JP4129459B2 - 改質触媒用不織布および織布 - Google Patents

改質触媒用不織布および織布 Download PDF

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JP4129459B2
JP4129459B2 JP2005034712A JP2005034712A JP4129459B2 JP 4129459 B2 JP4129459 B2 JP 4129459B2 JP 2005034712 A JP2005034712 A JP 2005034712A JP 2005034712 A JP2005034712 A JP 2005034712A JP 4129459 B2 JP4129459 B2 JP 4129459B2
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noble metal
reforming catalyst
polymer
length direction
nonwoven fabric
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JP2006218413A (ja
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正道 三倉
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有限会社末富エンジニアリング
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    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01DMECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00Formation of filaments, threads, or the like
    • D01D5/28Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30Conjugate filaments; Spinnerette packs therefor
    • D01D5/36Matrix structure; Spinnerette packs therefor
    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/242Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
    • D03D15/25Metal
    • D03D15/258Noble metal
    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/242Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
    • D03D15/275Carbon fibres
    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/292Conjugate, i.e. bi- or multicomponent, fibres or filaments
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/002Inorganic yarns or filaments
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust 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
    • F01N3/24Exhaust 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
    • F01N3/28Construction of catalytic reactors
    • F01N3/2803Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2835Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support fibrous
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00Inorganic fibres
    • D10B2101/10Inorganic fibres based on non-oxides other than metals
    • D10B2101/12Carbon; Pitch
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00Inorganic fibres
    • D10B2101/20Metallic fibres
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2240/00Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
    • F01N2240/30Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a fuel reformer
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2310/00Selection of sound absorbing or insulating material
    • F01N2310/14Wire mesh fabric, woven glass cloth or the like
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/10Fibrous material, e.g. mineral or metallic wool
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/18Composite material
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/20Plastics, e.g. polymers, polyester, polyurethane
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2370/00Selection of materials for exhaust purification
    • F01N2370/02Selection of materials for exhaust purification used in catalytic reactors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2510/00Surface coverings
    • F01N2510/06Surface coverings for exhaust purification, e.g. catalytic reaction
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3065Including strand which is of specific structural definition
    • Y10T442/3089Cross-sectional configuration of strand material is specified
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608Including strand or fiber material which is of specific structural definition
    • Y10T442/609Cross-sectional configuration of strand or fiber material is specified
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608Including strand or fiber material which is of specific structural definition
    • Y10T442/609Cross-sectional configuration of strand or fiber material is specified
    • Y10T442/611Cross-sectional configuration of strand or fiber material is other than circular

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Toxicology (AREA)
  • Combustion & Propulsion (AREA)
  • Health & Medical Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Catalysts (AREA)
  • Nonwoven Fabrics (AREA)
  • Fuel Cell (AREA)
  • Hydrogen, Water And Hydrids (AREA)

Description

この発明は、燃料電池に用いる水素燃料を得る際に、改質触媒として用いる不織布等に関する。
近年新たなエネルギー発電装置として、燃料電池が脚光を浴びている。燃料電池は、燃料となる水素と、空気中の酸素とを化学反応させることにより電気を作り出す仕組みであり、その発電効率の高さと環境に対する負荷の低さから、さまざまな利用法が模索されている。
ここで燃料となる水素は空気中にほとんど存在しないため、通常は都市ガスに含まれるメタノール等に水蒸気を反応させて作り出されており、その際に触媒として白金等の貴金属が用いられる。
例えば、特許文献1には、白金を担持した所定の元素とZrとの複合酸化物を含有する改質触媒が提案されている。
しかしこのような構成では、貴金属の量が多くなるため、結果的に水素燃料の製造コストが高くなる問題があった。
特開2002−121006号公報
そこでこの発明の解決しようとする課題は、燃料電池用の水素燃料を得るための都市ガス等の改質触媒において、貴金属の量を減らすことで水素燃料製造コストの低減を図ることである。
上記した課題を解決するため、この発明は、カーボン繊維の外周面に、一定の間隔をおいて長さ方向に連続する複数の凹入面を設け、各凹入面に長さ方向に連続する筋状貴金属部を埋没させた、断面円形の複合繊維からなる改質触媒用不織布を形成したのである。ここで貴金属とは白金、パラジウム、ロジウム、イリジウム、ルテニウム等希少でありかつ化学的に安定した触媒に用いるのに好適な金属をいう。
また、この発明は、カーボン繊維の外周面に、一定の間隔をおいて長さ方向に連続する複数の凹入面を設け、各凹入面に長さ方向に連続する筋状貴金属部を埋没させた、断面円形の複合繊維からなる改質触媒用織布を形成したのである。
前記繊維の径は5μm〜100μmであるのが好ましい。
改質触媒用不織布または織布を、カーボン繊維の外周面に、一定の間隔をおいて長さ方向に連続する複数の凹入面を設け、各凹入面に長さ方向に連続する筋状金属部を埋没させた、断面円形の複合繊維から形成することにより、外周面は貴金属で覆われているため、改質触媒としての性能は維持しつつも、貴金属の量が従来の金属板等からなる改質触媒とは比較にならないほど減少させることができる。そのため、結果的に水素燃料製造コストを低減することができる。また、同じく貴金属の減量により改質触媒の重量を軽減することができる。さらに、改質触媒が主にカーボン繊維で出来ているため柔軟で加工が容易となり、製品としての応用範囲が広がる。
また、改質触媒を不織布とすることで表面積を従来の金属板等に比べて飛躍的に増大させることができるため、触媒反応の効率を上げることができる。
繊維の径を5μm〜100μmとすることで、製品として繰り返しの使用に耐える強度を保持しつつ、表面積を増大させ触媒反応の効率を上げることができる。
以下、図面を参照しつつこの発明の実施の形態について説明する。ここでは、この発明にかかる改質触媒用不織布12を、メルトブロー法により製造する方法を述べる。
まず、原料となるポリマー10aと貴金属粉末を混入したポリマー10bを用意する。ポリマー10aとしては、石油ピッチ、石炭ピッチおよびエポキシ樹脂、フェノール樹脂等の熱硬化性樹脂または、硬化剤を混入した溶融紡糸可能な樹脂が用いられる。貴金属としては、白金、パラジウム、ロジウム、イリジウム、ルテニウムなどが用いられ、後に還元処理することを条件に塩化白金、酸化白金などの金属塩で代替することもできる。貴金属粉末の粒径は3μ以下であるのが好ましく、ポリマーへの混入率は40容量%未満であるのが好ましい。
この原料10a、10bを図1に示すようにホッパ20a、20bに投入し、押出機30a、30bで加熱溶融し、ダイ40に供給して繊維11として紡出し、紡出した繊維11を捕集ネットからなるコンベア50上にシート状に堆積させこれをコンベア50から剥離しながら、場合によりカレンダロール60を通過させた後、巻取機70で巻き取って不織布12を製造するのがメルトブロー法の概略工程である。
繊維11を、図2のようにポリマー10aからなる軸繊維11aの外周に、等間隔に4つの断面円弧状の凹入面を設け、そこに貴金属を混入したポリマー10bからなる内周が前記凹入面の断面円弧状に対応して円弧状に膨らみ、外周が軸繊維11a外周の凹入面を除いた部分の両端を延長した断面円形に対応して円弧状に膨らんだ筋状部11bを埋没させ、全体として断面円形となる複合繊維とするには、図3(a)、(b)のようなダイ40を用いる。
図3(a)のようにダイ40は、軸ポリマー導入口40aから導入された溶融したポリマー10aと、貴金属混入ポリマー導入口40bから導入された溶融した貴金属混入ポリマー10bとを複合部40cで合流させる。図3(b)のように複合部40cでは、外周等間隔に四方が凹入した直進する軸ポリマー流路40dと、前記凹入した四方を埋め合わせるように、4つの貴金属混入ポリマー流路40eが形成され、溶融した貴金属を混入したポリマーが溶融したポリマーを軸としてその四方に埋没して取り巻くようにして合流し、全体として断面円形を形成するようになっている。さらに図3(a)のように、こうしてできたものを紡糸口40fから吐出し、熱風導入口40gを経て熱風吐出スリット40hから噴出した高温のエアーで紡出する仕組みとなっている。なお、このようにして形成された複合繊維11は、ポリマーからなる軸繊維11aの一部が外周面に露出しているため、メルトブロー法による繊維の自己接着積層に支障が生じない。
こうしてできた不織布12をさらに、1500℃から1600℃の間で焼成し、黒鉛化処理を施してポリマーをカーボン繊維にすることで改質触媒用不織布が完成する。このようにしてできた改質触媒は、従来の金属板等と異なり柔軟なカーボン繊維から成る不織布でできているため、加工が容易で製品としての応用範囲が広がる。なお、貴金属の替わりに貴金属塩を用いた場合には、同時に金属還元処理を施して金属単体に還元する。また、必要に応じて不融化処理を施してもよい。
この実施の形態では不織布12をメルトブロー法により製造したがこれに限られず、ニードルパンチ法、スパンレース法、スパンボンド法など公知の製法で製造することができる。また、複合繊維11で織布を製造してもよく、その場合も織機を使った公知の製法が用いられる。
このようにして形成された繊維の径は、製品として使用に耐える十分な強度を保持しつつも、触媒効率を考えると可能な限り小さくすることが望ましいため、約1μm〜50μmとするのがよい。
メルトブロー法の概略図 複合繊維の拡大斜視図 (a)はダイの縦断面図、(b)はその矢印横断面図
符号の説明
10a ポリマー
10b 貴金属混入ポリマー
11 繊維
11a 軸繊維
11b 筋状部
12 不織布
20a、20b ホッパ
30a、30b 押出機
40 ダイ
40a 軸ポリマー導入口
40b 貴金属混入ポリマー導入口
40c 複合部
40d 軸ポリマー流路
40e 貴金属混入ポリマー流路
40f 紡糸口
40g 熱風導入口
40h 熱風吐出スリット
50 コンベア
60 カレンダロール
70 巻取機

Claims (3)

  1. カーボン繊維の外周面に、一定の間隔をおいて長さ方向に連続する複数の凹入面を設け、各凹入面に長さ方向に連続する筋状貴金属部を埋没させた、断面円形の複合繊維からなる改質触媒用不織布。
  2. カーボン繊維の外周面に、一定の間隔をおいて長さ方向に連続する複数の凹入面を設け、各凹入面に長さ方向に連続する筋状貴金属部を埋没させた、断面円形の複合繊維からなる改質触媒用織布。
  3. 前記複合繊維の径は5μm〜100μmである請求項1に記載の不織布または請求項2に記載の織布。
JP2005034712A 2005-02-10 2005-02-10 改質触媒用不織布および織布 Expired - Fee Related JP4129459B2 (ja)

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US11/325,426 US20060178068A1 (en) 2005-02-10 2006-01-05 Non-woven and woven fabric for use as reforming catalyst

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US4583299A (en) * 1984-12-20 1986-04-22 Trw Inc. Fluidization aid for cohesive materials
US5037697A (en) * 1986-01-22 1991-08-06 Nitto Boseki Co., Ltd. Carbon fiber and process for producing the same
US5326633A (en) * 1986-03-24 1994-07-05 Ensci, Inc. Coated substrates
EP0421944A3 (en) * 1989-08-31 1992-06-17 Tanaka Kikinzoku Kogyo K.K. Composite carbon fibre and process for preparing same
WO1998053897A1 (en) * 1997-06-02 1998-12-03 Hitco Carbon Composites, Inc. High performance filters
FR2771309B1 (fr) * 1997-11-24 2000-02-11 Messier Bugatti Elaboration de support de catalyseur en fibres de carbone active
AU2003252658A1 (en) * 2002-07-17 2004-02-02 Bussan Nanotech Research Institute Inc. Method for producing fine carbon fiber
US7501012B2 (en) * 2003-08-26 2009-03-10 Auburn University Microfibrous entrapment of small reactive particulates and fibers for high contacting efficiency removal of contaminants from gaseous or liquid streams

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