ3／ＳｉＯ2が上記範囲外のアルミナ繊維では、高
温時の結晶化および結晶成長による繊維の劣化が早く、
長期の使用に不向きである。DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail. In the present invention, an alumina fiber mat mainly composed of a laminated sheet of alumina fibers is used as the substrate mat. The fiber length of the alumina fiber is usually 20 to 20.
0 mm, fiber diameter is usually 1 to 40 μm, preferably 2 to 2 μm.
0 μm. The alumina fiber has an Al 2 O 3 / SiO 2 weight ratio (hereinafter referred to as Al 2 O 3 / SiO 2 ) = 70/30.
A mullite composition of ~ 74/26 is preferred. A
In the case of alumina fiber having l 2 O 3 / SiO 2 outside the above range, the fiber is rapidly deteriorated due to crystallization and crystal growth at high temperature,
Not suitable for long-term use.
【０００９】上記のムライト組成アルミナ繊維の結晶化
度は０〜１０％であることが好ましい。ここで、結晶化
度とは１３００℃で４時間焼成して完全に結晶化したム
ライトのＣｕＫα線によるＸ線回折における２θ＝２
６．３°に発現するピークの強度に対する、ムライト組
成アルミナ繊維の２θ＝２６．３°のピーク強度を百分
率（％）で表したものである。低結晶性のムライト組成
アルミナ繊維は、結晶成長の核となる結晶が少ないた
め、８００〜１０００℃の加熱によっても繊維の劣化が
生じ難い。The mullite-containing alumina fiber preferably has a crystallinity of 0 to 10%. Here, the crystallinity refers to 2θ = 2 in X-ray diffraction by CuKα ray of mullite completely baked at 1300 ° C. for 4 hours.
The peak intensity at 2θ = 26.3 ° of the mullite-containing alumina fiber with respect to the intensity of the peak appearing at 6.3 ° is expressed as a percentage (%). Since the low-crystalline mullite-containing alumina fiber has few crystals serving as nuclei for crystal growth, the fiber hardly deteriorates even when heated at 800 to 1000 ° C.
【００１０】また、粒径４５μｍ以上の大粒径のショッ
トは、繊維の切断を起こし、マットの復元性を損う傾向
がある。また、大粒径のショットは、マットの比重を部
分的に増大させ、熱伝導率などが不均一となる原因とな
る。例えば、排気ガス浄化用触媒コンバータにおいてモ
ノリス保持材として使用した場合、触媒の均一保持が困
難となる虞がある。従って、本発明で使用するアルミナ
繊維は、粒径４５μｍ以上のショットの含有率が７重量
％以下であることが好ましい。Also, shots having a large particle size of 45 μm or more tend to cut fibers and impair the resilience of the mat. In addition, the shot having a large particle diameter partially increases the specific gravity of the mat, which causes the thermal conductivity and the like to become non-uniform. For example, when used as a monolith holding material in a catalytic converter for purifying exhaust gas, it may be difficult to uniformly hold the catalyst. Therefore, the alumina fiber used in the present invention preferably has a content of shots having a particle size of 45 μm or more of 7% by weight or less.
【００１１】更に、アルミナ繊維の単繊維引張強度は、
好ましくは１５０〜４００ｋｇ／ｍｍ2である。引張強
度が１５０ｋｇ／ｍｍ2に満たないと耐熱性マットとし
て使用する際に十分な面圧が得られない。一方、４００
ｋｇ／ｍｍ2を超えると繊維が脆くなる傾向がある。Further, the single fiber tensile strength of the alumina fiber is:
Preferably it is 150 to 400 kg / mm 2 . If the tensile strength is less than 150 kg / mm 2 , sufficient surface pressure cannot be obtained when used as a heat resistant mat. On the other hand, 400
If it exceeds kg / mm 2 , the fibers tend to be brittle.
【００１２】上述のアルミナ繊維は、他のセラミック繊
維と比較し、耐熱性に優れ、軟化収縮などの熱劣化が極
めて少ないため、耐熱性マットとして使用する際に弾力
性に富んでいる。すなわち、低い嵩密度で高い保持力を
発生し且つその温度変化が少ない。従って、例えば、触
媒コンバーターにおけるモノリス保持材として使用した
場合、熱膨張の差によってモノリスと金属製シェルとの
間隔が変化し、その嵩密度が上昇した場合にも、モノリ
スに対する保持圧が急激に変化することがない点におい
て優れている。The above-mentioned alumina fiber has excellent heat resistance and extremely little thermal deterioration such as softening shrinkage as compared with other ceramic fibers, and therefore has high elasticity when used as a heat-resistant mat. That is, a high holding force is generated at a low bulk density, and the temperature change is small. Therefore, for example, when used as a monolith holding material in a catalytic converter, the spacing between the monolith and the metal shell changes due to the difference in thermal expansion, and even when the bulk density increases, the holding pressure on the monolith changes rapidly. It is excellent in that it does not.
【００１３】前記のアルミナ質繊維のマットは、例え
ば、オキシ塩化アルミニウム等のアルミナ源、シリカゾ
ル等のシリカ源、ポリビニルアルコール等の有機バイン
ダー及び水の混合物から成る紡糸原液を使用し、次の様
にして得られる。すなわち、紡糸したアルミナ繊維前駆
体を積層してシート化し、次いで、好ましくはニードル
パンチングを施した後、通常１０００〜１５００℃で焼
成する。The above-mentioned alumina fiber mat is prepared by using, for example, a spinning dope comprising a mixture of an alumina source such as aluminum oxychloride, a silica source such as silica sol, an organic binder such as polyvinyl alcohol, and water. Obtained. That is, the spun alumina fiber precursor is laminated to form a sheet, and then, preferably after needle punching, is usually fired at 1000 to 1500 ° C.
【００１４】上記のニードルパンチング処理は、繊維の
一部を積層面に対して縦方向に配向させる効果がある。
従って、シート内のアルミナ繊維前駆体の一部がシート
を貫通して縦方向に配向してシートを緊縛するため、シ
ートの嵩比重が高められ、また、層間の剥離や層間のず
れが防止される。ニードルパンチングの密度は通常１〜
５０打／ｃｍ2であり、ニードルパンチングの密度によ
り、マットの厚さ、嵩比重、強度などが調節される。マ
ットの厚さは通常３〜３０ｍｍであり、嵩密度は通常
０．１〜０．３ｇ／ｃｍ3である。The above-described needle punching has an effect of orienting a part of the fibers in the longitudinal direction with respect to the lamination surface.
Therefore, since a part of the alumina fiber precursor in the sheet penetrates the sheet and is oriented in the vertical direction to bind the sheet, the bulk specific gravity of the sheet is increased, and separation between layers and displacement between layers are prevented. You. Needle punching density is usually 1 ~
Was 50 strokes / cm 2, the density of needle punching, the mat thickness, bulk density, strength, etc. are adjusted. The thickness of the mat is usually 3 to 30 mm, and the bulk density is usually 0.1 to 0.3 g / cm 3 .
【００１５】なお、本発明においては、アルミナ繊維に
その他のセラミック繊維や無機膨張材を補助的に併用し
てもよい。この場合、マットに均一に混合してもよい
が、特に加熱される箇所を避けて局在させることによ
り、補助材の性能を維持しつつ低コスト化することが可
能である。上記のセラミック繊維としては、シリカ繊
維、ガラス繊維、石綿繊維などが挙げられ、無機膨張材
としては、ベントナイト、膨張性バーミキュライト、膨
張性黒鉛などが挙げられる。In the present invention, other ceramic fibers or inorganic expanders may be used in combination with the alumina fibers. In this case, the auxiliary material may be uniformly mixed with the mat, but it is possible to reduce the cost while maintaining the performance of the auxiliary material, particularly by localizing the heated material while avoiding a portion to be heated. Examples of the ceramic fiber include silica fiber, glass fiber, and asbestos fiber, and examples of the inorganic expandable material include bentonite, expandable vermiculite, and expandable graphite.
【００１６】本発明の製造方法は、基本的には、従来公
知の方法と同様に、アルミナ質繊維マットに有機バイン
ダー液を含浸させる第１工程、有機バインダー液が含浸
されたアルミナ質繊維マットを厚さ方向に圧縮する第２
工程、圧縮されたアルミナ質繊維マットの厚さを維持し
たまま有機バインダー液の媒体液を除去する第３工程を
包含する。The production method of the present invention basically comprises a first step of impregnating an organic binder liquid into an alumina fiber mat, and a step of impregnating the alumina fiber mat impregnated with the organic binder liquid, in the same manner as a conventionally known method. The second to compress in the thickness direction
And a third step of removing the medium liquid of the organic binder liquid while maintaining the thickness of the compressed alumina fiber mat.
【００１７】上記の有機バインダーとしては、各種のゴ
ム、熱可塑性樹脂、熱硬化性樹脂などを使用できる。上
記のゴム類としては、天然ゴム；エチルアクリレートと
クロロエチルビニルエーテルの共重合体、ｎ−ブチルア
クリレートとアクリロニトリルの共重合体、エチルアク
リレートとアクリロニトリルの共重合体などのアクリル
ゴム；ブタジエンとアクリロニトリルの共重合体のニト
リルゴム；ブタジエンゴム等が挙げられる。熱可塑性樹
脂としては、アクリル酸、アクリル酸エステル、アクリ
ルアミド、アクリロニトリル、メタクリル酸、メタクリ
ル酸エステル等の単独重合体および共重合体であるアク
リル系樹脂；アクリロニトリル・スチレン共重合体；ア
クリロニトリル・ブタジエン・スチレン共重合体などが
挙げられる。また、熱硬化性樹脂としては、ビスフェノ
ール型エポキシ樹脂、ノボラック型エポキシ樹脂などが
挙げられる。上記の有機バインダーの中ではアクリル又
はメタクリル系のポリマーであるアクリル系樹脂が好ま
しい。As the organic binder, various rubbers, thermoplastic resins, thermosetting resins and the like can be used. Examples of the rubbers include natural rubbers; acrylic rubbers such as a copolymer of ethyl acrylate and chloroethyl vinyl ether, a copolymer of n-butyl acrylate and acrylonitrile, and a copolymer of ethyl acrylate and acrylonitrile; and a copolymer of butadiene and acrylonitrile. Polymer nitrile rubber; butadiene rubber and the like. Examples of the thermoplastic resin include acrylic resins which are homopolymers and copolymers of acrylic acid, acrylic acid ester, acrylamide, acrylonitrile, methacrylic acid, methacrylic acid ester, etc .; acrylonitrile / styrene copolymer; acrylonitrile / butadiene / styrene And copolymers. Examples of the thermosetting resin include a bisphenol epoxy resin and a novolak epoxy resin. Among the above organic binders, an acrylic resin which is an acrylic or methacrylic polymer is preferable.
【００１８】本発明において、上記の有機バインダー
は、２５℃で測定した表面張力が２５ｄｙｎ／ｃｍ以上
となる様に調製された水分散液（ラテックス）として使
用される。すなわち、本発明の特徴は、アルミナ質繊維
マットの表面相および内部に対する有機バインダー水分
散液の含浸が均一に行われる様にするため、有機バイン
ダー水分散液の表面張力を一定値以上に制御した点に存
する。有機バインダー水分散液の表面張力が２５ｄｙｎ
／ｃｍ未満の場合は、アルミナ質繊維マット中に保持さ
れず通り抜ける量が多いため、何度も含浸操作を繰り返
す必要があり、しかも、最初に含浸された有機バインダ
ーが乾燥することにより樹脂膜が生成される結果、その
後の含浸が困難となり、時には、含浸が不均一となる。
なお、有機バインダー水分散液の表面張力の上限は通常
５０ｄｙｎ／ｃｍである。In the present invention, the above organic binder is used as an aqueous dispersion (latex) prepared so that the surface tension measured at 25 ° C. becomes 25 dyn / cm or more. That is, the feature of the present invention is that the surface tension of the organic binder aqueous dispersion is controlled to a certain value or more so that the impregnation of the organic binder aqueous dispersion into the surface phase and the interior of the alumina fiber mat is performed uniformly. Lies in the point. The surface tension of the organic binder aqueous dispersion is 25 dyn
If it is less than / cm, the impregnating operation needs to be repeated many times because the amount of the resin film passing through without being retained in the alumina fiber mat is large, and the resin film is dried by drying the impregnated organic binder first. As a result, the subsequent impregnation becomes difficult and sometimes the impregnation is non-uniform.
The upper limit of the surface tension of the organic binder aqueous dispersion is usually 50 dyn / cm.
【００１９】前記の第１工程、第２工程、第３工程は、
例えば、特許第３０２５４３３号公報などに記載された
公知の方法に従って行うことが出来る。The first step, the second step, and the third step include:
For example, it can be performed according to a known method described in Japanese Patent No. 3025433.
【００２０】すなわち、第１工程（アルミナ質繊維マッ
トに有機バインダー液を含浸させる工程）は、例えば、
有機バインダー液にマットを浸漬する方法、マットに有
機バインダー液を噴霧する方法などで行うことが出来
る。有機バインダーの含有量（有効成分としての値）
は、アルミナ繊維１００重量部に対し、通常３〜３０重
量部、好ましくは５〜２０重量部である。有機バインダ
ーの含有量が３重量部未満の場合は、マットの反発力に
よって成形体としての厚さを維持できない虞があり、３
０重量部を超える場合は、コスト高になる他、成形体の
柔軟性が損なわれる虞がある。That is, the first step (the step of impregnating the alumina-based fiber mat with the organic binder liquid) includes, for example,
The method can be carried out by a method of dipping the mat in an organic binder liquid or a method of spraying the organic binder liquid on the mat. Organic binder content (value as active ingredient)
Is usually 3 to 30 parts by weight, preferably 5 to 20 parts by weight, based on 100 parts by weight of the alumina fiber. If the content of the organic binder is less than 3 parts by weight, the thickness of the molded article may not be maintained due to the repulsive force of the mat.
If the amount exceeds 0 parts by weight, the cost may increase and the flexibility of the molded article may be impaired.
【００２１】第２工程（有機バインダー液が含浸された
アルミナ質繊維マットを厚さ方向に圧縮する工程）は、
プレス板、プレスローラー等の圧縮手段によって行うこ
とが出来る。プレス板としては、２枚の透液性板状体、
典型的にはパンチングメタル、樹脂ネット、金網（メッ
シュ）、多孔板または通気性の良い板状体などを使用し
得る。圧縮手段には、バインダー液の吸引手段を併用す
るのが好ましい。The second step (the step of compressing the alumina fiber mat impregnated with the organic binder liquid in the thickness direction)
It can be performed by a compression means such as a press plate or a press roller. As the press plate, two liquid-permeable plate-like bodies,
Typically, a punching metal, a resin net, a wire mesh (mesh), a perforated plate, or a plate-like material having good air permeability can be used. It is preferable to use a suction means for the binder liquid in combination with the compression means.
【００２２】第３工程（圧縮されたアルミナ質繊維マッ
トの厚さを維持したまま有機バインダー液の媒体液を除
去する工程）は、第２工程に引き続き行われ、有機バイ
ンダーが変質や分解を起こさない温度条件下で高温熱風
処理することにより行うことが出来る。The third step (a step of removing the medium of the organic binder liquid while maintaining the thickness of the compressed alumina fiber mat) is performed subsequent to the second step, and the organic binder is deteriorated or decomposed. It can be performed by high-temperature hot air treatment under non-temperature conditions.
【００２３】本発明の製造方法で得られた耐熱性マット
は、厚さ方向に圧縮されたアルミナ質繊維マット中に熱
分解によって消失する有機バインダーが実質的に均一に
存在して厚さが実質的に均一である。In the heat-resistant mat obtained by the production method of the present invention, the thickness of the heat-resistant mat is substantially uniform because the organic binder disappeared by thermal decomposition is present in the alumina fiber mat compressed in the thickness direction substantially uniformly. Is uniformly uniform.
【００２４】従って、本発明の製造方法で得られた耐熱
性マットは、排気ガス浄化用触媒コンバーターにおける
モノリス保持材、すなわち、モノリスと当該モノリスの
外側を覆う金属性シェルとの間に装入されるモノリス保
持材として好適に使用される。この場合、本発明の製造
方法で得られた耐熱性マット（モノリス保持材）は、厚
さが実質的に均一であるため、装着がスムーズに行われ
て表面付近の繊維の破損が防止され、また、隙間のない
均一装着が可能である。また、本発明の耐熱性マット
は、上記の特徴を活かし、モノリス保持材以外の各種の
耐熱性パッキング材としても好適に使用し得る。Therefore, the heat-resistant mat obtained by the production method of the present invention is inserted between the monolith holding material in the catalytic converter for purifying exhaust gas, that is, the monolith and the metallic shell covering the outside of the monolith. It is suitably used as a monolith holding material. In this case, since the heat-resistant mat (monolith holding material) obtained by the production method of the present invention has a substantially uniform thickness, the mounting is performed smoothly and the breakage of fibers near the surface is prevented, In addition, uniform mounting without gaps is possible. Further, the heat-resistant mat of the present invention can be suitably used as various heat-resistant packing materials other than the monolith holding material by utilizing the above characteristics.
【００２５】[0025]
【実施例】次に、実施例により本発明を具体的に説明す
るが、本発明はその要旨を超えない限り、以下の実施例
によって限定されるものではない。以下の諸例におい
て、有機バインダー水分散液の表面張力は、ウイルヘル
ミーのプレート法を使用したクルス社製の自動表面張力
計「Ｋ１２」によって測定した。Next, the present invention will be described in detail with reference to examples. However, the present invention is not limited to the following examples unless it exceeds the gist of the present invention. In the following examples, the surface tension of the aqueous organic binder dispersion was measured by an automatic surface tensiometer “K12” manufactured by Cruz using the Wilhelmy plate method.
【００２６】実施例１ アルミナ質繊維マットとして、Ａｌ2Ｏ3／ＳｉＯ2重量
比＝７２／２８、結晶化度０％、繊維径約４μｍ、４５
μｍ以上のショットを４重量％含有し、短繊維引張強度
２００ｋｇ／ｍｍ2のアルミナ繊維のマット（厚さ１
２．５ｍｍ、嵩密度０．１ｇ／ｃｍ3）を使用した。Example 1 As an alumina fiber mat, Al 2 O 3 / SiO 2 weight ratio = 72/28, crystallinity 0%, fiber diameter about 4 μm, 45
4% by weight of a shot having a thickness of 1 μm or more and a mat of alumina fibers having a short fiber tensile strength of 200 kg / mm 2 (thickness: 1 mm).
2.5 mm and a bulk density of 0.1 g / cm 3 ) were used.
【００２７】先ず、上記のマット１００重量部当たり、
２５℃で測定した表面張力が３６ｄｙｎ／ｃｍのアクリ
レート系ラテックス（中央理化工業社製「ＦＫ６４」）
１５重量部を添着した。その後、圧縮乾燥（１３０℃で
１時間）して厚さ６ｍｍの耐熱性マットを得た。得られ
た耐熱性マットを厚さ方向にカッターで切断し、切断面
を観察した結果、有機バインダーが実質的に均一に存在
していた。First, per 100 parts by weight of the above mat,
Acrylate latex whose surface tension measured at 25 ° C. is 36 dyn / cm (“FK64” manufactured by Chuo Rika Kogyo Co., Ltd.)
15 parts by weight were attached. Then, it was compressed and dried (at 130 ° C. for 1 hour) to obtain a heat-resistant mat having a thickness of 6 mm. The resulting heat-resistant mat was cut in the thickness direction with a cutter, and the cut surface was observed. As a result, the organic binder was present substantially uniformly.
【００２８】次いで、モノリスと金属性シェル（キャ
ン）との間にモノリス保持材として上記の耐熱性マット
を装着し排気ガス浄化用触媒コンバータを製作した。こ
のときのキャンとモノリスの隙間は約３．５ｍｍであ
る。耐熱性マットの装着は、その厚さが実質的に均一で
あるため、無理な力を掛けることなく容易に行うことが
出来た。また、装着後、キャンを電動カッターで切り開
き、耐熱性マット表面を観察したところ、表面の傷みは
なく良好に装着されていることが確認された。Next, the above-mentioned heat-resistant mat was mounted as a monolith holding material between the monolith and the metallic shell (can) to produce a catalytic converter for purifying exhaust gas. At this time, the gap between the can and the monolith is about 3.5 mm. Since the thickness of the heat-resistant mat was substantially uniform, it could be easily performed without applying excessive force. After the mounting, the can was cut open with an electric cutter, and the surface of the heat-resistant mat was observed. As a result, it was confirmed that the surface was not damaged and the mounting was good.
【００２９】実施例２ 実施例１において、２５℃で測定した表面張力が３０ｄ
ｙｎ／ｃｍのアクリレート系ラテックス（日本ゼオン社
製「Ｎｉｐｏｌ ８５１」）を使用した以外は、実施例
１と同様にして耐熱性マットの製造および触媒コンバー
タの製作を行って評価した。耐熱性マットを厚さ方向に
カッターで切断し、切断面を観察した結果、有機バイン
ダーが均一に存在していた。また、耐熱性マットは、厚
さが均一であり、触媒コンバータの製作において良好に
装着できた。Example 2 In Example 1, the surface tension measured at 25 ° C. was 30 d.
Except that an acrylate / latex latex of yn / cm (“Nipol 851” manufactured by Zeon Corporation) was used, a heat-resistant mat and a catalytic converter were manufactured and evaluated in the same manner as in Example 1. The heat resistant mat was cut in the thickness direction with a cutter, and the cut surface was observed. As a result, the organic binder was uniformly present. Further, the heat-resistant mat was uniform in thickness, and was successfully mounted in the production of the catalytic converter.
【００３０】比較例１ 実施例１において、アクリレート系ラテックス（中央理
化工業社製「ＦＫ６４」）に界面活性剤（３Ｍ社製「フ
ローラドＦＣ１３５」）を１０００ｐｐｍ添加し、表面
張力１８ｄｙｎ／ｃｍに低下させて使用したした以外
は、実施例１と同様にして耐熱性マットの製造および触
媒コンバータの製作を行って評価した。耐熱性マットの
製作の際、上記のアクリレート系ラテックスがアルミナ
質繊維マット中に保持されず通り抜けるため、目的の添
着量に達する迄に、複数回の含浸操作が必要であった。
また、得られた耐熱性マットを厚さ方向にカッターで切
断し、切断面を観察した結果、有機バインダーの存在状
態は不均一であった。Comparative Example 1 In Example 1, 1000 ppm of a surfactant ("Florad FC135" manufactured by 3M) was added to an acrylate latex ("FK64" manufactured by Chuo Rika Kogyo Co., Ltd.) to lower the surface tension to 18 dyn / cm. A heat-resistant mat and a catalytic converter were manufactured and evaluated in the same manner as in Example 1 except that the heat-resistant mat was used. In the production of the heat-resistant mat, the acrylate latex passes through the alumina fiber mat without being held in the mat, so that a plurality of impregnation operations are required until the target amount of adhering is reached.
Further, the obtained heat-resistant mat was cut in the thickness direction with a cutter, and the cut surface was observed. As a result, the state of the organic binder was uneven.
【００３１】[0031]
【発明の効果】以上説明した本発明によれば、厚さ方向
に圧縮されたアルミナ質繊維マット中に熱分解によって
消失する有機バインダーが含有されて成る耐熱性マット
の製造方法であって、有機バインダーが実質的に均一に
存在して厚さが実質的に均一な耐熱性マットが得られる
様に改良された製造方法が提供される。According to the present invention described above, there is provided a method for producing a heat-resistant mat comprising an organic binder which disappears by thermal decomposition in an alumina fiber mat compressed in a thickness direction. An improved manufacturing method is provided wherein the binder is substantially uniform and a heat resistant mat having a substantially uniform thickness is obtained.
フロントページの続き (51)Int.Cl.7 識別記号 ＦＩ テーマコート゛(参考） Ｄ０６Ｍ 15/263 Ｆ０１Ｎ 3/28 ３１１Ｐ Ｆ０１Ｎ 3/28 ３１１ Ｄ０６Ｍ 101:00 // Ｄ０６Ｍ 101:00 Ｃ０４Ｂ 35/80 Ａ Ｋ (72)発明者 野口 勇二 新潟県上越市福田１番地 三菱化学産資株 式会社直江津工場内 Ｆターム(参考） 3G091 AB01 BA07 BA39 GA06 GB01Z GB10Z GB16Z GB19Z HA27 HA28 HA29 HA31 4G069 AA15 BA01A BA01B BA02B BA22B CA03 DA06 EA03X EA03Y EA07 EA16 EA19 ED05 ED06 EE01 4L033 AA09 AC05 CA18 4L047 AA06 BA15 BA23 BC07 CB06 CC16 DA00 Continued on the front page (51) Int.Cl. 7 Identification symbol FI Theme coat II (Reference) D06M 15/263 F01N 3/28 311P F01N 3/28 311 D06M 101: 00 // D06M 101: 00 C04B 35/80 AK (72) Inventor Yuji Noguchi 1 Fukuda, Joetsu-shi, Niigata F-term in Naoetsu Plant of Mitsubishi Chemical Corporation 3G091 AB01 BA07 BA39 GA06 GB01Z GB10Z GB16Z GB19Z HA27 HA28 HA29 HA31 4G069 AA15 BA01A BA01B BA02B BA22B CA03 DA06 EA03X EA03Y EA07 EA16 EA19 ED05 ED06 EE01 4L033 AA09 AC05 CA18 4L047 AA06 BA15 BA23 BC07 CB06 CC16 DA00
Claims (4)
液を含浸させる第１工程、有機バインダー液が含浸され
たアルミナ質繊維マットを厚さ方向に圧縮する第２工
程、圧縮されたアルミナ質繊維マットの厚さを維持した
まま有機バインダー液の媒体液を除去する第３工程を包
含する耐熱性マットの製造方法において、有機バインダ
ー液として、２５℃で測定した表面張力が２５ｄｙｎ／
ｃｍ以上の有機バインダー水分散液を使用することを特
徴とする耐熱性マットの製造方法。A first step of impregnating the alumina fiber mat with an organic binder liquid; a second step of compressing the alumina fiber mat impregnated with the organic binder liquid in a thickness direction; In a method for producing a heat-resistant mat including a third step of removing a medium liquid of an organic binder liquid while maintaining a thickness, a surface tension measured at 25 ° C. of 25 dyn /
A method for producing a heat-resistant mat, comprising using an aqueous dispersion of an organic binder having a size of at least 1 cm.
ｄｙｎ／ｃｍの有機バインダー水分散液を使用する請求
項１に記載の製造方法。2. The surface tension measured at 25 ° C. is 25 to 50.
The production method according to claim 1, wherein a dyn / cm aqueous dispersion of an organic binder is used.
請求項２又は３に記載の製造方法。3. The method according to claim 2, wherein the organic binder is an acrylic resin.
りの有機バインダーの含有量が３〜３０重量部である請
求項１〜３の何れかに記載の製造方法。4. The method according to claim 1, wherein the content of the organic binder per 100 parts by weight of the alumina fiber mat is 3 to 30 parts by weight.
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|---|---|---|---|
| JP2001103370A JP2002302859A (en) | 2001-04-02 | 2001-04-02 | Method for manufacturing heat-resisting mat |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001103370A JP2002302859A (en) | 2001-04-02 | 2001-04-02 | Method for manufacturing heat-resisting mat |
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|---|---|
| JP2002302859A true JP2002302859A (en) | 2002-10-18 |
Family
ID=18956441
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|---|---|---|---|
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2004300617A (en) * | 2003-03-31 | 2004-10-28 | Dainippon Ink & Chem Inc | Aqueous dispersion of thermoset resin composition for fiber binder, and method for producing the same |
| JP2006342774A (en) * | 2005-06-10 | 2006-12-21 | Ibiden Co Ltd | Holding sealant and method for production thereof |
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| JPH07238451A (en) * | 1994-02-22 | 1995-09-12 | Nippon Zeon Co Ltd | Binder composition for nonwoven fabric and production of nonwoven fabric |
| JPH09946A (en) * | 1995-04-13 | 1997-01-07 | Mitsubishi Chem Corp | Nonlight holding material and its production as well as catalyst converter using this monolith |
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| JP2006342774A (en) * | 2005-06-10 | 2006-12-21 | Ibiden Co Ltd | Holding sealant and method for production thereof |
| JP4665618B2 (en) * | 2005-06-10 | 2011-04-06 | イビデン株式会社 | Manufacturing method of holding sealing material |
| US8533950B2 (en) | 2005-06-10 | 2013-09-17 | Ibiden Co., Ltd. | Method of manufacturing holding and sealing material |
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