JP5215296B2 - 多層実装マット - Google Patents
多層実装マット Download PDFInfo
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- JP5215296B2 JP5215296B2 JP2009513408A JP2009513408A JP5215296B2 JP 5215296 B2 JP5215296 B2 JP 5215296B2 JP 2009513408 A JP2009513408 A JP 2009513408A JP 2009513408 A JP2009513408 A JP 2009513408A JP 5215296 B2 JP5215296 B2 JP 5215296B2
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Description
本願は、2006年6月1日に出願された米国仮出願整理番号60/803664の優先権を主張し、その開示はその/それらの全体が本明細書に参考として組み込まれる。
本発明は、汚染防止要素(例えば、触媒キャリア、フィルタ要素、及びこれらの組み合わせ)を汚染防止装置(例えば、触媒コンバータ、排気フィルタ)に実装する際に使用するために操作上適合された多層実装マット、その実装マットを製造する方法、及びその実装マットを含む汚染防止装置に関する。
本発明の多層実装マットは、接着剤によって共に結合される少なくとも2つのマット層を含む。これらの層は、膨張性材料及び非膨張性材料を含む種々の材料から製造できる。
本発明の多層実装マットにおいて、マット層は、少なくとも1つの無機コロイド粒子及び無機水溶性塩のうち少なくとも1つを含む接着剤で共に結合される。
本発明の多層実装マットは、接着剤を第1の実装マット層の主要面に適用し、その接着剤がコーティングされた第1の実装マット層の面に第2の実装マット層の主要面を共に軽く圧縮することによって製造できる。本明細書で使用する時、「圧縮する」という用語は、マット表面の結合のために十分な接触が生じるのに適切な圧力を適用する(例えば、軽い圧力、例えば指の圧力は、特定の実施形態に関して適切であり得る)ことを意味する。
本発明の多層実装マットは、第1の層、第2の層、及びそれらの間に挟持された接着剤(上述したもの)を有する。接着剤は、第1の層の主要面と第2の層の主要面を共に結合する。マット層は、同じ材料又は異なる材料を含むことができる。例えば、第1及び第2の層は両方とも膨張性層(同じ膨張性材料又は異なる材料)であることができ;第1及び第2の層は両方とも非膨張性材料(同じ非膨張性材料又は異なる材料)であることができ;或いは第1の層は膨張性層であることができ、第2の層は非膨張性層であることができる(逆もまた同様)。多層実装マットはまた、追加のマット層を有することもできる。本発明の多層実装マットの好ましい3層実施形態は、例えば、膨張性層が2つの非膨張性層との間に挟持されている「サンドイッチ」構造を有する。
引張り強度試験
この試験は、マット間の接着剤結合の強度を示す。サンプルは、2.5cm(1インチ)×15cm(6インチ)の大きさのマットのストリップの一方の末端部面に接着剤を塗り、接着剤をその末端部から少なくとも2.5cm(1インチ)延ばすように調製した。2.5cm(1インチ)×15cm(6インチ)の大きさのマットの第2のストリップを、それが6.5cm2(1平方インチ)で第1のストリップを覆うように第1のストリップ上に配置し、各ストリップの自由末端部を反対方向に延ばした。コーティングされた領域を、指で軽く押し、結合ラインから過剰な接着剤を搾り取った。積層されたサンプルを80℃に設定されたオーブンに約60分間置いた。サンプルを取出し、室温まで(少なくとも10分間)冷却させた。引張り試験は、上方つかみ具に一方の末端部をクランプし、試験機の下方つかみ具に他方の末端部をクランプし、2.5cm/分(1インチ/分)のクロスヘッド速度で引くことにより、モデル100−P−12引張り試験機(テスト・リソースズ(Test Resources)(ミネソタ州シャコピ(Shakopee))から入手可能)で行った。引張り強度を1平方センチメートルあたりのグラム(1平方インチあたりのポンド)で記録し、破壊モードを記載した。マットの凝集破壊は、接着剤結合強度が、マットの凝集強度を超え、マット内で離層が生じることを示した。接着破壊は、実質的にそのままマットが互いに引き離れることで特徴付けられ、接着剤がマットを共に保持していないことを示した。混合破壊とは、両方の破壊モードが試験サンプル中に観測されたことを示す。
マットの2つのストリップを2.54cm×20.3cm(1インチ×8インチ)に切断した。接着剤をペイント刷毛を用いて各ストリップの約10.6cm(5インチインチ)に適用した。マットの2つのストリップのコーティングされた表面を指で軽く押して共に合わせ、結合ラインから過剰の接着剤を搾り取った。2層サンプルを150℃に設定されたオーブンに約10分間置いた。サンプルを取出し、室温まで(少なくとも10分間)冷却させた。積層されたサンプルは、モデル100−P−12引張り試験機を用い、ストリップそれぞれの自由末端部を試験機の上方及び下方つかみ具に注意深くクランプすることによってT−剥離接着について試験した。クロスヘッド速度は、12.7cm/分(5インチ/分)であり、つかみ具の分離は25cm(10インチ)であった。グラム/センチメートル幅(グラム/インチ幅)の平均抵抗力及び破壊モードを記録した。破壊モードは、引張り強度試験に関して上述した通りである。
この試験は、マット材料を円に曲げた場合に互いに接着した状態をどの程度保つかを定量的に示す。2.5cm(1インチ)×20cm(8インチ)の大きさのマットの2つのストリップに接着剤を塗り、次いで指で軽くコーティングされた表面を共に押し、過剰な接着剤を搾り出すことによってサンプルを調製した。サンプルを150℃に設定されたオーブンにて約10分間乾燥した。室温まで冷却した後、サンプルを6.4cm(2.5インチ)直径の円筒に包んだ。結果は合格であった、すなわちマットは互いに接着した状態にあった;或いは失格であった、すなわちマットの2つのストリップは互いに分離した(通常、マットの離層がほとんどないか、全くない)又はマット内でクラックを示した。マット界面内における接着剤のクラックは、マット自体にクラックが生じない限り許容可能である。
実施例1は、液体のケイ酸ナトリウム(PQコーポレーション(PQ Corporation)(ペンシルベニア州バリーフォージ(Valley Forge))から入手可能なケイ酸ナトリウムタイプN)の薄層を坪量が800グラム/平方メートルの膨張性実装マット(3M社(3M Co.)(ミネソタ州セントポール(St. Paul)によって製造される3M(登録商標)インターラム(Interam)(登録商標)550膨張性マット)の2.5cm(1インチ)×15cm(6インチ)のストリップ上に塗り、同じ材料の第2のストリップをその上に押さえることによって、上述した引張り強度試験の手順に従って調製した。試験結果を表1に示している。
実施例4〜16は、実施例1に記載された膨張性マット及び以下の表2に示される接着剤を用いて調製された。試験サンプルを調製し、引張り強度試験、曲げ試験、及びT−剥離接着試験の試験手順に従って試験した。結果を表2に示す。T−剥離接着のためのサンプルは、引張り試験機にて行わなかったが、手で引き離して、破壊モードを記録した。
実施例4 − ナルコ(Nalco)(イリノイ州ナパビル(Naperville))から入手可能なナルコ(Nalco)2327
実施例5 − 水道水で50/50に希釈されたケイ酸ナトリウム(PQコーポレーション(PQ Corporation)(ペンシルベニア州バリーフォージ(Valley Forge))から入手可能なPQ(登録商標)ケイ酸ナトリウムタイプN)
実施例6 − PQコーポレーション(PQ Corporation)(ペンシルベニア州バリーフォージ(Valley Forge))から入手可能なケイ酸ナトリウムタイプN
実施例7 − 水中50%硫酸アルミニウム(ミョウバン)(ホーキンス(Hawkins Inc.)(ミネソタ州ミネアポリス(Minneapolis))から入手可能)
実施例8 − コロイド状のモンモリロナイト(サザン・クレイ・プロダクツ(Southern Clay Products Inc.)(テキサス州ゴンザレス(Gonzales))(ロックウッド(Rockwood)の子会社)から入手可能なゲルホワイト(Gelwhite)L)
実施例9 − ケイ酸ナトリウムリチウムマグネシウム(ロックウッド・アディティブズ(Rockwood Additives)(英国ウイドネス(Widnes)から入手可能なラポナイト(LAPONITE)RD)
実施例10 − コロイド状のモンモリロナイト粘土(ミネラル・コロイド(MINERAL COLLOID)(登録商標)BP(登録商標)(サザン・クレイ・プロダクツ(Southern Clay Products Inc)(テキサス州ゴンザレス(Gonzales))(ロックウッド(Rockwood)の子会社)から入手可能))
実施例11 − ケイ酸塩を50/50重量で有するナルコ(Nalco)2327
実施例12 − ミョウバンを50/50重量で有するナルコ(Nalco)2327
実施例13 − 飽和ホウ酸を50/50重量で有するナルコ(Nalco)2327
実施例14 − ミョウバン50/50重量のケイ酸ナトリウムタイプN
実施例15 − ホウ酸を有するケイ酸ナトリウムタイプN
実施例16 − ミョウバン50/50を有するゲルホワイトL
(実施例17〜38)
実施例17〜33は、実施例1に記載された膨張性マット及び以下の表3に示される接着剤を用いて調製された。サンプルは、T−剥離試験手順に従って調製及び試験された。
実施例17 − ナルコ(Nalco)(イリノイ州ナパビル(Naperville))から入手可能なナルコ(Nalco)1056
実施例18 − ナルコ(Nalco)(イリノイ州ナパビル(Naperville))から入手可能なナルコ(Nalco)2329
実施例19 − ナルコ(Nalco)(イリノイ州ナパビル(Naperville))から入手可能なナルコ(Nalco)1130
実施例20 − ナルコ(Nalco)(イリノイ州ナパビル(Naperville))から入手可能なナルコ(Nalco)1030
実施例21 − W.R.グレース(W.R. Grace Co.)(メリーランド州コロンビア(Columbia))から入手可能なルドックス(Ludox)PW50ECバイモード
実施例22 − ホーキンス(Hawkins Inc.)(ミネソタ州ミネアポリス(Minneapolis))から入手可能な50%硫酸アルミニウム
実施例23 − ナルコ(Nalco)(イリノイ州ナパビル(Naperville))から入手可能な35%アルミン酸ナトリウム
実施例24 − ホーキンス(Hawkins Inc.)(ミネソタ州ミネアポリス(Minneapolis)から入手可能な飽和塩化カリウム
実施例25 − EMサイエンス(EM Science)(ニュージャージー州チェリーヒル(Cherry Hill)から入手可能な飽和塩化ナトリウム
実施例26 − PQコーポレーション(PQ Corp.)(ペンシルベニア州バリーフォージ(Valley Forge))から入手可能なスティクソ(Stixso)(商標)ケイ酸ナトリウム
実施例27 − PQコーポレーション(PQ Corp.)(ペンシルベニア州バリーフォージ(Valley Forge))から入手可能なタイプNケイ酸ナトリウム
実施例28 − 水中5%ゲルホワイト
実施例29 − ロックウッド・アディティブズ(Rockwood Additives, LTD)(ニュージャージー州プリンストン(Princeton))から入手可能な5%ラポナイト(Laponite)RD
実施例30 − グレース・コンストラクション・プロダクツ(Grace Construction Products)(マサチューセッツ州ケンブリッジ(Cambridge))から入手可能なミクロライト(Microlite)剥離バーミキュライト
実施例31 − R.T.バンダービルト社(R.T. Vanderbilt Co)(コネチカット州ノールウォーク(Norwalk))から入手可能なディクシ・クレイ(Dixie Clay)(200nm);ワーリング(Waring)ブレンダにて60秒間ブレンドされ粒径を下げたもの
実施例32 − ワイオ−ベン(Wyo-Ben)(モンタナ州ビリングス(Billings))から入手可能なベントナイト粘土
実施例33 − ロックウッド・アディティブズ(Rockwood Additives, LTD)(ニュージャージー州プリンストン(Princeton))から入手可能なラポナイト(Laponite)RD/ケイ酸ナトリウムゲル
(実施例34)
3層マットは、接着剤としてケイ酸ナトリウムタイプNを用いて実施例3に記載される2つの非膨張性マットを実施例1に記載される膨張性マットに積層することによって調製した。膨張性マットは、2つの非膨張性マットの間に挟持させた。3層のものは可撓性であったので、クラックも離層も生じることなくコージライトモノリスの周りを容易に包むことができた。
比較例C1〜C11は、実施例1に記載される膨張性マットと、T−剥離接着試験のためのサンプルを製造するために以下に列挙された接着剤とを用いて調製した。サンプルは、手で分離して、完全に離れた(結合なし)、又は引張り試験機のつかみ具にクランプするには十分に共に保持されていなかった(弱い結合)。破壊は全て接着破壊であり、マット中の離層はなかった。
C2−水中20%二酸化チタン(2ミクロン)−結合なし
C3−JTベーカー(JT Baker)から入手可能な酸化カルシウム粉末−結合なし
C4−キャボット(Cabot)から入手可能なM−5ヒュームドシリカ−結合なし
C5−ワーリング(Waring)ブレンダにてブレンドされたM−5−結合なし
C6−水酸化アルミニウム−結合なし
C7−水中20%硫酸カルシウム、EMサイエンス(EM Science)(ニュージャージー州チェリーヒル(Cherry Hill))−弱い結合
C8−ディクシ・クレイ(Dixie Clay)200nm−ブレンドされていない)−弱い結合
C9−水酸化アルミニウム(3.5ミクロン)、ハーバー(Huber Inc)(ジョージア州ノルクロス(Norcross))−弱い結合
CR10−水酸化マグネシウム(5ミクロン)、アルバマール(Albemarle Inc.)(ルイジアナ州バトン・ルージュ(Baton Rouge))−弱い結合
C11−水−結合なし
本発明の様々な変更や改変は、本発明の範囲及び趣旨を逸脱せずに、当業者には明らかとなるであろう。本発明は、本明細書で示される例示的な実施形態及び実施例によって不当に限定されるべく意図されていないこと、並びに、かような実施例及び実施形態は、以下に示されるように、本明細書に示す請求項によってのみ限定されるべく意図されている、本発明の範囲に沿った例示として提示されること、を理解すべきである。
Claims (4)
- 汚染防止装置に汚染防止要素を実装する際に使用するために操作上適合させた多層実装マットであって、前記マットが乾燥しており、前記マットが第1層と、第2層と、前記第1層の主要面と前記第2層の主要面とを共に結合させるためにその間に挟持されている接着剤とを含み、前記接着剤が300nm未満の平均直径を有する無機コロイド粒子及び無機水溶性塩の少なくとも1つを含み、
前記接着剤が、前記第1層及び前記第2層の厚みの20%未満に浸透する、多層実装マット。 - 前記接着剤がゲルである、請求項1に記載の多層実装マット。
- 多層実装マットを製造する方法であって、前記方法が、
(a)300nm未満の平均直径を有する無機コロイド粒子又は無機水溶性塩の少なくとも1つを含む接着剤を第1実装マット層の主要面に適用する工程と、
(b)第2実装マット層の主要面を前記第1実装マット層の前記接着剤コーティングされた面に共に圧縮させて多層実装マットを形成する工程と、
(c)前記多層実装マットを乾燥させる工程とを含み、
前記接着剤が、前記第1層及び前記第2層の厚みの20%未満に浸透する、
方法。 - ケーシングと、前記ケーシング内に配置された汚染防止要素と、前記汚染防止要素を前記ケーシング内に実装するためにその間に配置された請求項1に記載の多層実装マットとを含む汚染防止装置。
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2007
- 2007-05-29 CA CA 2653652 patent/CA2653652A1/en not_active Abandoned
- 2007-05-29 JP JP2009513408A patent/JP5215296B2/ja active Active
- 2007-05-29 CN CN2007800201988A patent/CN101460717B/zh active Active
- 2007-05-29 WO PCT/US2007/069839 patent/WO2007143437A2/en active Application Filing
- 2007-05-29 US US12/302,707 patent/US8277925B2/en active Active
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EP2038523B1 (en) | 2013-01-09 |
KR20090025215A (ko) | 2009-03-10 |
BRPI0711781A2 (pt) | 2011-11-29 |
PL2038523T3 (pl) | 2013-05-31 |
BRPI0711781B1 (pt) | 2019-02-05 |
WO2007143437A3 (en) | 2008-04-10 |
US20090304560A1 (en) | 2009-12-10 |
CN101460717B (zh) | 2013-01-16 |
CA2653652A1 (en) | 2007-12-13 |
ZA200810851B (en) | 2009-12-30 |
JP2009539031A (ja) | 2009-11-12 |
KR101489005B1 (ko) | 2015-02-02 |
EP2363582A1 (en) | 2011-09-07 |
EP2038523A2 (en) | 2009-03-25 |
US8277925B2 (en) | 2012-10-02 |
WO2007143437A2 (en) | 2007-12-13 |
CN101460717A (zh) | 2009-06-17 |
EP2363582B1 (en) | 2019-11-13 |
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