JP2016011638A - 保持材、その製造方法及びそれを用いた気体処理装置 - Google Patents
保持材、その製造方法及びそれを用いた気体処理装置 Download PDFInfo
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- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/0211—Arrangements for mounting filtering elements in housing, e.g. with means for compensating thermal expansion or vibration
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- B01D46/0002—Casings; Housings; Frame constructions
- B01D46/0005—Mounting of filtering elements within casings, housings or frames
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- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
- F01N3/0226—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being fibrous
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- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
- F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
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- 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
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- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
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- 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
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- F01N3/285—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration specially adapted for fibrous supports, e.g. held in place by screens
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- 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
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- 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
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- 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
- F01N3/2864—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 the mats or gaskets comprising two or more insulation layers
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- D—TEXTILES; PAPER
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Abstract
Description
1.アルミナ60重量%以上とシリカ40重量%以下からなるアルミナ繊維を含む第1のマットと、
前記第1のマットより充填密度0.30g/cm3における面圧が高い、シリカ60重量%以上とアルミナ40重量%以下からなるシリカ繊維を含む第2のマットを、積層した保持材。
2.前記第1のマット及び/又は第2のマットは、さらに有機バインダーを1〜20重量%含む1記載の保持材。
3.前記保持材の厚さが、6mm〜20mmの範囲にある1又は2記載の保持材。
4.前記第1のマットが内側で、前記第2のマットを外側にした円筒状積層体である1〜3のいずれか記載の保持材。
5.気体処理装置に用いるための1〜4のいずれか記載の保持材。
6.アルミナ60重量%以上とシリカ40重量%以下からなるアルミナ繊維から第1のマットを作製し、
前記第1のマットより面圧が高い、シリカ60重量%以上とアルミナ40重量%以下からなるシリカ繊維から第2のマットを作製し、
前記第1のマットと前記第2のマットを積層して接合する保持材の製造方法。
7.筒状に形成された処理構造体と、
前記処理構造体を収容するケーシングと、
前記処理構造体と前記ケーシングとの間隙に介装される1〜5のいずれか記載の保持材とを具備し、
前記保持材の第1のマットが、前記処理構造体に接触する側にある
気体処理装置。
8.前記処理構造体が、触媒担持体又は排ガスフィルタである7記載の気体処理装置。
図1は、本発明の保持材を装着した気体処理装置の一実施形態を模式的に示す断面図である。図示される気体処理装置10は、筒状に形成された処理構造体1と、処理構造体1を収容するケーシング2と、処理構造体1に装着されて処理構造体1とケーシング2との間隙に介装された保持材3とから構成されている。そして、本発明に係る保持材3は、アルミナ繊維マット3A(第1のマット)とシリカ繊維マット3B(第2のマット)とを積層して構成される。
また、好ましくは、アルミナとシリカを98重量%以上又は100重量%(但し不可避不純物を含む)含む。
また、好ましくは、アルミナとシリカを98重量%以上又は100重量%含む(但し不可避不純物を含む)。
シリカ繊維マットの面圧は、アルミナ繊維マットより、好ましくは充填密度0.30g/cm3で1.2倍以上、より好ましくは1.3倍以上高い。または、好ましくは充填密度0.40g/cm3で1.4倍以上高い。
シリカ繊維は予め加熱処理して強度を高めることが好ましい。
無機バインダーとしては、例えば、アルミナゾル、シリカゾル等が挙げられる。また有機バインダーとしては、例えば、ゴム系材料、水溶性有機高分子化合物、熱可塑性樹脂、熱硬化性樹脂等が挙げられる。
また、有機バインダーとしてパルプ等の有機繊維を少量配合する事も可能である。凝集剤としては、例えばポリアクリルアミド系高分子化合物等が挙げられる。
また、本発明の保持材は、又は第1のマットと第2のマットは、それぞれ、無機繊維と有機バインダーを合わせて90重量%以上、95重量%以上又は100重量%(不可避不純物を含んで)含むことができる。本発明の保持材は例えば焼成することにより、有機バインダーを焼失されてもよい。
保持材の厚みは限定されないが、通常6mm〜20mmである。アルミナ繊維マットとシリカ繊維マットの厚みは、それぞれ、通常3mm〜10mmである。アルミナ繊維マットとシリカ繊維マットの厚みは、同じでも異なってもよい。アルミナ繊維マット3Bによる耐熱性と、シリカ繊維マット3Bによる高い面圧とをバランス良く発現するには、アルミナ繊維マット3Aが全厚の35〜80%、シリカ繊維マット3Bが全厚の20〜65%とすることが好ましい。
本発明において、アルミナ繊維マットは、シリカ繊維マットより、耐熱性が高いが、面圧は低い。一方、シリカ繊維マットは、アルミナ繊維マットより、耐熱性は低いが面圧は高い。保持材は、圧縮された状態で、処理構造体とケーシングの間に装着される。気体処理装置は使用時に1000℃まで加熱され得る。その際、金属製のケーシングが膨張するので、圧縮は弱まる。使用が停止されると冷却され、ケーシングが収縮すると、圧縮は強まる。本発明では、圧縮が強まるときアルミナ繊維マットが主として潰れる。すなわち、アルミナ繊維は潰れて繊維が折れるが、潰れないシリカ繊維は、繊維折損が起こらず、高い面圧を発揮し続ける。アルミナ繊維は、荷重負荷に対してクッション材として機能し得る。
2つのマットを、それぞれ独立に製造してから、これらのマットを積層界面で接合して、両者が積層された保持材を得る方法がある。接着剤、縫合等で接合できる。例えば、アルミナ繊維及び有機バインダーを含有するスラリーを調製し、吸引脱水成形し、アルミナ繊維湿潤マット3Aを得る。次いで、同様にシリカ繊維湿潤マットを得る。アルミナ繊維湿潤マット3Aとシリカ繊維シリカ繊維マットを重ね、熱プレスして、マットの界面付近に含まれる有機バインダーを融着させる。得られた積層体を所定の厚さに圧縮する。
アルミナ繊維(96.0重量%のAl2O3及び4.0重量%のSiO2)と、有機バインダー(アクリル樹脂)(無機繊維と有機バインダーの合計100重量%に対し10重量%)とを水に分散させることにより、水性スラリーを調製した。
次いで、金網を有する脱水成形型に水性スラリーを流し込み、脱水成形して、アルミナ繊維製湿潤成形体を得た。
積層成形体を円板形状に加工し、700℃で1時間加熱して焼成することにより、直径が50.8mm、厚さが10mmの円板形状である保持材を得た。保持材は、アルミナ繊維製マット700g/m2、シリカ繊維製マット900g/m2の積層体であった。
シリカ繊維を使用しないで、アルミナ繊維だけを使用した他は、実施例1と同様にして、保持材を製造した。保持材は、アルミナ繊維製マット1600g/m2の単層体であった。
尚、上記と同様にして厚さ8mmのマットを製造した。作製したマットについて以下の方法で面圧を測定したところ、充填密度0.30g/cm3で20.4N/cm2、0.40g/cm3で44.5N/cm2、0.50g/cm3で75.8N/cm2であった。
・充填密度(g/cm3)=マットm2あたりの重量(g/m2)/圧縮ストローク量(mm)/1000
・面圧値(N/cm2)=圧縮による発生荷重(N)/試験体面積(cm2)
アルミナ繊維を使用しないで、シリカ繊維だけを使用したこと他は、比較例1と同様にして、保持材を製造した。保持材は、シリカ繊維製マット1600g/m2の単層体であった。
尚、上記と同様にして厚さ8mmのマットを製造した。作製したマットの面圧を比較例1と同様にして測定したところ、充填密度0.30g/cm3で26.9N/cm2、0.40g/cm3で69.6N/cm2、0.50g/cm3で127.4N/cm2、0.60g/cm3で192.0N/cm2であった。
図2に示す試験装置40(島津(株)製熱間面圧試験機サーボパルサー)を使用して、保持材の熱間面圧試験を行い、保持材の面圧を測定した。試験装置40は、インコネル(登録商標)製の円板(直径80mm、厚さ30mm)である上圧盤41(処理構造体に相当する部材)と、上圧盤41に対向して配置されるインコネル(登録商標)製の円板(直径80mm、厚さ30mm)である下圧盤42(ケーシングに相当する部材)とを備えていた。
図2に示す試験治具を用いて、厚さ10mmの保持材を、荷重をかけて5mmまで圧縮し400℃に加熱した。その後、治具を離して圧縮を解放し、復元状態を観察した。
実施例1の保持材の復元率は、約180%、比較例1の保持材は、約110%、比較例2の保持材は、約160%であった。復元率が高いことは、加熱されたときのケース膨張に対する面圧が高いことを意味する。
実施例1の保持材は、アルミナ製マットの耐熱性を有するとともに、アルミナ製マットが、シリカ製マットより優先的に潰れることにより、シリカ製マットのダメージを低減でき、面圧の低減を抑制できる。
2 ケーシング
3 保持材
3A アルミナ繊維マット
3B シリカ繊維マット
10 気体処理装置
20 保持材
40 試験装置
41 上圧盤
42 下圧盤
Claims (8)
- アルミナ60重量%以上とシリカ40重量%以下からなるアルミナ繊維を含む第1のマットと、
前記第1のマットより充填密度0.30g/cm3における面圧が高い、シリカ60重量%以上とアルミナ40重量%以下からなるシリカ繊維を含む第2のマットを、積層した保持材。 - 前記第1のマット及び/又は第2のマットは、さらに有機バインダーを1〜20重量%含む請求項1記載の保持材。
- 前記保持材の厚さが、6mm〜20mmの範囲にある請求項1又は2記載の保持材。
- 前記第1のマットが内側で、前記第2のマットを外側にした円筒状積層体である請求項1〜3のいずれか記載の保持材。
- 気体処理装置に用いるための請求項1〜4のいずれか記載の保持材。
- アルミナ60重量%以上とシリカ40重量%以下からなるアルミナ繊維から第1のマットを作製し、
前記第1のマットより面圧が高い、シリカ60重量%以上とアルミナ40重量%以下からなるシリカ繊維から第2のマットを作製し、
前記第1のマットと前記第2のマットを積層して接合する保持材の製造方法。 - 筒状に形成された処理構造体と、
前記処理構造体を収容するケーシングと、
前記処理構造体と前記ケーシングとの間隙に介装される請求項1〜5のいずれか記載の保持材とを具備し、
前記保持材の第1のマットが、前記処理構造体に接触する側にある
気体処理装置。 - 前記処理構造体が、触媒担持体又は排ガスフィルタである請求項7記載の気体処理装置。
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