JP5841541B2 - ディーゼル粒状物のフィルター中の結合材の移行を軽減してフィルターの圧力低下と温度勾配とを減少するための、重合体のバリヤー被膜を製造する方法 - Google Patents
ディーゼル粒状物のフィルター中の結合材の移行を軽減してフィルターの圧力低下と温度勾配とを減少するための、重合体のバリヤー被膜を製造する方法 Download PDFInfo
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Description
ディーゼル粒状物のフィルターの製造において、ハニカムフィルターを集成してスキンで覆うためにセメントとスキンが使用される。セメントとスキンがそれらの接着機能を達成するために、ハニカム支持体に対する接着を形成するために、それらの調合物中に結合材が必須である。結合材は通常、無機および有機結合材を含む。セメントとスキンの適用工程中に、結合材は毛細管力により多孔性ハニカム支持体中に移行し、乾燥後に結合力を形成する。セメントとスキンの焼成後、有機結合材は焼き尽くされる(burned off)が、無機結合材はハニカム支持体内に残留し、焼結して、界面に無機結合物を形成する。
一つの態様において、セラミックのハニカム構造物と様々なそれらの製法が開示される。セラミック構造物は、重合体で被覆されて重合体のバリヤー被膜を形成され、そして無機繊維と、非晶質シリケート、アルミナイトまたはアルミノシリケート・ガラスおよびその他の無機粒子よりなる結合相とよりなるセメントで一緒に接着された、少なくとも二種
の別々の比較的小型のセラミックのハニカムを含むことができる。重合体はハニカム構造物の孔中に浸透性であって、その上に薄いバリヤー層を形成して、孔中へのあらゆる無機繊維と結合相または水の移行を軽減する。重合体は更に、ハニカム構造物が排気フィルターに形成される時に、どんな圧力低下をも経験しないように、セメントとハニカムスキンの燃焼温度以下で焼き尽くすようになっている。
その一例が図3に示されるセラミックのハニカム10は、ハニカム本体の長さを通して軸方向に延伸する複数のセルをもつことを特徴とする。セル12は多数の交差する壁14により区画される。壁と交差点16は、セル18の数およびそれらの切断面のサイズとディメンションを規定する。多数の濾過または触媒の適用のために典型的なハニカムは25
〜1000個のセル/平方インチ(約4〜150個のセル/平方センチメーター)の断面積(すなわち縦の延びに対して横方向)を含むと考えられる。より厚いまたはより薄い壁の厚さを使用することができると考えられるが、壁の厚さは、典型的には0.05〜10mm、好適には0.2〜1mmである。
粒子を含む。
リカとコロイド状アルミナの混合物を含む。このようなコロイド状物質は1ミクロメーター未満、好適には250ナノメーター未満の数平均粒度をもつ粒状物の形態を採る。粒子は水またはその他のキャリヤー液中に分散されることができる。粒子は結晶質または非晶質であることができる。コロイド状粒子は好適には非晶質である。コロイドは好適にはシリケート、アルミネート、アルミノシリケート・ゾルである。コロイド状シリカ製品は一般に塩基性pHおよび、電気泳動により測定される陰性の表面電荷をもつ。コロイド状アルミナは望ましくは酸性のpHをもち、電気泳動により測定されるとアルミナ粒子が陽性の電荷をもつ。実例となるコロイドは、PQ Corporation,Valley Forge,PA.からのKASILおよびN、Zaclon Incorporated,Cleveland,OHからのZACSIL、Occidental Chemical Corporatin,Dallas,TXからのSodium Silicates(珪酸ナトリウム)、Nyacol Nanotechnologies Inc.からのNexsilコロイド状シリカおよびAl 20コロイド状アルミナ、Aremco Products Inc.,Valley Cottage,NYからのAshland MAおよびAremco 644Aおよび644Sのような商品名で市販のものである。
ければならず、その90重量%までを構成することができる。この計算の目的のための「固形分」はセメント組成物が燃焼された後にスキン中に残留する、充填材および無機結合相を含むスキン形成組成物中の無機物質により構成される。大部分の場合、固形分は無機繊維、コロイド状シリカおよび/またはコロイド状アルミナ、プラス、存在することができるあらゆる無機充填材粒子でできていると考えられる。キャリヤー流体と有機物質は一般に、1回または複数の乾燥工程中に組成物から喪失され、乾燥スキン中にもはや存在しない。従って、「固形分」はどんな量のこれらの物質をも含まない。
は一般に、全組成物の約25重量%〜最大約90重量%である。キャリヤー流体の好適な量は全組成物の40〜70重量%である。
ウムと白金は、1以上の工程においてハニカム上に堆積されて、自動車の機関からのような動力装置の排気から、煤煙、NOx化合物、一酸化炭素および炭化水素のような粒状物を同時に除去することができるフィルターを形成することができる。
LLC,Niagara Falls,NYから市販のFIBERFRAX Long
Staple Fine繊維)、13.5重量%のコロイド状アルミナ(Nyacol
Nano Technologies,Inc,Ashland,MAから市販のAL20SD)、40.5重量%の水、2重量%のメチルセルロース(The Dow Chemical Co.Midland,MIから市販のMETHOCEL A15LV)、および2重量%のポリエチレングリコール400(Alfa Aesar,Ward Hill,MAから市販)を混合して均一な混合物を達成した。
により測定した。本実施例のセメントの粘度は図6に示され、実施例1のものと比較するために使用される。
ax LLC,Niagara Falls,NYから市販のFIBERFRAX Long Staple Fine繊維)、14.4重量%のコロイド状アルミナ(Nyacol Nano Technologies,Inc,Ashland,MAから市販のAL20SD)、36.6重量%の水、2.1重量%のメチルセルロース(The Dow Chemical Co.Midland,MIから市販のMETHOCEL A15LV)、および2.1重量%のポリエチレングリコール400(Alfa Aesar,Ward Hill,MAから市販)を混合して均一な混合物を達成した。
644S)を混合して均一な混合物を達成した。644Aコロイド状アルミナは4のpHをもち、他方644Sコロイド状シリカは9のpHをもち、アルミナとシリカ結合材の混合は結合材のゲル化をもたらし、繊維は結合材ゲル中に懸濁された。
Claims (8)
- 親水性有機重合体で被覆されて重合体のバリヤー被膜を形成され、そして無機繊維と、非晶質シリケート、アルミナイトまたはアルミノシリケート・ガラスおよびその他の無機粒子よりなる結合相とを含むセメントで一緒に接着された、少なくとも二種の別々の比較的小型のセラミックハニカムよりなるセラミックのハニカム構造物であって、ここで前記重合体が、前記ハニカム構造物の孔中に浸透性であるか、または孔を覆って、その上に薄いバリヤー層を形成して、前記孔中への前記無機繊維と結合相との移行を軽減し、ここで、前記重合体のバリヤー被膜がセメントおよびハニカムスキンの燃焼温度以下で焼き尽くされるか、または冷温硬化セメントが使用される場合は、適用中のハニカム操作温度以下で焼き尽くされる前の状態である、セラミックのハニカム構造物。
- 重合体が前記バリヤー被膜を形成した後に、前記重合体が前記ハニカムスキンまたはセメント溶剤に不溶性である、請求項1のセラミックのハニカム構造物。
- 重合体のバリヤー層が固化後に、それが前記の孔を少なくとも一部を充填するかまたは覆う、請求項2のセラミックのハニカム構造物。
- 親水性有機重合体が、アクリル誘導体、アミン官能性重合体、エーテル、スチレン、ポリスチレンスルホネート重合体、ビニル酸、ビニルアルコールおよびそれらの混合物よりなる群から選択される、請求項1のセラミックのハニカム構造物。
- セラミックのハニカム構造物を重合体で被覆して、重合体のバリヤー被膜を形成し、
重合体のバリヤー被膜を硬化し、ここで、前記バリヤーは親水性であり、
無機繊維と、非晶質シリケート、アルミナイトまたはアルミノシリケート・ガラスおよびその他の無機粒子よりなる結合相とを含むセメントを適用し、ここで前記重合体は、前記ハニカム構造物の孔中に浸透性であるか、またはそれを覆って、その上に薄いバリヤー層を形成して前記孔中への前記無機繊維と結合相との移行を軽減し、そして
前記重合体のバリヤー被膜を、セメントとハニカムスキンの燃焼温度以下、または冷温硬化セメントが使用される場合は、適用中のハニカム操作温度以下で焼き尽くす、
工程を含んでなる、セラミックのハニカム構造物を形成する方法。 - 重合体のバリヤーが前記の孔中への無機結合材の移行を軽減する、請求項5の方法。
- 重合体が少なくとも1種の無機重合体を含み、そして前記無機重合体が反復単位内に炭素以外の元素を含む、請求項5の方法。
- 重合体が前記バリヤー被膜を形成した後に、前記重合体があらゆるハニカムスキンまたはセメント溶剤に不溶性である、請求項5の方法。
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PCT/US2011/020045 WO2011082399A1 (en) | 2009-12-31 | 2011-01-03 | Method of making polymeric barrier coating to mitigate binder migration in a diesel particulate filter to reduce filter pressure drop and temperature gradients |
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WO2011082399A1 (en) | 2011-07-07 |
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