JP4138079B2 - Manufacturing method of exhaust gas purification catalyst converter - Google Patents
Manufacturing method of exhaust gas purification catalyst converter Download PDFInfo
- Publication number
- JP4138079B2 JP4138079B2 JP16632998A JP16632998A JP4138079B2 JP 4138079 B2 JP4138079 B2 JP 4138079B2 JP 16632998 A JP16632998 A JP 16632998A JP 16632998 A JP16632998 A JP 16632998A JP 4138079 B2 JP4138079 B2 JP 4138079B2
- Authority
- JP
- Japan
- Prior art keywords
- holding
- exhaust gas
- metal shell
- catalyst
- sealing material
- 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.)
- Expired - Fee Related
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- Exhaust Gas After Treatment (AREA)
Description
【０００１】
【産業上の利用分野】
本発明は、排気ガス浄化用触媒コンバーター、特に自動車等の排気ガス浄化用触媒コンバーターの製造方法に関する。
【０００２】
【従来の技術】
従来、主として車両に搭載する排気ガス浄化用触媒コンバーターにおいては、触媒保持体と前記触保持体の外方を覆う金属製シェルと、両者の間に配置した保持シール材よりなる。
前記触媒保持体には白金等の触媒が担持されている。触媒保持体としては、例えばその断面をハニカム状に成形したコージェライト担体を用いる。
【０００３】
次に、保持シール材について、現在バーミキュライトとセラミックファイバー等との混合物である熱膨張性保持シール材が主であるが、近年、排気ガス規制の強化により排気ガス温度が著しく上昇しており、従来の熱膨張性保持シール材では耐熱性が不足であるため、近年、無機繊維のマット状物からなる無膨張性保持シール材が用いられつつある。
前記保持シ−ル材は、自動車の走行中等において触媒保持体が外周の金属製シェルと当接することによる破損を防ぎ、また、金属製シェルと触媒保持体との間から排気ガスがリークすることを防ぐために用いられている。
【０００４】
前記保持シ−ル材を用いて排気ガス浄化用コンバーターを製造する方法は、外周の金属製シェルを予め二分割しておいて、触媒保持体に巻き付けた保持シ−ル材を挟み込む方法（キャニング）が一般的である。
また、作業性の向上等から、金属製シェルを最初からパイプ状にしておき、保持シール材を触媒保持体に巻き付けたのち、かかるパイプ内へ圧入する方法が実施されている。
【０００５】
尚、前記無機繊維のマット状物からなる無膨張性保持シール材については、無機繊維のマット状物が嵩高いため、前記触媒保持体への組み付け性を改善する必要があり、特開昭５７−１４６９５４、特開昭５９−１２６０２３等に挙げられているように、有機フィルムを用いて真空パックする方法や、無機繊維のマット状物に、有機バインダーを含浸，塗布することにより、マット状物の厚みを小さくする試みがなされている。
【０００６】
【発明が解決しようとする課題】
前記パイプ内へ圧入する方法で排気ガス浄化用触媒コンバーターを組み立てる場合、結晶質アルミナ繊維のマット状物からなる前記保持シ−ル材を、前記触媒保持体の外側に予め巻き付けたのち、これを円筒状金属製シェルの中に圧入する際、保持シ−ル材が金属製シェルに引っ掛かり挿入できないという問題点があった。
【０００７】
【課題を解決するための手段】
上掲の問題点に関して鋭意研究した結果、下記要旨構成にかかる本発明に想到した。
即ち、本発明は、触媒保持体と、前記触媒保持体の外方を覆う円筒状金属シェルとの間に配置する結晶質アルミナ繊維のマット状物の片側端部に有機バインダーを含浸させることにより、マットの厚み方向に傾斜を持たせた物であり、かかる保持シール材を前記触媒保持体に巻き付けたのち、厚み方向に傾斜を持たせた側より、前記円筒状金属シェルに挿入し、この時の保持シール材の充填密度が０．１〜０．６ｇ／ｃｍ3 の範囲内にあることを特徴とする排気ガス浄化用コンバーターの製造方法である。
さらには、前記保持シ−ル材の傾斜を持たせた部位の樹脂含有率が１〜１０％であることを特徴とする排気ガス浄化用触媒コンバーターの製造方法である。
【０００８】
まず、前記触媒保持体としては、例えばハニカム状のものを用いる。また、前記触媒保持体には、例えばコージェライト等により作成する。
次に、前記保持シール材は、結晶質アルミナ繊維のマット状物を用いる。一般に、結晶質アルミナ繊維のマット状物は嵩高い為、これを円筒状金属製シェルの中に圧入する際、マットが金属製シェルに引っ掛かり挿入できない。従って、本発明においては、前記保持シ−ル材を構成するアルミナ繊維のマット状物の片側端部に有機バインダーを含浸させることにより、マットの厚み方向に傾斜を持たせ、この傾斜を持たせた側より前記円筒状金属シェル内に圧入することにより、マットが金属シェルに引っ掛からないで挿入できる。
【０００８】
また、前記保持シール材の片側端部に傾斜を持たせる手段としては、かかる部位にＮＢＲ，ＳＢＲ等の有機バインダーを含浸させ形状保持させることが有効であり、かかる有機バインダーの含有率は１〜１０ｗｔ％である。ここで、有機バインダーの含有率が１％未満の場合、アルミナ繊維の反発力が高いため、傾斜のついた状態を維持することが困難であり、一方、含有率が１０％を越えると、排気ガス中の有機成分が多くなり、環境に悪影響を与える。
【０００９】
また、かかる保持シール材は触媒保持体と金属シェルとの間に、０．１〜０．６ｇ／ｃｍ3 の範囲内の充填密度で配置する必要がある。これは、充填密度が０．１ｇ／ｃｍ3 未満の場合、振動等によって触媒保持体がズレるのを防止するための必要面圧を確保することが困難であり、一方、０．６ｇ／ｃｍ3 より大きくすると繊維が圧壊してしまい耐久性が劣化してしまう。
【００１０】
【実施例】
実施例１
触媒保持体として外径φ１３０ｍｍ、長さ１００ｍｍのコージェライトモノリスを用いた。また円筒状金属シェルにはサイズが外径φ１４１ｍｍ、板厚１．５ｍｍ、ＳＵＳ３０４を用い、保持シール材として嵩密度０．２ｇ／ｃｍ3 、厚み２５ｍｍの結晶質アルミナ繊維のマット状物を用い、かかるマット状物の片側端部には有機バインダー（ＮＢＲ）を４ｗｔ％含浸させ、厚み方向に傾斜を持たせることにより、最も厚みの薄い部分が４ｍｍとなるように調整した。
【００１１】
前記保持シール材を、前記触媒保持体に巻き付けたのち、保持シール時の合わせ部を粘着テープで仮止めした後、保持シ−ル材の傾斜を持たせた端部側より円筒状金属シェルに挿入した。挿入の際、保持シ−ル材が金属シェルに引っ掛かることなく、容易に金属シェル内に圧入が可能であった。
【００１２】
実施例２
実施例１と同じ構造であるが、有機バインダー使用量のみ１０ｗｔ％とし、実施例１と同様に保持シ−ル材の傾斜を持たせた端部側より、円筒状金属シェル内への挿入を試みた結果、保持シ−ル材が金属シェルに引っ掛かることなく、容易に金属シェル内に圧入が可能であった。
【００１３】
比較例
実施例１と同じ構造であるが、有機バインダー使用量のみ０．５ｗｔ％とし、実施例１と同様に保持シ−ル材の傾斜を持たせた端部側より、円筒状金属シェル内への挿入を試みた結果、保持シ−ル材が金属シェルに引っ掛かり、金属シェル内に圧入出来なかった。
【００１４】
【発明の効果】
このように、前記保持シ−ル材を構成する、結晶質アルミナ繊維のマット状物の片側端部に有機バインダーを１〜１０ｗｔ％含浸させることにより、マットの厚み方向に傾斜を持たせた物であり、かかる保持シール材を前記触媒保持体に巻き付けたのち、厚み方向に傾斜を持たせた側より、前記円筒状金属シェル内へ挿入することにより、生産性を飛躍的に改善することが可能となる。[0001]
[Industrial application fields]
The present invention relates to an exhaust gas purifying catalytic converter, and more particularly to a method for manufacturing an exhaust gas purifying catalytic converter for an automobile or the like.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, an exhaust gas purifying catalytic converter mainly mounted on a vehicle includes a catalyst holder, a metal shell that covers the outside of the contact holder, and a holding seal member disposed between the two.
A catalyst such as platinum is supported on the catalyst holder. As the catalyst holding body, for example, a cordierite carrier whose cross section is formed in a honeycomb shape is used.
[0003]
Next, with regard to the holding seal material, the heat expansion holding seal material, which is currently a mixture of vermiculite and ceramic fibers, is mainly used, but in recent years, exhaust gas temperature has been remarkably increased due to stricter exhaust gas regulations. Since the heat-expandable holding sealing material is insufficient in heat resistance, a non-expandable holding sealing material made of an inorganic fiber mat-like material is being used in recent years.
The holding seal material prevents damage due to the catalyst holder coming into contact with the metal shell on the outer periphery during traveling of an automobile, etc., and exhaust gas leaks from between the metal shell and the catalyst holder. It is used to prevent
[0004]
The method of manufacturing the converter for purifying exhaust gas using the holding seal material is a method in which the outer peripheral metal shell is divided into two in advance and the holding seal material wrapped around the catalyst holding body is sandwiched (canning). ) Is common.
In order to improve workability, a method has been implemented in which a metal shell is formed into a pipe shape from the beginning, and a holding sealing material is wound around a catalyst holding body and then press-fitted into the pipe.
[0005]
Incidentally, the non-intumescent holding sealing material made of the inorganic fiber mat is required to improve the assemblability to the catalyst holder because the inorganic fiber mat is bulky. As described in JP-A-146954 and JP-A-59-126023, a mat-like product is obtained by vacuum packing using an organic film or by impregnating and applying an organic binder to a mat-like product of inorganic fibers. Attempts have been made to reduce the thickness.
[0006]
[Problems to be solved by the invention]
When assembling the exhaust gas purifying catalytic converter by press-fitting into the pipe, the holding seal material made of crystalline alumina fiber mat is wound around the catalyst holding body in advance, When press-fitting into a cylindrical metal shell, there is a problem that the holding seal material is caught in the metal shell and cannot be inserted.
[0007]
[Means for Solving the Problems]
As a result of earnest research on the above-mentioned problems, the present inventors have arrived at the present invention according to the following summary configuration.
That is, the present invention impregnates an organic binder at one end of a crystalline alumina fiber mat-like material disposed between a catalyst holder and a cylindrical metal shell covering the outside of the catalyst holder. The mat is provided with an inclination in the thickness direction, and after the holding sealing material is wound around the catalyst holder, it is inserted into the cylindrical metal shell from the side provided with the inclination in the thickness direction. The exhaust gas purifying converter manufacturing method is characterized in that the packing density of the holding sealing material at the time is in the range of 0.1 to 0.6 g / cm 3 .
Further, the present invention provides the method for producing a catalytic converter for purifying exhaust gas, wherein the resin content of the portion where the holding seal material is inclined is 1 to 10%.
[0008]
First, as the catalyst holding body, for example, a honeycomb-shaped one is used. The catalyst holder is made of, for example, cordierite.
Next, a crystalline alumina fiber mat is used as the holding sealing material. In general, since the mat-like material of crystalline alumina fibers is bulky, the mat cannot be caught and inserted into the metal shell when it is press-fitted into the cylindrical metal shell. Therefore, in the present invention, an organic binder is impregnated into one end of the alumina fiber mat that constitutes the holding seal material, thereby providing an inclination in the thickness direction of the mat. The mat can be inserted without being caught by the metal shell by press-fitting into the cylindrical metal shell from the other side.
[0008]
Further, as a means for inclining one end of the holding sealing material, it is effective to impregnate such a part with an organic binder such as NBR, SBR, etc., and the content of the organic binder is 1 to 10 wt%. Here, when the content of the organic binder is less than 1%, the repulsive force of the alumina fiber is high, so it is difficult to maintain the inclined state. On the other hand, when the content exceeds 10%, the exhaust gas is exhausted. The organic component in the gas increases, which adversely affects the environment.
[0009]
Further, such a holding sealing material needs to be arranged between the catalyst holding body and the metal shell with a packing density in the range of 0.1 to 0.6 g / cm 3 . This is because when the packing density is less than 0.1 g / cm 3, it is difficult to secure a necessary surface pressure for preventing the catalyst holder from being displaced due to vibration or the like, while 0.6 g / cm 3. If it is larger, the fibers are crushed and the durability is deteriorated.
[0010]
【Example】
Example 1
A cordierite monolith having an outer diameter of 130 mm and a length of 100 mm was used as the catalyst holder. In addition, the cylindrical metal shell uses an outer diameter of φ141 mm, a plate thickness of 1.5 mm, and SUS304, and uses a crystalline alumina fiber mat having a bulk density of 0.2 g / cm 3 and a thickness of 25 mm as a holding sealing material. One end of the mat-like material was impregnated with 4 wt% of an organic binder (NBR) and inclined in the thickness direction so that the thinnest portion was adjusted to 4 mm.
[0011]
After wrapping the holding sealing material around the catalyst holding body, temporarily fix the mating part at the time of holding sealing with an adhesive tape, and then attach it to the cylindrical metal shell from the end side where the holding seal material is inclined. Inserted. During insertion, the holding seal material could be easily pressed into the metal shell without being caught by the metal shell.
[0012]
Example 2
Although it is the same structure as Example 1, only the organic binder usage-amount shall be 10 wt%, and it inserts in a cylindrical metal shell from the edge part side which gave the inclination of the holding seal material similarly to Example 1. As a result, it was possible to easily press-fit the holding seal material into the metal shell without being caught by the metal shell.
[0013]
Comparative Example The structure is the same as in Example 1, but only the amount of organic binder used is 0.5 wt%, and in the cylindrical metal shell from the end side where the holding seal material is inclined as in Example 1. As a result of trying to insert into the metal shell, the holding seal material was caught by the metal shell and could not be press-fitted into the metal shell.
[0014]
【The invention's effect】
Thus, the thing which gave the inclination to the thickness direction of the mat | matte by impregnating 1-10 wt% of organic binders in the one side edge part of the mat-like thing of the crystalline alumina fiber which comprises the said holding seal material. After winding the holding sealing material around the catalyst holding body and inserting it into the cylindrical metal shell from the side inclined in the thickness direction, the productivity can be drastically improved. It becomes possible.
Claims (2)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP16632998A JP4138079B2 (en) | 1998-05-30 | 1998-05-30 | Manufacturing method of exhaust gas purification catalyst converter |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP16632998A JP4138079B2 (en) | 1998-05-30 | 1998-05-30 | Manufacturing method of exhaust gas purification catalyst converter |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH11343846A JPH11343846A (en) | 1999-12-14 |
| JP4138079B2 true JP4138079B2 (en) | 2008-08-20 |
Family
ID=15829353
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP16632998A Expired - Fee Related JP4138079B2 (en) | 1998-05-30 | 1998-05-30 | Manufacturing method of exhaust gas purification catalyst converter |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP4138079B2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH08282944A (en) * | 1995-04-19 | 1996-10-29 | Yamaguchi Shokai:Kk | Domestic elevator and its construction method |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR100518111B1 (en) | 2000-03-22 | 2005-10-04 | 이비덴 가부시키가이샤 | Catalyst converter and diesel particulate filter system |
| JP2002070544A (en) * | 2000-08-25 | 2002-03-08 | Ibiden Co Ltd | Holding seal material used in catalyst converter for exhaust emission control |
| JP2007162583A (en) * | 2005-12-14 | 2007-06-28 | Toyota Motor Corp | Seal member for catalytic converter, and catalytic converter |
| JP6421636B2 (en) * | 2015-02-18 | 2018-11-14 | 三菱ケミカル株式会社 | Retaining material for exhaust gas purification equipment |
-
1998
- 1998-05-30 JP JP16632998A patent/JP4138079B2/en not_active Expired - Fee Related
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH08282944A (en) * | 1995-04-19 | 1996-10-29 | Yamaguchi Shokai:Kk | Domestic elevator and its construction method |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH11343846A (en) | 1999-12-14 |
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