JP2010284571A - Catalyst carrier holding material using nonwoven fabric containing heat-fusible fibers - Google Patents
Catalyst carrier holding material using nonwoven fabric containing heat-fusible fibers Download PDFInfo
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- JP2010284571A JP2010284571A JP2009138527A JP2009138527A JP2010284571A JP 2010284571 A JP2010284571 A JP 2010284571A JP 2009138527 A JP2009138527 A JP 2009138527A JP 2009138527 A JP2009138527 A JP 2009138527A JP 2010284571 A JP2010284571 A JP 2010284571A
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- 239000000835 fiber Substances 0.000 title claims abstract description 102
- 239000003054 catalyst Substances 0.000 title claims abstract description 94
- 239000000463 material Substances 0.000 title claims abstract description 66
- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 55
- 239000012784 inorganic fiber Substances 0.000 claims abstract description 22
- 230000035699 permeability Effects 0.000 claims abstract description 16
- 229920000728 polyester Polymers 0.000 claims description 28
- -1 polyethylene Polymers 0.000 claims description 14
- 238000007789 sealing Methods 0.000 claims description 11
- 239000004698 Polyethylene Substances 0.000 claims description 10
- 229920000573 polyethylene Polymers 0.000 claims description 10
- 239000000758 substrate Substances 0.000 claims description 10
- 239000004743 Polypropylene Substances 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 abstract description 20
- 239000002184 metal Substances 0.000 abstract description 20
- 238000000034 method Methods 0.000 abstract description 16
- 239000005416 organic matter Substances 0.000 abstract description 5
- 238000011068 loading method Methods 0.000 abstract description 3
- 239000010408 film Substances 0.000 description 16
- 230000003197 catalytic effect Effects 0.000 description 13
- 230000000052 comparative effect Effects 0.000 description 8
- 239000007789 gas Substances 0.000 description 7
- 239000011230 binding agent Substances 0.000 description 6
- 239000006185 dispersion Substances 0.000 description 6
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 6
- 229920001577 copolymer Polymers 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 238000002844 melting Methods 0.000 description 4
- 230000008018 melting Effects 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 238000000746 purification Methods 0.000 description 4
- 238000004804 winding Methods 0.000 description 4
- 229920001634 Copolyester Polymers 0.000 description 3
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 2
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 2
- 239000003522 acrylic cement Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910002091 carbon monoxide Inorganic materials 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229920013716 polyethylene resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920003002 synthetic resin Polymers 0.000 description 2
- 239000000057 synthetic resin Substances 0.000 description 2
- 239000011800 void material Substances 0.000 description 2
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 239000002518 antifoaming agent Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 229910052878 cordierite Inorganic materials 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 1
- 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 1
- 238000007599 discharging Methods 0.000 description 1
- 229920005674 ethylene-propylene random copolymer Polymers 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000002783 friction material Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- 239000004707 linear low-density polyethylene Substances 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 229920006267 polyester film Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 229910052902 vermiculite Inorganic materials 0.000 description 1
- 235000019354 vermiculite Nutrition 0.000 description 1
- 239000010455 vermiculite Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
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Abstract
Description
本発明はガソリンエンジン、ディーゼルエンジン等の内燃機関から排出される排気ガス浄化装置（排気ガス浄化用触媒コンバータ又は単に触媒コンバータと呼ばれる）に組み込まれる触媒担体を金属容器内に保持するための触媒担体保持材に関する。 The present invention relates to a catalyst carrier for holding a catalyst carrier incorporated in an exhaust gas purification device (referred to as an exhaust gas purification catalytic converter or simply a catalytic converter) discharged from an internal combustion engine such as a gasoline engine or a diesel engine in a metal container. It relates to a holding material.
自動車等の車両には、周知の如く、そのエンジンの排気ガス中に含まれる一酸化炭素、炭化水素、窒素酸化物等の有害成分を除去するために、触媒コンバータが積載されている。
触媒コンバータは金属容器、触媒担体、触媒担体保持材により構成されている。
触媒担体は、エンジンの排気ガス中に含まれる一酸化炭素、炭化水素、窒素酸化物等の有害成分を除去するために持ちられ、例えばコージェライト等からなる円筒状のハニカム状成形体に貴金属触媒等が担持されたものが一般的である。
触媒担体保持材は、触媒担体と金属容器の間に触媒担体を巻きつけるように搭載される。触媒担体保持材は触媒担体と金属容器の間を排気ガスが洩れ出ることを防止し、また自動車走行中の振動により触媒担体と金属容器が直接接触し触媒担体が損傷することを防止するために用いられる。
触媒担体保持材はアルミナ繊維やムライト繊維あるいはその他のセラミック繊維等の無機繊維を有機バインダーを用いて所定厚さのマット状に成形したものが主流となっている。
As is well known, vehicles such as automobiles are loaded with a catalytic converter in order to remove harmful components such as carbon monoxide, hydrocarbons and nitrogen oxides contained in the exhaust gas of the engine.
The catalytic converter includes a metal container, a catalyst carrier, and a catalyst carrier holding material.
The catalyst carrier is used to remove harmful components such as carbon monoxide, hydrocarbons and nitrogen oxides contained in the exhaust gas of the engine. For example, a noble metal catalyst is formed on a cylindrical honeycomb-shaped formed body made of cordierite. Etc. are generally supported.
The catalyst carrier holding material is mounted so that the catalyst carrier is wound between the catalyst carrier and the metal container. The catalyst carrier holding material prevents the exhaust gas from leaking between the catalyst carrier and the metal container, and also prevents the catalyst carrier and the metal container from coming into direct contact with each other due to vibration during driving of the automobile and damaging the catalyst carrier. Used.
The catalyst carrier holding material is mainly formed by molding inorganic fibers such as alumina fibers, mullite fibers, or other ceramic fibers into a mat having a predetermined thickness using an organic binder.
触媒コンバータはまず触媒を担持した触媒担体の周囲に、触媒担体保持材であるマットを巻き付け、次いでこれを金属容器に収納する。
収納の方法は一般的には２通りある。ひとつは、あらかじめ２分割された金属容器の一方に触媒担体保持材を巻いた触媒担体を挿入し、もう片方で覆った後容器を固定具や溶接によって固定する方法であり、もうひとつは、筒型容器の片側の末端から触媒担体保持材を巻きつけた触媒担体を圧入する方法である。
いずれの方法でも触媒担体保持材を巻いた触媒担体を金属容器にスムーズに挿入するための検討がなされている。
The catalytic converter first wraps a mat, which is a catalyst carrier holding material, around a catalyst carrier carrying a catalyst, and then stores this in a metal container.
There are generally two ways of storage. One is a method in which a catalyst carrier with a catalyst carrier holding material is inserted into one of the two metal containers divided in advance and covered with the other, and then the container is fixed by a fixture or welding. This is a method of press-fitting a catalyst carrier around which a catalyst carrier holding material is wound from one end of the mold container.
In any method, studies have been made to smoothly insert a catalyst carrier wound with a catalyst carrier holding material into a metal container.
例えば特許文献１では触媒担体保持基材の上に有機不織布を配置し、さらにこの有機不織布に両面テープを貼り付けた後に、触媒担体の外周に上記両面テープを介して有機不織布及び触媒担体保持材を巻き付けて中間部品を作製し、次いで、この中間部品を筒型金属ケースの中へ圧入することを特徴とする触媒コンバータの製造方法を開示している。
特許文献２では触媒担体保持基材の表裏両面または外周を合成樹脂製フィルムで被覆した触媒保持材を触媒担体の外周に巻き付ける方法を開示している。
特許文献３では無機繊維製の基材と、基材の少なくとも金属容器側表面に形成され、２５℃でのヤング率が０．３ＭＰａ以下である粘弾性層とを備えることを特徴とする触媒担体保持材が開示されている
For example, in Patent Document 1, an organic non-woven fabric is disposed on a catalyst carrier holding base material, and a double-sided tape is attached to the organic non-woven fabric. An intermediate part is manufactured by winding the intermediate part, and then the intermediate part is press-fitted into a cylindrical metal case.
Patent Document 2 discloses a method of winding a catalyst holding material in which the front and back surfaces or the outer periphery of a catalyst carrier holding base material is covered with a synthetic resin film around the outer circumference of the catalyst carrier.
In Patent Document 3, a catalyst carrier comprising an inorganic fiber base material and a viscoelastic layer formed on at least a metal container side surface of the base material and having a Young's modulus at 25 ° C. of 0.3 MPa or less. Retaining material is disclosed
触媒コンバータは製品として使用する前に、焼成処理して触媒担体保持材の有機バインダーを焼失する作業を行っている。このような焼成処理は、メーカーにとって大きな負担となっており、重要課題となっている。
一方有機バインダーを低減すると無機繊維の結束力が弱まって触媒コンバータ用保持材が厚くなりまた有機バインダー焼失後の保持力が低下する問題がある。また、有機バインダーの減少により強度が低下し触媒担体への巻きつけ時の触媒担体保持材の金属容器側表面の亀裂や繊維脱落が問題となる。また、触媒担体保持材を巻いた触媒担体を金属容器挿入時の摩擦係数の増大といった問題も考えられる。
Prior to use as a product, the catalytic converter is baked to burn off the organic binder of the catalyst carrier holding material. Such a baking process is a big burden for a manufacturer and is an important issue.
On the other hand, when the organic binder is reduced, there is a problem that the binding force of the inorganic fibers is weakened and the holding material for the catalytic converter becomes thick and the holding power after the organic binder is burnt down is lowered. Further, the strength decreases due to the reduction of the organic binder, and cracks on the surface of the metal carrier side of the catalyst carrier holding material and fiber dropout at the time of winding around the catalyst carrier become a problem. Further, there may be a problem that the coefficient of friction is increased when the catalyst carrier around which the catalyst carrier holding material is wound is inserted into the metal container.
特許文献１では、両面テープを貼り付ける必要があるので工程が増えてしまい作業性が非常に悪い。また，触媒担体保持材と触媒担体との接触面に，坪量の高い（坪量１９ｇ／ｃｍ３）ポリエチレン樹脂不織布をホットプレスで貼り付け，保持シール体−有機不織布の一体マットが形成される方法を開示しているが、この方法では坪量の高い材料を用いていることと、ポリエチレン樹脂不織布がホットプレスによりフィルム化してしまうため取り付け後の焼却処理で多大なエネルギーを必要とする。
特許文献２ではその表裏両面または外周を合成樹脂製フィルムで被覆した触媒担体保持材を触媒担体の外周に巻き付ける方法を開示しているが、特許文献１と同様フィルムで触媒担体保持材を被覆すると装填後焼失処理時に加熱空気の通路を塞ぐ為有機物の焼失に時間がかかる。
特許文献３では粘弾性層が粘着性を有するためその表面を低摩擦材料からなる平滑層が必要となる。さらに平滑層として極薄のフィルムを使用した場合摩擦係数の低減効果が低い。
そこで本発明は触媒担体保持基材と不織布を熱接着により固定し触媒担体保持材を容易に製造し、触媒担体保持材を金属容器にスムーズに挿入し、焼成処理して焼失する有機物を低減するとともにスムーズに有機物を排出することを課題とする。
In patent document 1, since it is necessary to affix a double-sided tape, a process increases and workability | operativity is very bad. Also, a high-basis weight (basis weight 19 g / cm 3 ) polyethylene resin nonwoven fabric is attached to the contact surface between the catalyst carrier holding material and the catalyst carrier with a hot press to form an integrated mat of the holding sealing body and the organic nonwoven fabric. Although the method is disclosed, in this method, a material having a high basis weight is used, and since the polyethylene resin nonwoven fabric is formed into a film by hot pressing, a large amount of energy is required for the incineration treatment after the attachment.
Patent Document 2 discloses a method of winding a catalyst carrier holding material whose front and back surfaces or outer periphery is covered with a synthetic resin film around the outer periphery of the catalyst carrier. It takes time to burn off organic substances because the passage of heated air is blocked during the burning process after loading.
In Patent Document 3, since the viscoelastic layer has adhesiveness, a smooth layer made of a low friction material is required on the surface thereof. Further, when an extremely thin film is used as the smooth layer, the effect of reducing the friction coefficient is low.
Therefore, the present invention fixes the catalyst carrier holding substrate and the nonwoven fabric by thermal bonding, easily manufactures the catalyst carrier holding material, smoothly inserts the catalyst carrier holding material into the metal container, and reduces the organic matter that is burned off by firing. At the same time, the issue is to discharge organic substances smoothly.
本発明者らは上記問題に鑑み鋭意検討した結果、触媒担体保持基材である無機繊維を含む繊維マットの少なくとも一面に熱融着繊維を含む通気性が良く低坪量の不織布を有する触媒担体保持材とすることにより上記問題が解決されることを見出し本発明に至った。
すなわち本発明の第１は、触媒担体を保持するためにその外周を覆う触媒担体保持材であって、無機繊維を含む繊維マットから構成される触媒担体保持基材の少なくとも一方の表面に熱融着繊維を含む不織布を有し、該不織布が通気度１５０ｃｍ３／(ｃｍ２・s)以上であることを特徴とする触媒担体保持材。
本発明の第２は、熱融着繊維を含む不織布の坪量が２ｇ／ｍ２以上８ｇ／ｍ２以下であることを特徴とする請求項１に記載の触媒担体保持材。
As a result of intensive studies in view of the above problems, the present inventors have found that a catalyst carrier having a non-woven fabric with good air permeability and low basis weight containing heat-sealing fibers on at least one surface of a fiber mat containing inorganic fibers as a catalyst carrier holding substrate. The present inventors have found that the above problems can be solved by using a holding material, and have reached the present invention.
That is, the first aspect of the present invention is a catalyst carrier holding material that covers the outer periphery of the catalyst carrier to hold the catalyst carrier, and is thermally fused to at least one surface of a catalyst carrier holding substrate composed of a fiber mat containing inorganic fibers. A catalyst carrier holding material comprising a nonwoven fabric containing attached fibers, wherein the nonwoven fabric has an air permeability of 150 cm 3 / (cm 2 · s) or more.
The second aspect of the present invention is the catalyst carrier holding material according to claim 1, wherein the basis weight of the nonwoven fabric containing the heat-sealing fibers is 2 g / m 2 or more and 8 g / m 2 or less.
本発明の第３は、熱融着繊維を含む不織布の厚みが１０μｍ以上５０μｍ以下であることを特徴とする請求項１又は請求項２に記載の触媒担体保持材。
本発明の第４は、熱融着繊維を含む不織布を構成する熱融着繊維成分として共重合ポリエステル、ポリエチレン、ポリプロピレンの中から選ばれる少なくとも１種を２０質量％から８０質量％含むことを特徴とする請求項１から請求項３のいずれか１項に記載の触媒担体保持材。
The third aspect of the present invention is the catalyst carrier holding material according to claim 1 or 2, wherein the thickness of the nonwoven fabric containing the heat-sealing fibers is 10 μm or more and 50 μm or less.
4th of this invention is characterized by including 20 mass% to 80 mass% of at least 1 sort (s) chosen from copolymer polyester, polyethylene, and polypropylene as a heat-fusion fiber component which comprises the nonwoven fabric containing a heat-fusion fiber. The catalyst carrier holding material according to any one of claims 1 to 3.
本発明の触媒担体保持材は、触媒担体保持基材である無機繊維を含む繊維マットの少なくとも一面に熱融着繊維を含む通気性が良く低坪量の不織布を有すること特徴とする触媒担体保持材である。熱融着繊維を含む通気性が良く低坪量の不織布を有することにより、無機繊維を含む繊維マットと不織布を熱接着により固定し触媒担体保持材を容易に製造できる。（保持材と不織布を張り合わせるための接着剤や両面テープが不要である）。不織布が触媒担体保持材と金属容器の摩擦を軽減するため触媒担体保持材を金属容器にスムーズに挿入することができる。不織布は坪量が非常に低く、フィルムと比較して通気性が高いため焼成処理して焼失する有機物を低減するとともにスムーズに有機物を排出するという効果を有するものである。 The catalyst carrier holding material of the present invention has a non-woven fabric with good air permeability and low basis weight containing heat-sealing fibers on at least one surface of a fiber mat containing inorganic fibers as a catalyst carrier holding substrate. It is a material. By having a non-woven fabric with good air permeability and low basis weight including heat-sealing fibers, a fiber mat containing inorganic fibers and the non-woven fabric can be fixed by thermal bonding to easily produce a catalyst carrier holding material. (No adhesive or double-sided tape is required to bond the holding material to the nonwoven fabric.) Since the nonwoven fabric reduces friction between the catalyst carrier holding material and the metal container, the catalyst carrier holding material can be smoothly inserted into the metal container. The nonwoven fabric has an extremely low basis weight and has high air permeability as compared with the film. Therefore, the nonwoven fabric has an effect of reducing the organic matter burned out by the baking treatment and discharging the organic matter smoothly.
以下、本発明について詳細に説明する。本発明に使用する触媒担体については公知のものが使用できる。また触媒担体保持材の基材としては、既存の基材を使用する。
例えば、無機繊維と少量の有機バインダーとを湿式成形した後、圧縮した状態で乾燥した圧縮マット、無機繊維を集綿したものをニードル加工したブランケットからなるマット、無機繊維とバーミキュライト等の膨張材とを湿式成形した膨張マット等のマット材等を使用する。あるいは、乾式によりマット材を形成したものでも良い。
本発明の触媒コンバータ用保持材は、該触媒担体保持材の少なくとも一面に熱融着繊維を含む不織布を設けたことを特徴とする
Hereinafter, the present invention will be described in detail. A well-known thing can be used about the catalyst support | carrier used for this invention. An existing base material is used as the base material for the catalyst carrier holding material.
For example, a wet mat of inorganic fiber and a small amount of an organic binder, and then a compressed mat dried in a compressed state, a mat made of a blanket obtained by collecting inorganic fibers and needle processing, an inorganic fiber and an expanding material such as vermiculite A mat material such as an expansion mat formed by wet molding is used. Or what formed the mat material by the dry type may be used.
The holding material for a catalytic converter according to the present invention is characterized in that a non-woven fabric containing heat-sealing fibers is provided on at least one surface of the catalyst carrier holding material.
本発明を触媒コンバータに用いた例を図１〜図３を用いて説明する。
図１は本発明の触媒担体保持材の斜視図である。触媒担体保持基材の少なくとも１面に熱融着繊維を含む不織布を熱、レーザー、超音波等で接着することができる。より好ましくは熱により接着する方法であり熱融着繊維の融点以上で加熱することにより触媒担体保持基材に熱融着繊維を含む不織布を接着することができる。触媒担体保持基材の形状は公知のものが使用できる。
図２は触媒担体に本発明の触媒担体保持材を巻装した状態を示す斜視図である。
触媒担体と触媒担体保持材は公知の方法で固定することができる。
図３は触媒コンバータの一例を示す断面図である。この図を用いてその構造を説明すると触媒担体は触媒担体保持材に巻装され金属容器内に装填されている。触媒担体保持基材と金属容器の間に熱融着繊維を含む不織布がある。
The example which used this invention for the catalytic converter is demonstrated using FIGS. 1-3.
FIG. 1 is a perspective view of a catalyst carrier holding material of the present invention. A non-woven fabric containing heat-sealing fibers can be bonded to at least one surface of the catalyst carrier holding substrate with heat, laser, ultrasonic waves, or the like. More preferably, it is a method of bonding by heat, and the non-woven fabric containing the heat-bonding fibers can be bonded to the catalyst carrier holding substrate by heating at a temperature equal to or higher than the melting point of the heat-bonding fibers. As the shape of the catalyst carrier holding substrate, known shapes can be used.
FIG. 2 is a perspective view showing a state in which the catalyst carrier holding material of the present invention is wound around the catalyst carrier.
The catalyst carrier and the catalyst carrier holding material can be fixed by a known method.
FIG. 3 is a cross-sectional view showing an example of a catalytic converter. The structure will be described with reference to this figure. The catalyst carrier is wound around a catalyst carrier holding material and loaded in a metal container. There is a non-woven fabric including heat-sealing fibers between the catalyst carrier holding substrate and the metal container.
本発明の不織布は通気度１５０ｃｍ３／(ｃｍ２・s)以上である。通気度を１５０ｃｍ３／(ｃｍ２・s)以上とすることで焼成処理過程でのフィルム化を防止し熱風の通過をスムーズにすることで発生する有機物を速やかに排出できる。より好ましくは通気度２００ｃｍ３／(ｃｍ２・s)以上である。また、通気度１０００ｃｍ３／(ｃｍ２・s)以下が無機繊維の脱落防止のために好ましい。より好ましくは通気度５００ｃｍ３／(ｃｍ２・s)以下である。 通気度は、配合する繊維の繊維径と坪量と不織布厚みを調整することで制御できる。
本発明の不織布は坪量２〜８ｇ／ｍ２であることが好ましい。坪量を坪量２ｇ／ｍ２以上とすることで不織布の強度を得られる。より好ましくは４ｇ／ｍ２以上である。また、坪量を８ｇ／ｍ２以下とすることで不要な有機分を低減することが出来る。より好ましくは６ｇ／ｍ２以下である。坪量は、抄紙時の繊維分散液の濃度と繊維分散液の抄紙網でのろ過量を調整することで制御できる。
The nonwoven fabric of the present invention has an air permeability of 150 cm 3 / (cm 2 · s) or more. By setting the air permeability to 150 cm 3 / (cm 2 · s) or more, it is possible to prevent the formation of a film in the baking process and to quickly discharge organic matter generated by smooth passage of hot air. More preferably, the air permeability is 200 cm 3 / (cm 2 · s) or more. Further, an air permeability of 1000 cm 3 / (cm 2 · s) or less is preferable for preventing the inorganic fibers from falling off. More preferably an air permeability of 500cm 3 / (cm 2 · s ) or less. The air permeability can be controlled by adjusting the fiber diameter, basis weight, and nonwoven fabric thickness of the fibers to be blended.
The nonwoven fabric of the present invention preferably has a basis weight of 2 to 8 g / m 2 . By setting the basis weight to 2 g / m 2 or more, the strength of the nonwoven fabric can be obtained. More preferably, it is 4 g / m 2 or more. Moreover, an unnecessary organic content can be reduced by making a basic weight into 8 g / m < 2 > or less. More preferably, it is 6 g / m 2 or less. The basis weight can be controlled by adjusting the concentration of the fiber dispersion during papermaking and the amount of filtration of the fiber dispersion through the papermaking net.
本発明の不織布は厚み５０μｍ以下であることが好ましい。熱接着不織布の厚みを薄とすることで熱接着後の製品の厚みを抑えることができ厚み変化を低減できる。より好ましくは４０μｍ以下である。
本発明の不織布は厚み１０μｍ以上であることが好ましい。１０μ以上厚くすることで保持基材の無機繊維の凹凸による金属容器への接触を妨げ摩擦係数を低減できる。より好ましくは２０μｍ以上である。
The nonwoven fabric of the present invention preferably has a thickness of 50 μm or less. By reducing the thickness of the thermal bonding nonwoven fabric, the thickness of the product after thermal bonding can be suppressed, and the change in thickness can be reduced. More preferably, it is 40 μm or less.
It is preferable that the nonwoven fabric of this invention is 10 micrometers or more in thickness. By increasing the thickness to 10 μm or more, the contact with the metal container due to the unevenness of the inorganic fibers of the holding substrate can be prevented and the friction coefficient can be reduced. More preferably, it is 20 μm or more.
熱融着性繊維とは８０℃〜１８０℃で熱融着性を有する繊維であり、例えば線状低密度ポリエチレン、低密度ポリエチレン、高密度ポリエチレン、エチレン−プロピレンランダム共重合体、ポリプロピレン、共重合ポリプロピレンなどのポリオレフイン系繊維、共重合ポリエステル繊維である。さらに芯がポリエステルで鞘がポリエチレンで構成される芯鞘型複合繊維や芯がポリエステルで鞘がテレフタル酸とイソフタル酸の共重合ポリエステルで構成される芯鞘型複合繊維は鞘が熱融着する温度で芯が融着しないため不織布のフィルム化を防止できるためより好ましく用いることが出来る。
また上記の繊維は混合して用いても良く、ポリエステル繊維とポリエチレン繊維の混合物、ポリエステル繊維と共重合ポリエステル繊維の混合物、芯部がポリエステルで鞘部が共重合ポリエステルからなる芯鞘繊維とポリエステル繊維の混合物、芯部がポリエステルで鞘部がポリエチレンからなる芯鞘繊維とポリエステル繊維の混合物が好ましく用いることができる。
The heat-fusible fiber is a fiber having heat-fusibility at 80 ° C. to 180 ° C., for example, linear low density polyethylene, low density polyethylene, high density polyethylene, ethylene-propylene random copolymer, polypropylene, copolymer Polyolefin fibers such as polypropylene and copolyester fibers. Furthermore, the core-sheath type composite fiber in which the core is made of polyester and the sheath is made of polyethylene or the core is made of polyester and the sheath is made of a copolymer polyester of terephthalic acid and isophthalic acid. In addition, since the core is not fused, it can be used more preferably because the nonwoven fabric can be prevented from being formed into a film.
The above-mentioned fibers may be used in combination. A mixture of polyester fiber and polyethylene fiber, a mixture of polyester fiber and copolymerized polyester fiber, a core-sheath fiber and polyester fiber in which the core is made of polyester and the sheath is made of copolymerized polyester. A mixture of core-sheath fiber and polyester fiber, in which the core part is polyester and the sheath part is made of polyethylene, can be preferably used.
あるいはまた、芯部がポリエステルで鞘部が共重合ポリエステルからなる芯鞘繊維、芯部がポリエステルで鞘部がポリエチレンからなる芯鞘繊維を単独で用いても良い。特に好ましくは芯部がポリエステルで鞘部が共重合ポリエステルからなる芯鞘繊維とポリエステル繊維の混合物である。
これらの割合としては熱接着性を得るために融点が８０度〜１８０度の樹脂を含む繊維が２０重量％以上含むことが好ましい。より好ましくは４０％以上である。また熱接着時にフィルム状に溶融することを防止するために融点が８０度〜１８０度の樹脂を含む繊維が８０重量％以下含むことが好ましい。
Alternatively, a core-sheath fiber in which the core part is polyester and the sheath part is made of copolymerized polyester, and a core-sheath fiber in which the core part is polyester and the sheath part is made of polyethylene may be used alone. Particularly preferred is a mixture of core-sheath fibers and polyester fibers, the core part of which is polyester and the sheath part is made of a copolyester.
As these ratios, it is preferable to contain 20% by weight or more of fibers containing a resin having a melting point of 80 to 180 degrees in order to obtain thermal adhesiveness. More preferably, it is 40% or more. In order to prevent melting in the form of a film at the time of thermal bonding, it is preferable that the fiber containing a resin having a melting point of 80 ° to 180 ° is contained by 80% by weight or less.
本発明の不織布は、繊維長２ｍｍ〜８ｍｍにカットした短繊維を湿式抄紙法により不織布としたものであり、繊維の分散が極めて良好であるため、坪量２〜８ｇ／ｍ２という低坪量で高い繊維分散性が得られ均一である。
繊維長２ｍｍ以上とすることで抄紙時の紙強度を維持できる。より好ましくは３ｍｍ以上である。また、繊維長を８ｍｍ以下とすることで抄紙時の分散均一性を向上することができる。より好ましくは６ｍｍ以下であり、さらに好ましくは５ｍｍ以下である。繊維長の測定は任意に抽出した２０本の繊維をマイクロスコープ（キーエンス社製）にて５０倍に拡大投影し、モニター画面上に映し出した繊維の端部から端部迄を繊維の幅から大幅にずれないようにして各点間距離を計測した。
また、短繊維は均一で薄いシートを作製するために平均繊維径２０μｍ以下であることが好ましい。より好ましくは１５μｍ以下である。シートに適度な弾力性、通気性を保つために平均繊維径は２μｍ以上が好ましい。より好ましくは４μｍ以上である。平均繊維径の測定は任意に抽出した２０本の繊維についてマイクロスコープ（キーエンス社製）にて１０００倍に拡大投影し、モニター画面上に映し出した繊維１本あたり任意の３箇所の繊維径を計測し平均値を算出した。
The non-woven fabric of the present invention is a non-woven fabric obtained by wet papermaking by using short fibers cut to a fiber length of 2 mm to 8 mm, and the fiber dispersion is very good. Therefore, the basis weight is as low as 2 to 8 g / m 2. High fiber dispersibility is obtained and is uniform.
By setting the fiber length to 2 mm or more, the paper strength at the time of papermaking can be maintained. More preferably, it is 3 mm or more. Moreover, the dispersion uniformity at the time of papermaking can be improved by making fiber length into 8 mm or less. More preferably, it is 6 mm or less, More preferably, it is 5 mm or less. Fiber length is measured by 20 times of arbitrarily extracted fibers magnified and projected 50 times with a microscope (manufactured by KEYENCE), and the fiber end to end projected on the monitor screen is greatly enlarged from the fiber width. The distance between each point was measured without slipping.
The short fibers preferably have an average fiber diameter of 20 μm or less in order to produce a uniform and thin sheet. More preferably, it is 15 μm or less. In order to maintain appropriate elasticity and breathability in the sheet, the average fiber diameter is preferably 2 μm or more. More preferably, it is 4 μm or more. The average fiber diameter is measured by enlarging and projecting 20 arbitrarily extracted fibers with a microscope (manufactured by KEYENCE) 1000 times, and measuring the fiber diameters at any three locations for each fiber displayed on the monitor screen. The average value was calculated.
本発明の不織布は湿式抄造法で作製することができる。繊維を離解機で水に均一に混合分散した後、円網抄紙機、長網抄紙機、または傾斜短網抄紙機、あるいはそれらを組み合わせたコンビネーション抄紙機などで抄造し、網上に該繊維が平面状に均一に分散した紙層を形成する。その後、ドラムドライヤー、ヤンキードライヤー、熱風ドライヤーなどの乾燥機で繊維を融着して不織布の最終強度を得るものである。 The nonwoven fabric of the present invention can be produced by a wet papermaking method. After the fibers are uniformly mixed and dispersed in water with a disaggregator, the fibers are made with a circular paper machine, a long net paper machine, a slanted short paper machine, or a combination paper machine combining them, and the fibers are placed on the net. A paper layer uniformly dispersed in a plane is formed. Then, the final strength of the nonwoven fabric is obtained by fusing the fibers with a dryer such as a drum dryer, Yankee dryer or hot air dryer.
本発明を実施例に基づいて更に具体的に説明するが、本発明はこれら実施例などにより何ら限定されるものではない。不織布の特性測定結果を表１に示す。 The present invention will be described more specifically based on examples, but the present invention is not limited to these examples. The characteristic measurement results of the nonwoven fabric are shown in Table 1.
[実施例１]
平均繊維径４μｍ、繊維長３ｍｍのポリエステル短繊維６０質量％と平均繊維径１２μｍ、繊維長５ｍｍの共重合ポリエステル短繊維４０質量％を混合した後消泡剤を添加し、高速離解機（パルパー）で水分散し繊維分散液を調整した。この繊維分散液にポリエチレンオキサイドを添加し、１９０メッシュ相当の抄紙網を備えた傾斜短網抄紙機で抄紙し表面温度１５０℃のヤンキードライヤーで加熱乾燥し、坪量４ｇ／ｍ２の不織布を得た。この不織布を無機繊維マットの表面にあて熱接着して触媒担体保持材を作製した。
[Example 1]
After mixing 60% by mass of short polyester fibers with an average fiber diameter of 4μm and 3mm fiber length and 40% by mass of copolyester short fibers with an average fiber diameter of 12μm and fiber length of 5mm, an antifoaming agent is added and a high-speed disintegrator (pulper) To prepare a fiber dispersion. Polyethylene oxide is added to this fiber dispersion, paper is made with an inclined short net paper machine equipped with a paper mesh equivalent to 190 mesh, and heated and dried with a Yankee dryer having a surface temperature of 150 ° C. to obtain a nonwoven fabric having a basis weight of 4 g / m 2. It was. The nonwoven fabric was applied to the surface of the inorganic fiber mat and thermally bonded to prepare a catalyst carrier holding material.
[実施例２]
平均繊維径４μｍ、繊維長３ｍｍのポリエステル短繊維２０質量％と平均繊維径１１μｍ、繊維長５ｍｍの芯部ポリエステル／鞘部共重合ポリエステルの芯鞘型短繊維８０質量％を混合したこと、坪量を５ｇ／ｍ２としたこと以外は実施例１と同様にして触媒担体保持材を作製した。
[Example 2]
Mixing 20% by mass of polyester short fibers with an average fiber diameter of 4 μm and a fiber length of 3 mm and 80% by mass of core-sheath short fibers of an average fiber diameter of 11 μm and a fiber length of 5 mm of core polyester / sheath copolymer polyester, basis weight A catalyst carrier holding material was produced in the same manner as in Example 1 except that the amount was 5 g / m 2 .
[実施例３]
平均繊維径４μｍ、繊維長３ｍｍのポリエステル短繊維４０質量％と平均繊維径１２μｍ、繊維長５ｍｍの芯部ポリエステル／鞘部ポリエチレンの芯鞘型短繊維６０質量％を混合したこと、坪量を７ｇ／ｍ２としたこと以外は実施例１と同様にして触媒担体保持材を作製した。
[Example 3]
40% by mass of polyester short fibers having an average fiber diameter of 4 μm and a fiber length of 3 mm and 60% by mass of core-sheathed short fibers of core polyester / sheath polyethylene having an average fiber diameter of 12 μm and a fiber length of 5 mm were mixed, and the basis weight was 7 g. A catalyst carrier holding material was produced in the same manner as in Example 1 except that the ratio was / m 2 .
[実施例４]
平均繊維径１１μｍ、繊維長５ｍｍの芯部ポリエステル／鞘部共重合ポリエステルの芯鞘型短繊維１００質量％を用いたこと、坪量を６ｇ／ｍ２としたこと以外は実施例１と同様にして触媒担体保持材を作製した。
[Example 4]
Example 1 except that 100% by mass of core-sheath short fiber of core polyester / sheath copolymer polyester having an average fiber diameter of 11 μm and a fiber length of 5 mm was used, and the basis weight was 6 g / m 2. Thus, a catalyst carrier holding material was produced.
[比較例１]
坪量１９ｇ／ｍ２、厚み６８μｍのポリエチレン繊維からなる不織布を無機繊維マットの表面にあて熱接着した、熱接着により不織布は表面がフィルム状に溶融した。
[Comparative Example 1]
A nonwoven fabric made of polyethylene fibers having a basis weight of 19 g / m 2 and a thickness of 68 μm was thermally bonded to the surface of the inorganic fiber mat. The surface of the nonwoven fabric was melted into a film by thermal bonding.
[比較例２]
坪量２０ｇ／ｍ２、厚み５７μｍの芯部がポリエステル繊維で鞘部が共重合ポリエステル繊維からなる不織布を無機繊維マットの表面にあて熱接着した。熱接着により不織布は表面がフィルム状に溶融した。
[Comparative Example 2]
A nonwoven fabric having a basis weight of 20 g / m 2 , a thickness of 57 μm and a core portion made of polyester fibers and a sheath portion made of copolymerized polyester fibers was applied to the surface of the inorganic fiber mat and thermally bonded. The surface of the nonwoven fabric was melted into a film by heat bonding.
[比較例３]
坪量２ｇ／ｍ２、厚み１．８μｍのポリエステルフィルムを無機繊維マットの表面にアクリル系接着剤を用いて接着した。
[Comparative Example 3]
A polyester film having a basis weight of 2 g / m 2 and a thickness of 1.8 μm was bonded to the surface of the inorganic fiber mat using an acrylic adhesive.
[比較例４]
坪量４６ｇ／ｍ２、厚み５０μｍのポリエチレンフィルムを無機繊維マットの表面にアクリル系接着剤を用いて接着した。
[Comparative Example 4]
A polyethylene film having a basis weight of 46 g / m 2 and a thickness of 50 μm was adhered to the surface of the inorganic fiber mat using an acrylic adhesive.
表１に示すように、本願発明の触媒担体保持材は比較例と比べて熱接着時のフィルム化が防止でき、焼却性に優れ、摩擦係数の低減効果が優れている。 As shown in Table 1, the catalyst carrier holding material of the present invention can prevent film formation at the time of thermal bonding as compared with the comparative example, is excellent in incineration, and is excellent in the effect of reducing the friction coefficient.
通気度：
ＪＩＳＬ−１０９６：１９９９ ８．２７．１Ａ法により測定した。通気度が３００ｃｍ３／(ｃｍ２・s)を超える場合は２枚以上重ねて測定し、１枚あたりの通気度に換算した値を用いた。
坪量：
恒温恒湿（２０℃、６５％ＲＨ）で２４時間静置した試験片（３１．５ｃｍ×３１．５ｃｍ）１０枚の質量を測定した。
厚み：
ＪＩＳＰ−８１１８により測定した。
Air permeability:
Measured by JISL-1096: 1999 8.27.1A method. When the air permeability exceeded 300 cm 3 / (cm 2 · s), two or more sheets were stacked and measured, and the value converted into the air permeability per sheet was used.
Basis weight:
The mass of 10 test pieces (31.5 cm × 31.5 cm) that were allowed to stand at constant temperature and humidity (20 ° C., 65% RH) for 24 hours was measured.
Thickness:
It was measured by JISP-8118.
熱接着時フィルム化：
実施例及び比較例の不織布を無機繊維マットに熱接着した後、不織布表面を目視で評価した。不織布の空隙部が見られるものを○、不織布の空隙部が溶融した繊維により閉塞しフィルム状に見える場合を×とした。またフィルムは×とした。
焼却性：
実施例及び比較例の不織布或いはフィルムをアルミ平板に挟み込み加熱焼却テストを行った。ブランクとしてポリエチレンフィルムを用いた場合より熱重量減少速度が速いものを○、同等のものを△、遅いものを×とした。
摩擦係数の低減効果：
実施例及び比較例の不織布或いはフィルムを無機繊維マットに貼り付けＳＵＳ板との摩擦係数を測定した。
無機繊維マットとＳＵＳ板との摩擦係数に対して、摩擦係数に大幅な低下が見られたものを○、摩擦係数に若干低下が見られたものを△、摩擦係数の低下が見られなかったものを×とした。
Filming during thermal bonding:
After thermally bonding the nonwoven fabrics of Examples and Comparative Examples to the inorganic fiber mat, the surface of the nonwoven fabric was visually evaluated. The case where the void portion of the nonwoven fabric was observed was rated as “◯”, and the case where the nonwoven fabric void portion was blocked by the melted fiber and looked like a film was marked as “X”. Moreover, the film was set as x.
Incineration:
The nonwoven fabrics or films of Examples and Comparative Examples were sandwiched between aluminum flat plates, and a heat incineration test was performed. The case where the thermal weight reduction rate was faster than the case where a polyethylene film was used as a blank was indicated as ◯, the equivalent as △, and the slower as x.
Reduction effect of friction coefficient:
The nonwoven fabric or film of an Example and a comparative example was affixed on the inorganic fiber mat, and the friction coefficient with the SUS board was measured.
The friction coefficient between the inorganic fiber mat and the SUS plate was ○ when the friction coefficient was significantly reduced, △ when the friction coefficient was slightly decreased, and the friction coefficient was not decreased. The thing was made into x.
本発明の触媒担体保持材はガソリンエンジン、ディーゼルエンジン等の内燃機関から排出される排気ガス浄化装置（排気ガス浄化用触媒コンバータ又は単に触媒コンバータと呼ばれる）に組み込まれる触媒担体を金属容器内に保持するために有効であり、さらには耐熱ガスケット、耐熱フィルターなどとしても有効である。 The catalyst carrier holding material of the present invention holds a catalyst carrier incorporated in an exhaust gas purification device (referred to as an exhaust gas purification catalytic converter or simply a catalytic converter) discharged from an internal combustion engine such as a gasoline engine or a diesel engine in a metal container. It is also effective as a heat-resistant gasket, heat-resistant filter and the like.
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| JP2009138527A JP2010284571A (en) | 2009-06-09 | 2009-06-09 | Catalyst carrier holding material using nonwoven fabric containing heat-fusible fibers |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2013221414A (en) * | 2012-04-13 | 2013-10-28 | Nichias Corp | Holding material for gas-processing device, gas-processing device, and method relating to the same |
| CN103850764A (en) * | 2014-03-28 | 2014-06-11 | 北海市辉煌朗洁环保科技有限公司 | Screw fastening and sealing type casting housing catalytic muffler for high-emission commercial vehicle |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2000343634A (en) * | 1999-06-07 | 2000-12-12 | Mitsubishi Chemicals Corp | Heat resistant mat |
| JP2001032710A (en) * | 1999-07-22 | 2001-02-06 | Ibiden Co Ltd | Exhaust emission controlling catalytic converter and its manufacture |
-
2009
- 2009-06-09 JP JP2009138527A patent/JP2010284571A/en active Pending
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2000343634A (en) * | 1999-06-07 | 2000-12-12 | Mitsubishi Chemicals Corp | Heat resistant mat |
| JP2001032710A (en) * | 1999-07-22 | 2001-02-06 | Ibiden Co Ltd | Exhaust emission controlling catalytic converter and its manufacture |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2013221414A (en) * | 2012-04-13 | 2013-10-28 | Nichias Corp | Holding material for gas-processing device, gas-processing device, and method relating to the same |
| US9266063B2 (en) | 2012-04-13 | 2016-02-23 | Nichias Corporation | Holding material for gas treatment device, gas treatment device, and method relating to same |
| CN103850764A (en) * | 2014-03-28 | 2014-06-11 | 北海市辉煌朗洁环保科技有限公司 | Screw fastening and sealing type casting housing catalytic muffler for high-emission commercial vehicle |
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