JP4268182B2 - 排気ガス処理装置およびその製造方法 - Google Patents
排気ガス処理装置およびその製造方法 Download PDFInfo
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- JP4268182B2 JP4268182B2 JP2006266376A JP2006266376A JP4268182B2 JP 4268182 B2 JP4268182 B2 JP 4268182B2 JP 2006266376 A JP2006266376 A JP 2006266376A JP 2006266376 A JP2006266376 A JP 2006266376A JP 4268182 B2 JP4268182 B2 JP 4268182B2
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 39
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 22
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- LCCNCVORNKJIRZ-UHFFFAOYSA-N parathion Chemical compound CCOP(=S)(OCC)OC1=CC=C([N+]([O-])=O)C=C1 LCCNCVORNKJIRZ-UHFFFAOYSA-N 0.000 description 5
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- VSCWAEJMTAWNJL-UHFFFAOYSA-K aluminium trichloride Chemical compound Cl[Al](Cl)Cl VSCWAEJMTAWNJL-UHFFFAOYSA-K 0.000 description 4
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- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 3
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- 229910045601 alloy Inorganic materials 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
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- 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
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- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- 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
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- 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
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2310/00—Selection of sound absorbing or insulating material
- F01N2310/02—Mineral wool, e.g. glass wool, rock wool, asbestos or the like
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/10—Fibrous material, e.g. mineral or metallic wool
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
Description
前記第1の無機繊維の平均繊維長は、前記第2の無機繊維の平均繊維長よりも長いことを特徴とするシート材が提供される。
第1の無機繊維を含む第1のマットを提供する第1のステップと、
前記第1の無機繊維を含む第1のマットの上に、第2の無機繊維を含む第2のマットを積層する第2のステップと、
を有し、
前記第1の無機繊維の平均繊維長は、前記第2の無機繊維の平均繊維長よりも長いことを特徴とするシート材の製造方法が提供される。
前記保持シール材は、前述のようなシート材で構成され、
前記保持シール材は、前記積層シートの第1のマットの表面が外側となるようにして、前記排気ガス処理体に巻回されることを特徴とする排気ガス処理装置が提供される。
前述のいずれかの製造方法で製造されたシート材を、前記保持シール材として提供するステップと、
前記保持シール材を、前記シート材の第1のマットの表面が外側となるようにして、前記排気ガス処理体に巻回すステップと、
を有することを特徴とする排気ガス処理装置の製造方法が提供される。
前述のように、長繊維マットは、ニードリング法を用いて製作することができる。なお以下の説明では、無機繊維としてアルミナとシリカの混合物を含む長繊維マットを例に説明するが、長繊維マットの繊維材料は、これに限られるものではなく、例えばアルミナまたはシリカの一方のみで構成されても良い。あるいは、他の無機繊維を使用しても良い。
前述のように、短繊維マットは、抄造法を用いて製作することができる。なお以下の説明では、無機繊維としてアルミナとシリカの混合物を含む短繊維マットを例に説明するが、短繊維マットの繊維材料は、これに限られるものではなく、例えばアルミナまたはシリカの一方のみで構成されても良い。あるいは、他の無機繊維を使用しても良い。
このようにして製作された短繊維マットおよび長繊維マットを積層、一体化させることにより、本発明によるシート材を得ることができる。
次に、前述の方法で製作した各シート材を用いて、巻付試験を行った。巻付試験では、各シート材を外径が5インチの円柱に巻き付けて、前述のように、端部同士を嵌合し固定した際に、シート材に亀裂が生じるかどうかを目視で評価した。なお、実施例1乃至3に係るシート材では、長繊維マットの側が外周側となるようにして、円柱に巻き付けた。
各シート材に対して得られた巻付試験の結果をまとめて表1に示す。また、図12および13には、それぞれ、試験後の実施例1および比較例1に係るシート材の状況を撮影した写真を示す。巻付試験の結果、実施例1〜3のシート材では、巻付試験後のシート材に、亀裂は生じなかった。一方、比較例1および2に係る単層シート材では、巻付試験後に、外周側に亀裂が生じた。このように、本発明による長繊維マットと短繊維マットを積層させたシート材は、厚さが厚くなっても、十分な強度を有することが確認された。
4 排気管
10 排気ガス処理装置
12 ケーシング
20 排気ガス処理体
24 保持シール材
30 シート材
50 嵌合凸部
60 嵌合凹部
82 第1のマット(長繊維マット)
84 第2のマット(短繊維マット)
86 第3の層(界面層)
121、122、123、124 ケーシング
210 被覆排気ガス処理体
Claims (16)
- 排気ガス処理体と、該排気ガス処理体の外周面の少なくとも一部に巻回された保持シール材とを備える排気ガス処理装置であって、
前記保持シール材は、
第1の無機繊維を含む第1のマットと、第2の無機繊維を含む第2のマットの、少なくとも2つのマットを積層することによって構成されたシート材であって、
前記第1の無機繊維の平均繊維長は、前記第2の無機繊維の平均繊維長よりも長いシート材で構成され、
前記保持シール材は、前記シート材の第1のマットの表面が外側となるようにして、前記排気ガス処理体に巻回されることを特徴とする排気ガス処理装置。 - 前記シート材において、前記排気ガス処理体は、触媒担持体または排気ガスフィルタであることを特徴とする請求項1に記載の排気ガス処理装置。
- 前記シート材において、前記第1の無機繊維と前記第2の無機繊維は、同じ材質であることを特徴とする請求項1または2に記載の排気ガス処理装置。
- 前記シート材において、前記第1の無機繊維の平均繊維長は、20mm〜120mmの範囲であることを特徴とする請求項1乃至3のいずれか一つに記載の排気ガス処理装置。
- 前記シート材において、前記第2の無機繊維の平均繊維長は、0.5mm〜10mmの範囲であることを特徴とする請求項1乃至4のいずれか一つに記載の排気ガス処理装置。
- 前記シート材において、前記第1のマットおよび/または第2のマットは、さらに結合材を有することを特徴とする請求項1乃至5のいずれか一つに記載の排気ガス処理装置。
- 前記シート材は、前記第1のマットと第2のマットの界面に、界面層を有することを特徴とする請求項1乃至6のいずれか一つに記載の排気ガス処理装置。
- 前記シート材において、前記界面層の厚さは、約0.05mm〜2mmの範囲であることを特徴とする請求項1乃至7のいずれか一つに記載の排気ガス処理装置。
- 前記シート材の厚さは、6mm〜20mmの範囲にあることを特徴とする請求項1乃至8のいずれか一つに記載の排気ガス処理装置。
- 排気ガス処理体と、該排気ガス処理体の外周面の少なくとも一部に巻回された保持シール材と、を備える排気ガス処理装置の製造方法であって、
少なくとも2つのマットが積層されたシート材を製造するステップであって、
第1の無機繊維を含む第1のマットを提供する第1のステップ、および
前記第1の無機繊維を含む第1のマットの上に、第2の無機繊維を含む第2のマットを積層する第2のステップ、
を有し、
前記第1の無機繊維の平均繊維長は、前記第2の無機繊維の平均繊維長よりも長い、シート材を製造するステップと、
前記シート材を製造するステップで製造されたシート材を、前記保持シール材として提供するステップと、
前記保持シール材を、前記シート材の第1のマットの表面が外側となるようにして、前記排気ガス処理体に巻回すステップと、
を有することを特徴とする排気ガス処理装置の製造方法。 - 前記排気ガス処理体は、触媒担持体または排気ガスフィルタであることを特徴とする請求項10に記載の製造方法。
- 前記第2のステップは、前記第1のマットの上に、前記第2のマットを直接製作するステップを有することを特徴とする請求項10または11に記載の製造方法。
- 前記第2のステップは、前記第2のマットを単独で製作してから、前記第1のマットと前記第2のマットを積層させるステップを有することを特徴とする請求項10または11に記載の製造方法。
- さらに、前記第2のステップは、前記第1のマットと前記第2のマットの界面を、接着剤および/または縫いつけにより接合させるステップを有することを特徴とする請求項13に記載の製造方法。
- 前記第1のマットは、ニードリング法で製作されることを特徴とする請求項10乃至14のいずれか一つに記載の製造方法。
- 前記第2のマットは、抄造法で製作されることを特徴とする請求項10乃至15のいずれか一つに記載の製造方法。
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JP2006266376A JP4268182B2 (ja) | 2006-09-29 | 2006-09-29 | 排気ガス処理装置およびその製造方法 |
US11/763,799 US20080078150A1 (en) | 2006-09-29 | 2007-06-15 | Laminated sheet, method of producing the sheet, exhaust gas processing device, and method of producing the device |
CNB2007101269087A CN100534782C (zh) | 2006-09-29 | 2007-06-29 | 片材及其制造方法、和废气处理装置及其制造方法 |
KR1020070065712A KR100895232B1 (ko) | 2006-09-29 | 2007-06-29 | 적층 시트, 및 이 시트의 제조 방법과 배기 가스 처리장치, 및 이 장치의 제조 방법 |
DE200760000164 DE602007000164D1 (de) | 2006-09-29 | 2007-07-17 | Verbundmatte, Herstellungsverfahren dafür, Abgasverarbeitungsvorrichtung und Herstellungsverfahren für diese Vorrichtung |
EP20070014014 EP1908934B2 (en) | 2006-09-29 | 2007-07-17 | Use of a laminated sheet as a holding sealer of an exhaust gas processing device, exhaust gas processing device, and method of producing the device |
US12/582,330 US8328986B2 (en) | 2006-09-29 | 2009-10-20 | Laminated sheet, method of producing the sheet, exhaust gas processing device, and method of producing the device |
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US8328986B2 (en) | 2012-12-11 |
CN101152774A (zh) | 2008-04-02 |
DE602007000164D1 (de) | 2008-11-20 |
KR20080030465A (ko) | 2008-04-04 |
US20080078150A1 (en) | 2008-04-03 |
EP1908934B1 (en) | 2008-10-08 |
EP1908934B2 (en) | 2013-12-25 |
CN100534782C (zh) | 2009-09-02 |
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