JP2006516043A5 - Pollution control device for diesel engine exhaust gas system and mat for mounting pollution control element in pollution control device - Google Patents
Pollution control device for diesel engine exhaust gas system and mat for mounting pollution control element in pollution control device Download PDFInfo
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- JP2006516043A5 JP2006516043A5 JP2004524580A JP2004524580A JP2006516043A5 JP 2006516043 A5 JP2006516043 A5 JP 2006516043A5 JP 2004524580 A JP2004524580 A JP 2004524580A JP 2004524580 A JP2004524580 A JP 2004524580A JP 2006516043 A5 JP2006516043 A5 JP 2006516043A5
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- 239000000835 fiber Substances 0.000 claims description 16
- 239000011230 binding agent Substances 0.000 claims description 14
- 239000003365 glass fiber Substances 0.000 claims description 10
- WMGSQTMJHBYJMQ-UHFFFAOYSA-N aluminum;magnesium;silicate Chemical compound [Mg+2].[Al+3].[O-][Si]([O-])([O-])[O-] WMGSQTMJHBYJMQ-UHFFFAOYSA-N 0.000 claims description 7
- 239000005368 silicate glass Substances 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N al2o3 Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims 6
- 239000011521 glass Substances 0.000 claims 4
- 239000000395 magnesium oxide Substances 0.000 claims 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims 3
- 229910004298 SiO 2 Inorganic materials 0.000 claims 1
- 235000012239 silicon dioxide Nutrition 0.000 claims 1
- 239000000377 silicon dioxide Substances 0.000 claims 1
- 229910052814 silicon oxide Inorganic materials 0.000 claims 1
- 239000000919 ceramic Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 239000003054 catalyst Substances 0.000 description 3
- 230000003197 catalytic Effects 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229910002089 NOx Inorganic materials 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 210000002421 Cell Wall Anatomy 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 230000005684 electric field Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 230000008929 regeneration Effects 0.000 description 1
- 238000011069 regeneration method Methods 0.000 description 1
Description
業界では多くの実装マットが、高温で操作されるガソリンエンジンからの排気処理のための触媒コンバータを実装するために開発されている。公知の実装マットとしては、セラミックファイバー、膨張材料、ならびに有機および／または無機バインダーから構成された膨張シート材料が挙げられる。触媒コンバータを筐体に実装するのに有用な膨張シート材料は、例えば、米国特許第３，９１６，０５７号明細書（ハッチら（Ｈａｔｃｈ ｅｔ ａｌ．））、同第４，３０５，９９２号明細書（レンジャーら（Ｌａｎｇｅｒ ｅｔ ａｌ．））、同第５，１５１，２５３号明細書（メリーら（Ｍｅｒｒｙ ｅｔ ａｌ．））、同第５，２５０，２６９号明細書（レンジャー（Ｌａｎｇｅｒ））および同第５，７３６，１０９号明細書（ホワースら（Ｈｏｗｏｒｔｈ ｅｔ ａｌ．））に記載されている。近年、多結晶セラミックファイバーとバインダーから構成された非熱膨張マットが、非常に薄いセル壁のために非常に強度の低い、いわゆる超薄壁モノリスに特に用いられている。非熱膨張マットとしては、例えば、米国特許第４，０１１，６５１号明細書（ブラッドベリーら（Ｂｒａｄｂｕｒｙ ｅｔ ａｌ．））、同第４，９２９，４２９号明細書（メリー（Ｍｅｒｒｙ））、同第５，０２８，３９７号明細書（メリー（Ｍｅｒｒｙ））、同第５，９９６，２２８号明細書（ショウジら（Ｓｈｏｊｉ ｅｔ ａｌ．））および同第５，５８０，５３２号明細書（ロビンソンら（Ｒｏｂｉｎｓｏｎ ｅｔ ａｌ．））に記載されたものが例示される。多結晶ファイバーは、通常の溶融形成セラミックファイバーより遥かに高価であるため、これらのファイバーを用いるマットは、例えば、超薄壁モノリスのように絶対的に必要な場合にのみ用いられている。 Many mounting mats in the industry have been developed to implement catalytic converters for exhaust treatment from gasoline engines operated at high temperatures. Known mounting mats include ceramic fiber, intumescent material, and inflatable sheet material composed of organic and / or inorganic binders. Inflatable sheet materials useful for mounting a catalytic converter in a housing include, for example, US Pat. No. 3,916,057 (Hatch et al.), US Pat. No. 4,305,992. (Langer et al.), 5,151,253 (Merry et al.), 5,250,269 (Langer) and No. 5,736,109 (Howorth et al.). In recent years, non-thermal expansion mats composed of polycrystalline ceramic fibers and binders are particularly used for so-called ultra-thin wall monoliths, which are very low strength due to very thin cell walls. Non-thermal expansion mats include, for example, US Pat. No. 4,011,651 (Bradbury et al.), 4,929,429 (Merry), 5,028,397 (Merry), 5,996,228 (Shoji et al.) And 5,580,532 (Robinson et al.). (Robinson et al.)) Is exemplified. Because polycrystalline fibers are much more expensive than conventional melt-formed ceramic fibers, mats using these fibers are used only when absolutely necessary, for example, ultra-thin wall monoliths.
ディーゼル酸化触媒（ＤＯＣ）は、放出されているディーゼル微粒子の可溶有機フラクション（ＳＯＦ）を酸化するために最新のディーゼルエンジンに用いられている。非常に低い排気ガス温度のために、従来の実装材料でのＤＯＣの実装には問題がある。ターボ過給直噴（ＴＤＩ）エンジンのような最新のディーゼルエンジンの排気ガスは３００℃を超えることはない。この温度は、たいていの膨張マットを膨張させるのに必要な温度より低い。膨張は、触媒コンバータ内の適正な圧力を発生させ維持するのに必要である。さらに、この温度は、膨張マット材料に含有される有機バインダーをバーンアウトするには低すぎる。これらの温度ではバインダーは軟化するのみで、セラミックファイバーの弾性を妨げる。その結果、従来の膨張実装マットを用いると、ＤＯＣで電界破壊が生じる。これらの問題点を回避するために、コンバータは、蛭石を膨張しバインダーをバーンアウトするために取り付ける前に熱処理されることがある。これは高価で、時間がかかる。補助ワイヤメッシュ「Ｌ」シールを用いて、低温で膨張マットの保持力を増大するばかりか、コストやアセンブリの複雑さも増大させる。やや良好に機能するたいていの非熱膨張マットはそれでも有機バインダーを含有しており、２００〜３００℃の温度範囲でファイバーの弾性を大幅に減じる。これは、希薄ＮＯｘ触媒、連続再生トラップ（ＣＲＴ）およびＮＯｘトラップをはじめとする他のディーゼル排気汚染制御装置にも当てはまるものと考えられる。 Diesel oxidation catalysts (DOC) are used in modern diesel engines to oxidize the soluble organic fraction (SOF) of the emitted diesel particulates. Due to the very low exhaust gas temperature, the mounting of DOC with conventional mounting materials is problematic. The exhaust gas of modern diesel engines such as turbocharged direct injection (TDI) engines does not exceed 300 ° C. This temperature is lower than that required to expand most expansion mats. Expansion is necessary to generate and maintain the proper pressure in the catalytic converter. Furthermore, this temperature is too low to burn out the organic binder contained in the expanded mat material. At these temperatures, the binder only softens, preventing the elasticity of the ceramic fibers. As a result, when a conventional expansion mounting mat is used, electric field breakdown occurs in DOC. In order to avoid these problems, the converter may be heat treated prior to mounting to expand the meteorite and burn out the binder. This is expensive and time consuming. The use of an auxiliary wire mesh “L” seal not only increases the retention of the expansion mat at low temperatures, but also increases cost and assembly complexity. Most non-thermal expansion mats that perform somewhat well still contain an organic binder and greatly reduce the elasticity of the fiber in the temperature range of 200-300 ° C. This is believed to be true for other diesel exhaust pollution control devices including lean NOx catalysts, continuous regeneration traps (CRT) and NOx traps.
米国特許第６，２３１，８１８号明細書は、アモルファスの無機ファイバーから構成される非熱膨張マットを用いることにより、低温ディーゼル触媒を実装する問題点を回避することを試みている。この特許には、マットは有機バインダーフリーとすることができると教示されているが、実施例で用いたマットのいくつかには大量のバインダーの使用を必要としていると考えられる。さらに、この米国特許で開示されている実装マットは、ディーゼルエンジン、特にＴＤＩエンジンから排気の処理を適切に行えない。 US Pat. No. 6,231,818 attempts to circumvent the problem of implementing low temperature diesel catalysts by using a non-thermal expansion mat composed of amorphous inorganic fibers. Although this patent teaches that the mat can be organic binder free, it is believed that some of the mats used in the examples require the use of large amounts of binder. Furthermore, the mounting mat disclosed in this US patent cannot adequately handle exhaust from diesel engines, particularly TDI engines.
本発明の一態様において、数平均直径が５μｍ以上および長さが０．５〜１５ｃｍのチョップドマグネシウムアルミニウムシリケートガラスファイバーをマットの総重量に基づいて少なくとも９０重量％含む不織非熱膨張性マットであって、ガラスファイバーはニードルパンチまたはステッチボンドされており、マットは有機バインダーを含まないまたは実質的に含まない不織非熱膨張性マットが提供される。「実質的に含まない」とは、マットの重量に基づいてバインダーの量が１重量％以下、好ましくは０．５重量％以下であることを意味する。マットは、機械の内燃機関（例えば、ディーゼルエンジン）の排気処理のための汚染制御装置に用いられる。エンジンは、例えば、発電機や自動車のような定置型機械に含まれる。実装マットは、汚染制御要素（例えば、ディーゼル汚染制御モノリス）を汚染制御装置の筐体（例えば、金属ケース）に実装し、ケースと汚染制御要素の間に配置されるのが一般的である。 In one aspect of the present invention, a nonwoven non-thermally expandable mat comprising at least 90% by weight of chopped magnesium aluminum silicate glass fibers having a number average diameter of 5 μm or more and a length of 0.5 to 15 cm, based on the total weight of the mat Wherein the glass fibers are needle punched or stitch bonded and the mat is provided with a non- woven, non-thermally expandable mat that is free or substantially free of organic binder. “Substantially free” means that the amount of binder is 1 wt% or less, preferably 0.5 wt% or less, based on the weight of the mat. The mat is used in a pollution control device for exhaust treatment of an internal combustion engine (for example, a diesel engine) of a machine. The engine is included in a stationary machine such as a generator or an automobile. The mounting mat generally mounts a pollution control element (for example, a diesel pollution control monolith) on a casing (for example, a metal case) of a pollution control device, and is disposed between the case and the pollution control element.
特定の態様によれば、汚染制御装置の筐体（例えば、金属ケース）に汚染制御要素（例えば、ディーゼル汚染制御モノリス）を実装するマットであって、マットは、数平均直径が５μｍ以上および長さが０．５〜１５ｃｍのチョップドマグネシウムアルミニウムシリケートガラスファイバーをマットの総重量に基づいて少なくとも９０重量％含む非熱膨張性マットであり、ガラスファイバーはニードルパンチまたはステッチボンドされており、マットは有機バインダーを含まないまたは実質的に含まず、チョップドマグネシウムアルミニウムシリケートガラスファイバーの少なくとも２つの層を含み、２つの層のガラスファイバー組成が異なるマットが提供される。本態様によるマットは、ディーゼルエンジン排気のための汚染制御装置用実装マットの性能および製造コストを最適化するのに特に好適であることが分かった。 According to a particular aspect, a mat for mounting a pollution control element (eg, a diesel pollution control monolith) on a pollution control device housing (eg, a metal case), the mat having a number average diameter of 5 μm or more and a length. A non-thermally expansible mat comprising at least 90% by weight of chopped magnesium aluminum silicate glass fiber having a thickness of 0.5 to 15 cm based on the total weight of the mat, the glass fiber being needle punched or stitch bonded and the mat being organic A mat is provided that is free or substantially free of binder and comprises at least two layers of chopped magnesium aluminum silicate glass fibers, the two layers having different glass fiber compositions. The mat according to this aspect has been found to be particularly suitable for optimizing the performance and manufacturing costs of a pollution control device mounting mat for diesel engine exhaust.
本発明の他の態様において、排気ガスを汚染制御装置に与えることにより、内燃機関（例えば、ディーゼルエンジン）から排気ガスを処理する方法であって、汚染制御装置は、不織実装マットを備えた筐体（例えば、金属ケース）に配列された汚染制御要素（例えば、ディーゼル汚染制御モノリス）を含み、不織実装マットは、ケースと汚染制御要素の間に配置され、数平均直径が５μｍ以上および長さが０．５〜１５ｃｍのチョップドマグネシウムアルミニウムシリケートガラスファイバーをマットの総重量に基づいて少なくとも９０重量％含む非熱膨張性マットであり、ガラスファイバーはニードルパンチまたはステッチボンドされており、マットは有機バインダーを含まないまたは実質的に含まない方法が提供される。 In another aspect of the invention, a method of treating exhaust gas from an internal combustion engine (eg, a diesel engine) by providing exhaust gas to the pollution control device, the pollution control device comprising a nonwoven mounting mat. Including a pollution control element (eg, a diesel pollution control monolith) arranged in a housing (eg, a metal case), wherein the nonwoven mounting mat is disposed between the case and the pollution control element and has a number average diameter of 5 μm or more and A non-thermally expandable mat containing at least 90% by weight of chopped magnesium aluminum silicate glass fiber having a length of 0.5-15 cm based on the total weight of the mat, the glass fiber being needle punched or stitch bonded, A method is provided that is free or substantially free of organic binders.
比較例７
比較例７（Ｃ７）は、高アルミナ多結晶セラミックファイバーでできた市販の非熱膨張性汚染制御装置実装マットから構成されていた。マットは実質的にショットフリーであり、平均直径は３ミクロンである。
Comparative Example 7
Comparative Example 7 (C7) consisted of a commercially available non-thermally expandable pollution control device mounting mat made of high alumina polycrystalline ceramic fibers. The mat is substantially shot free and has an average diameter of 3 microns.
Claims (4)
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP02078103A EP1388649B1 (en) | 2002-07-31 | 2002-07-31 | Mat for mounting a pollution control monolith in a pollution control device for the treatment of exhaust gas of a diesel engine powered machine |
| PCT/US2003/021455 WO2004011785A1 (en) | 2002-07-31 | 2003-07-08 | Mat for mounting a pollution control element in a pollution control device for the treatment of exhaust gas |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| JP2006516043A JP2006516043A (en) | 2006-06-15 |
| JP2006516043A5 true JP2006516043A5 (en) | 2009-09-24 |
| JP4575159B2 JP4575159B2 (en) | 2010-11-04 |
Family
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2004524580A Expired - Fee Related JP4575159B2 (en) | 2002-07-31 | 2003-07-08 | Pollution control device for diesel engine exhaust gas system and mat for mounting pollution control element in pollution control device |
Country Status (11)
| Country | Link |
|---|---|
| EP (2) | EP1388649B1 (en) |
| JP (1) | JP4575159B2 (en) |
| KR (1) | KR101037241B1 (en) |
| CN (1) | CN1678821B (en) |
| AT (1) | ATE419456T1 (en) |
| AU (1) | AU2003247946A1 (en) |
| BR (1) | BR0313074B1 (en) |
| DE (1) | DE60230603D1 (en) |
| MX (1) | MXPA05001251A (en) |
| WO (1) | WO2004011785A1 (en) |
| ZA (1) | ZA200501650B (en) |
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| KR20080063394A (en) | 2005-10-13 | 2008-07-03 | 쓰리엠 이노베이티브 프로퍼티즈 컴파니 | Multilayer mounting mats and pollution control devices containing same |
| WO2007047273A2 (en) | 2005-10-19 | 2007-04-26 | 3M Innovative Properties Company | Multilayer mounting mats and pollution control devices containing same |
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| EP2212072B1 (en) | 2007-10-09 | 2013-08-28 | 3M Innovative Properties Company | Method of making mounting mats for mounting pollution control element |
| EP2350367B1 (en) | 2008-11-03 | 2016-04-20 | 3M Innovative Properties Company | Mounting mat and pollution control device with the same |
| KR101719007B1 (en) | 2008-11-03 | 2017-04-04 | 쓰리엠 이노베이티브 프로퍼티즈 컴파니 | Mounting mat and pollution control device with the same |
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| WO2011047001A1 (en) * | 2009-10-13 | 2011-04-21 | 3M Innovative Properties Company | Non-woven mat and pollution control device with the same |
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2002
- 2002-07-31 AT AT02078103T patent/ATE419456T1/en not_active IP Right Cessation
- 2002-07-31 DE DE60230603T patent/DE60230603D1/en not_active Expired - Lifetime
- 2002-07-31 EP EP02078103A patent/EP1388649B1/en not_active Expired - Lifetime
-
2003
- 2003-07-08 AU AU2003247946A patent/AU2003247946A1/en not_active Abandoned
- 2003-07-08 WO PCT/US2003/021455 patent/WO2004011785A1/en not_active Application Discontinuation
- 2003-07-08 KR KR1020057001725A patent/KR101037241B1/en not_active IP Right Cessation
- 2003-07-08 EP EP03771589A patent/EP1561018A1/en not_active Withdrawn
- 2003-07-08 BR BRPI0313074-6A patent/BR0313074B1/en not_active IP Right Cessation
- 2003-07-08 MX MXPA05001251A patent/MXPA05001251A/en active IP Right Grant
- 2003-07-08 CN CN03820939XA patent/CN1678821B/en not_active Expired - Fee Related
- 2003-07-08 JP JP2004524580A patent/JP4575159B2/en not_active Expired - Fee Related
-
2005
- 2005-02-24 ZA ZA200501650A patent/ZA200501650B/en unknown
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