JP5971894B2 - 汚染コントロール要素用保持材、その製造方法及び汚染コントロール装置 - Google Patents
汚染コントロール要素用保持材、その製造方法及び汚染コントロール装置 Download PDFInfo
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- JP5971894B2 JP5971894B2 JP2011018570A JP2011018570A JP5971894B2 JP 5971894 B2 JP5971894 B2 JP 5971894B2 JP 2011018570 A JP2011018570 A JP 2011018570A JP 2011018570 A JP2011018570 A JP 2011018570A JP 5971894 B2 JP5971894 B2 JP 5971894B2
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Description
本発明の他の態様による汚染コントロール装置は、ケーシングと、ケーシング内に設置された汚染コントロール要素と、ケーシングと汚染コントロール要素との間に配置された上記保持材とを備える。
本発明のさらに別の態様によるケーシング内で汚染コントロール要素を巻回して保持するための保持材の製造方法では、電解質を含む溶液に有機バインダ及び無機微粒子を加え、さらに凝集剤を加えることで、凝集物が析出した液を準備する工程と、無機繊維材料からなるマットを凝集物が析出した液に浸漬させるか、凝集物が析出した液をマットに注ぐことにより、マット内に凝集物が析出した液を含浸し、凝集物をマットに付着させる工程とを備える。
この保持材によれば、有機バインダと無機微粒子とが、凝集物として一体化して、マット内に分散されているので、両組成がマット全体に分散して、マット内の無機繊維に付着し、それぞれの機能を効果的に発揮できる。有機バインダは、汚染コントロール装置の製造過程におけるファイバ片の飛散を抑制するとともに、無機微粒子は、有機バインダが燃焼した後もマット内に残存し、ケーシングの内面と汚染コントロール要素との間で十分に高い面圧の維持に効果を発揮する。
無機微粒子としては、例えば、金属酸化物、窒化物、炭化物、及びそれらの複合材料からなる群より選択される少なくとも1種類の材料からなるものを使用できる。また、平均粒径が1μm以下の無機微粒子を使用する場合は、表面エネルギーが高いため、焼結性があがり、すなわちより焼結しやすくなるため、無機繊維への固着性をより強固なものとすることができる。
上記製造方法によれば、あらかじめ有機バインダと無機微粒子からなる凝集物を析出させた後に、凝集物が析出した液をマットに含浸させるので、有機バインダ、無機微粒子をそれぞれ単独で分散させた場合には得られにくい、より均一な分散性をもって、マット内の略全体に有機バインダとともに無機微粒子を定着させることができる。
上記工程(a)は、有機バインダと、無機微粒子が分散したコロイド溶液とを含む混合液から凝集物が析出した液を調製する工程を含むことが好ましい。コロイド溶液を使用することで、サイズが十分に均一の凝集物を含む液を調製しやすいという利点がある。
10Lの水に6gの硫酸アルミニウムを加えて攪拌した。得られた水溶液のpHは4.5であった。この水溶液に下記の有機バインダ2.6g及びシリカゾル10gを添加して分散液を得た。この分散液に下記の液体アルミン酸ナトリウム3.5gを加えることにより、有機バインダ及び無機微粒子の凝集物が析出した溶液を調製した。
有機バインダ:日本ゼオン株式会社製、ニッポールLX874(商品名)、Tg:−31℃;
シリカゾル:日産化学工業株式会社製、スノーテックスO(商品名)、平均粒径10〜20nm;
液体アルミン酸ナトリウム:ナルコケミカル製、Nalco2372(商品名)。
10Lの水に1gの硫酸アルミニウムを加えて攪拌し、pH6.2の水溶液を得たとともに、有機バインダ(2.6g)及び無機微粒子を含む分散液に1gの液体アルミン酸ナトリウムを加えることにより、有機バインダ及び無機微粒子の凝集物が析出した溶液を調製したことの他は、実施例1と同様にして保持材を作製した。
Tgが−31℃の有機バインダの代わりに、Tgが−13℃の有機バインダ(日本ゼオン株式会社製、ニッポールLX821(商品名))を使用したことの他は、実施例1と同様にして保持材を作製した。表1に配合量等を示した。
Tgが−31℃の有機バインダの代わりに、Tgが+1℃の有機バインダ(日本ゼオン株式会社製、ニッポールLX811H(商品名))を使用したことの他は、実施例1と同様にして保持材を作製した。表1に配合量等を示した。
Tgが−31℃の有機バインダの代わりに、Tgが+25℃の有機バインダ(日本ゼオン株式会社製、ニッポールLX814(商品名))を使用したことの他は、実施例1と同様にして保持材を作製した。表1に配合量等を示した。
シリカゾル(日産化学工業株式会社製、スノーテックスO(商品名))の配合量を10gとする代わりに5gとしたことの他は、実施例1と同様にして保持材を作製した。表1に配合量等を示した。
シリカゾル(日産化学工業株式会社製、スノーテックスO(商品名))の配合量を10gとする代わりに40gとしたことの他は、実施例1と同様にして保持材を作製した。表1に配合量等を示した。
硫酸アルミニウムを加えた水溶液に有機バインダ(Tg:+1℃)のみを添加し、シリカゾルを添加しなかったことの他は、実施例4と同様にして保持材を作製した。表2に配合量等を示した。本比較例においては、ブランケットを通過させる液には凝集物は析出したが、そのサンプルの常温面圧は実施例等に較べ低い結果であった。
有機バインダ及び無機微粒子を含む分散液に液体アルミン酸ナトリウムを加えなかったことの他は、実施例1と同様にして保持材を作製した。表2に配合量等を示した。本比較例においては、ブランケットを通過させる液には凝集物の析出は認められず、またそれより作製したサンプルにはほとんど有機バインダおよび無機微粒子が定着しなかった。
10Lの水に硫酸アルミニウムを加えなかったことの他は、実施例1と同様にして保持材を作製した。表2に配合量等を示した。本比較例においては、ブランケットを通過させる液には凝集物の析出は認められず、有機バインダおよび無機微粒子が定着しなかった。
上記のようにしてそれぞれ作製した保持材について、有機バインダの含有量、ファイバ片の飛散率及び常温(室温)時での面圧を下記の手順に従って実施した。
各保持材から切り出した25mm×25mmのサンプルを110℃ 1時間オーブンで乾燥した後に有機バインダを含むサンプルの重量(W0)を測定した。その後そのサンプルを900℃の炉中で1時間加熱し、有機バインダを燃焼させた後の重量(W1)を測定した。マット内の有機バインダの含有率に相当する加熱減量(LOI)を以下の式より算出した。
加熱減量(LOI)wt% = (W0−W1)/W0 ×100
日本工業規格(JIS K−6830)に記載の衝撃試験機を用意し、同規格に記載される指針に従って衝撃試験を実施した。
(1)保持材(サイズ:250mm×250mm)から、試験片(サイズ:100mm×100mm)を打ち抜き型にて作製し、その質量を測定した。
(2)試験片をJIS K−6830に記載の衝撃試験機にセットし、30°の角度から衝撃を加えた。
(3)試験後の試験片を衝撃試験機から取り外し、その質量を再び測定した。
(4)試験の前後における試験片の質量変化からファイバ片の飛散量を計算した。
(1)保持材(サイズ:250mm×250mm)から、円形試験片(直径:45mm)を打ち抜き型にて作製し、その質量を測定した。
(2)質量の測定値から、充填密度が0.3g/cm3になるマット厚を計算した。
(3)試験片を圧縮試験機(型番「Autograph AG−I」、島津製作所製)の圧縮板の中心に載置し、上記の計算で求めた所定のマット厚になるまで20mm/分の速度で圧縮した。そのピーク時の圧力(面圧)を常温時面圧(kPa)とした。
(1)実施例1と同様にして作製した保持材(サイズ:250mm×250mm)から、円形試験片(直径:45mm)を打ち抜き型にて作製し、その質量を測定した。
(2)質量の測定値から、充填密度が0.23g/cm3(有機成分等の焼失成分を除く。)になるマット厚を計算した。
(3)圧縮試験機(型番「Autograph AG−I」、島津製作所製)が有する2枚のプレート(ステンレス鋼製)で試験片を挟み、上記の計算で求めた所定のマット厚になるまで20mm/分の速度で圧縮した。
(4)試験片を圧縮している状態で、2枚のプレートのうちの一方を900℃に加熱し、他方を650℃に加熱した。面圧の経時変化を観察するため、2枚のプレートがそれぞれ900℃及び650℃に到達した時点(試験開始時)から、30分毎に20時間にわたって面圧を測定した。表3及び図5に結果を示す。なお、この面圧変化は、下記式で近似でき、この近似式から十年後の面圧を算出した。
Y=aXb
式中、Xは時間(hr);Yは面圧(kPa);a、bは係数をそれぞれ示す。
Claims (12)
- ケーシング内で汚染コントロール要素を巻回して保持するための保持材であって、
無機繊維材料からなるマットと、
前記マット内に分散された、有機バインダ、及び金属酸化物、窒化物、炭化物、又はそれらの複合材料からなる無機微粒子を含有する、平均径50μm以下の凝集物と、
を備える、保持材。 - 前記有機バインダは、アクリル系ラテックスであり、かつガラス転移温度が15℃以下である、請求項1に記載の保持材。
- 前記有機バインダの含有率が当該保持材の全質量基準で0重量%より多く5重量%以下である、請求項1又は2に記載の保持材。
- 前記無機微粒子は、平均粒径が1μm以下である、請求項1〜3のいずれか一項に記載の保持材。
- 前記凝集物は、平均径が1μm以上である、請求項1〜4のいずれか一項に記載の保持材。
- ケーシングと、
前記ケーシング内に設置された汚染コントロール要素と、
前記ケーシングと前記汚染コントロール要素との間に配置された請求項1〜5のいずれか一項に記載の保持材と、
を備える汚染コントロール装置。 - 前記汚染コントロール要素は、触媒担体もしくはフィルター要素である、請求項6に記載の汚染コントロール装置。
- ケーシング内で汚染コントロール要素を巻回して保持するための保持材の製造方法であって、
電解質を含む溶液に有機バインダ、及び金属酸化物、窒化物、炭化物、又はそれらの複合材料からなる無機微粒子を加え、さらに凝集剤を加えることで、凝集物が析出した液を準備する工程と、
無機繊維材料からなるマットを前記凝集物が析出した液に浸漬させる、又は前記凝集物が析出した液を前記マットに注ぐことにより、前記マット内に凝集物が析出した液を含浸し、前記凝集物を前記マットに付着させる工程と、
を備える、方法。 - 前記液を準備する工程は、有機バインダと、無機微粒子が分散したコロイド溶液とを含む混合液から前記凝集物が析出した液を調製する工程を含む、請求項8に記載の方法。
- 前記有機バインダは、アクリル系ラテックスであり、かつガラス転移温度Tgが15℃以下である、請求項8又は9に記載の方法。
- 前記無機微粒子は、平均粒径が1μm以下である、請求項8〜10のいずれか一項に記載の方法。
- 前記液中に析出した前記凝集物は、その平均径が20μm以上、2mm以下である、請求項8〜11のいずれか一項に記載の方法。
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JP5112029B2 (ja) * | 2007-01-26 | 2013-01-09 | イビデン株式会社 | シート材およびその製造方法、排気ガス処理装置およびその製造方法、ならびに消音装置 |
EP2466004B1 (en) * | 2007-02-19 | 2016-06-22 | 3M Innovative Properties Company | Flexible fibrous material, pollution control device, and methods of making the same |
JP5046829B2 (ja) * | 2007-09-26 | 2012-10-10 | イビデン株式会社 | 保持シール材及び保持シール材の製造方法 |
JP5183296B2 (ja) * | 2008-05-15 | 2013-04-17 | イビデン株式会社 | 保持シール材、保持シール材の製造方法及び排ガス浄化装置 |
EP2328674B1 (en) * | 2008-08-29 | 2014-04-23 | Unifrax I LLC | Mounting mat with flexible edge protection and exhaust gas treatment device incorporating the mounting mat |
AU2009333811B2 (en) | 2009-01-05 | 2013-08-22 | Unifrax I Llc | High strength biosoluble inorganic fiber insulation mat |
US8075843B2 (en) * | 2009-04-17 | 2011-12-13 | Unifrax I Llc | Exhaust gas treatment device |
WO2011019396A2 (en) * | 2009-08-14 | 2011-02-17 | Unifrax I Llc | Mounting mat for exhaust gas treatment device |
US8071040B2 (en) | 2009-09-23 | 2011-12-06 | Unifax I LLC | Low shear mounting mat for pollution control devices |
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US9670814B2 (en) | 2017-06-06 |
WO2012106295A1 (en) | 2012-08-09 |
KR20140005275A (ko) | 2014-01-14 |
US20130305697A1 (en) | 2013-11-21 |
CN103429865B (zh) | 2017-03-15 |
CN103429865A (zh) | 2013-12-04 |
EP2670960B1 (en) | 2020-01-01 |
EP2670960A1 (en) | 2013-12-11 |
KR101943668B1 (ko) | 2019-01-29 |
JP2012157809A (ja) | 2012-08-23 |
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