JPH07267746A - Adhesive for waste gas filter and production of waste gas filter - Google Patents

Abstract

PURPOSE:To obtain an adhesive for a waste gas filter enhancing work efficiency and productivity and to produce a waste gas filter. CONSTITUTION:Sheets 1, 2 are superposed while holding an adhesive 3 and they are wound up to form a formed body. The adhesive 3 contains ceramic powder, starch and colored powder and this ceramic powder and ceramic powder used in the sheets 1, 2 are made of the same material.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an exhaust gas filter adhesive used in an exhaust gas filter mounted on an automobile or the like, and a method for manufacturing an exhaust gas filter.

[0002]

2. Description of the Related Art Exhaust gas filters are produced by laminating, for example, flat plate-shaped ceramic sheets and corrugated ceramic sheets,
These sheets were manufactured by joining the sheets with an adhesive, rolling up the laminated body, drying the rolled up body, and firing.

[0003]

However, in the above-mentioned conventional structure, since the adhesive and the sheet have the same color tone, it is difficult to visually confirm the joining between the sheets by the adhesive, and the workability is poor. However, there was a problem that the yield was low. Further, since the dried exhaust gas filter has weak mechanical strength, it collapses even if a small impact is applied, so that it must be handled with care and there is a problem that productivity is poor.

The present invention is intended to solve the above-mentioned conventional problems, and an object thereof is to provide an exhaust gas filter adhesive and an exhaust gas filter manufacturing method which have good workability, high yield, and high productivity.

[0005]

In order to achieve this object, the present invention uses an adhesive obtained by mixing ceramic powder, starch and color powder for joining sheets.

[0006]

With this construction, the adhesive can be colored and the bonding force between the sheets of the dried exhaust gas filter can be increased.

[0007]

EXAMPLES An exhaust gas filter adhesive in one example of the present invention will be described below.

The adhesive of this example was prepared by adding ceramic powder, starch, color powder (pigment) and water. That is, when an adhesive containing color powder is used for joining the sheets, the color tone of the adhesive and the sheets are different, and therefore the joining between the sheets by the adhesive can be easily confirmed with the naked eye, resulting in good workability. The yield can be increased. Further, when an adhesive containing starch is used for joining the sheets, the joining force between the sheets after the molded body is dried is increased, so that the mechanical strength can be improved.

The mixing ratio of the ceramic powder, the starch and the color powder is a weight ratio. When the ceramic powder is 100, the starch is 2
It is preferable that 0 to 30 and 0.05 to 0.5 of colored powder are included. When the amount of starch added is less than 20, there is a problem that the bonding force between the sheets is small, and when it exceeds 30, there is a problem that the shrinkage after drying is large and cracks are likely to occur in the bonded portion. If the amount of colored powder added is less than 0.05,
There is a problem that the adhesive cannot be colored sufficiently, and if it exceeds 0.5, there is a problem that the bonding force between the sheets is small. However, the addition amount of the starch and the color powder is the most preferable range, and even if it deviates a little from this range, it is possible to obtain better characteristics than the conventional one.

As the ceramic powder, a sericite-containing clay-based powder alone or a mixed powder of the sericite-containing clay-based powder and the siliceous powder (the mixing ratio is a weight ratio of sericite-containing clay-based powder: siliceous powder = 90: 10 is preferable)
Or a mixed powder of sericite-containing clay-based powder and mullite (mixing ratio is preferably sericite-containing clay-based powder: mullite = 85: 15 by weight), or mixed powder of sericite-containing clay-based powder and cordierite. (The compounding ratio is a weight ratio of clay powder containing sericite: cordierite = 80:
20 is preferable), kaolinite-containing clay-based powder, and the like are used.

Further, as the color powder, blue type, red type,
A yellow system or the like is used. There are blue 1 and blue 2 etc. in the blue system, and red 2, red 3 and red 102 in the red system.
No. 104, red No. 104, red No. 105, red No. 106, etc., and yellow-series includes yellow No. 4, yellow No. 5, etc. In addition to this, any color powder having a color tone different from that of the sheet and not adversely affecting the characteristics of the exhaust gas filter may be used.

Further, the adhesive of this embodiment has an outer ratio of 5 to 20.
A polymer binder of about wt% may be added. Polyvinyl alcohol, methyl cellulose, dynamite glycerin and the like are used as the polymer binder.

Example 1 As a ceramic powder, a mixed powder of clay-based powder containing sericite and siliceous powder, and Al ₂
The O ₃ -SiO ₂ based inorganic fiber and pulp, (Table 1) ratio was formulated as shown in, adding 300 liters of water were mixed and dispersed for 60 minutes in a distributed tank.

[0014]

[Table 1]

The slurry obtained by dispersion mixing is exclusively used
Transfer to a dilution tank with a stirrer, add water and
The product was 600 liters. Then turn the stirrer
194g AlCl₃ ・ 6H₂ O to 300 cc of water
Add the dissolved aqueous solution and after 5 minutes add 90 g of NaOH to 3
An aqueous solution dissolved in 00 cc of water was added to adjust the pH to 7.4-
It was adjusted to be 7.8. Next, add paper strength enhancer
Mixed powder, Al₂ O ₃ -SiO₂ Inorganic fiber
-Add 4.0% of the total weight of pulp and stir for 30 minutes
It was Then, this slurry is reduced to a dedicated secondary flocculation tank.
Paper is transferred while adding the polymer flocculant at the same time.
A sheet was produced by the manufacturing method.

Next, using the sheet having the above-described structure, lamination and winding are performed to form a molded body. An example of this is shown in FIGS. 1 and 2, respectively. 1 and 2,
Reference numeral 1 is a corrugated sheet, 2 is a flat sheet, 3 is an adhesive provided between the sheets 1 and 2, and the adhesive 3 is provided at a contact portion between the apex portion of the sheet 1 and the sheet 2. Has been. The adhesive 3 is composed of ceramic powder, starch, and color powder, and the ceramic powder is made of the same material as the ceramic powder (mixed powder of sericite-containing clay-based powder and siliceous powder) forming the sheets 1 and 2. Has been done. At this time, the ceramic powder composing the adhesive 3 is a mixture of sericite-containing clay-based powder and siliceous powder in a weight ratio of sericite-containing clay-based powder: siliceous powder = 90: 10. As the starch constituting the adhesive 3, a mixture of corn starch and potato starch in a weight ratio of 1: 1 was used.

Reference numeral 4 is a plug material provided in a hole formed between the sheets 1 and 2, 5 is a through hole provided between the sheets 1 and 2, and 6 is a laminated body of the sheets 1 and 2. It is a molded product having a diameter of 19 cm and a length of 20 cm, which is formed by rolling up.

Next, after drying this molded body at 100 ° C., it was set in an electric furnace and fired at 1500 ° C. to produce an exhaust gas filter for a diesel automobile.

In this embodiment, since the adhesive 3 containing the colored powder is used for joining the sheets 1 and 2, the color tone of the adhesive 3 is different from that of the sheets 1 and 2, and the sheet 1 made of the adhesive 3 is different. Since the joining between the two can be easily confirmed with the naked eye, the workability is improved and the yield is increased. Further, since the adhesive 3 containing starch is used, the bonding strength between the sheets 1 and 2 is high after drying, and the mechanical strength of the molded body 6 is improved. Therefore, even if an impact is applied to the molded body 6, the shape does not collapse as in the conventional case, and the handling becomes easy and the productivity is improved.

Since the exhaust gas filter for a diesel vehicle according to this embodiment has a high porosity, the pressure loss is 90 mm.
Low as Aq, high collection efficiency, and specific gravity of 0.5 g /
It was as light as cc. As a reference example, the pressure loss of conventional cordierite honeycomb ceramics is 1
It is as high as 40 mmAq and has a specific gravity of 0.9 g / cc.

Further, the exhaust gas filter for a diesel vehicle according to this embodiment has a coefficient of thermal expansion of 2.0 × 10 ⁻⁶ / ° C. or less between 30 and 800 ° C., and is molded using the adhesive 3. Therefore, the mechanical strength is high despite the high porosity, and the bending strength at room temperature is 100 to 120 kg / c.
It was m ² and had excellent thermal shock resistance. Furthermore, when the fine particles in the exhaust gas were collected for a certain period of time in the exhaust gas filter for a diesel vehicle according to this example and a regenerative combustion test was carried out, the fine particles burned in about 40 minutes, and regenerative combustion was very easy.

In the present embodiment, the firing temperature range of the molded body 6 is preferably 1480 to 1520 ° C. 14
At 80 ° C or lower, the mechanical strength is low and the thermal expansion coefficient is large. At 1520 ° C. or higher, the melting point of the clay containing sericite becomes close to that of the clay, and there is a possibility of partial melting.

(Example 2) The difference from (Example 1) is that instead of producing a corrugated sheet, a rectangular sheet is produced and the rectangular sheet is combined with a flat sheet. 190 x 230 x 2
A 50 mm prismatic shaped body was produced. At this time, the number of laminated layers of the molded body was 70 layers. Next, 100
After drying at ℃, set in an electric furnace, baked at 1500 ℃, processed into a columnar shape, to produce an exhaust gas filter for diesel automobiles.

Also in this embodiment, as in the case of (Example 1), since the adhesive 3 containing color powder was used for joining the sheets, the color tone of the adhesive differs from that of the sheets, and the adhesive 3 is used between the sheets. Since the joining can be easily confirmed with the naked eye, the workability is improved and the yield is increased. Further, since the adhesive 3 containing starch is used, the bonding strength between the sheets after drying is high, and the mechanical strength of the molded body is improved. Therefore, even if an impact is applied to the molded body, it does not lose its shape as in the conventional case, and the handling becomes easy and the productivity is improved.

The exhaust gas filter for a diesel vehicle according to this example also has a high porosity as in (Example 1),
It had low pressure loss, high collection efficiency, and light weight. Moreover, no cracks were formed during the drying of the molded body.

In the present embodiment, the firing temperature range of the molded body is preferably 1480 to 1520 ° C.

(Example 3) The structure was the same as that of (Example 1) except that the sericite-containing clay-based powder alone was used as the ceramic powder used for producing the sheet and the adhesive.

Next, after drying this molded body at 100 ° C., it was set in an electric furnace and fired at 1510 ° C. to produce an exhaust gas filter for a diesel vehicle.

Similarly, in this embodiment, since the adhesive 3 containing the colored powder was used for joining the sheets, the color tone of the adhesive 3 is different from that of the sheets 1 and 2, and the sheets 1 and 2 made of the adhesive 3 are different. Since the joining between them can be easily confirmed with the naked eye, the workability is improved and the yield is increased. Further, since the adhesive 3 containing starch is used, the bonding strength between the sheets 1 and 2 is high after drying, and the mechanical strength of the molded body 6 is improved. Therefore, even if an impact is applied to the molded body 6, the shape does not collapse as in the conventional case, and the handling becomes easy and the productivity is improved.

The exhaust gas filter for a diesel vehicle according to this example also has a high porosity as in (Example 1),
It had low pressure loss, high collection efficiency, and light weight.

In the present embodiment, the firing temperature range of the molded body 6 is preferably 1490 to 1530 ° C. 14
If the temperature is lower than 90 ° C, the firing becomes insufficient and the mechanical strength becomes weak.
Further, at 1530 ° C or higher, there is a possibility of partial melting.

(Example 4) The same structure as in Example 2 was carried out except that a mixed powder of sericite-containing clay-based powder and cordierite was used as the ceramic powder constituting the sheet and the adhesive.

Next, after drying this molded body at 100 ° C., it was set in an electric furnace and fired at 1450 ° C. to produce an exhaust gas filter for diesel automobiles.

In this embodiment as well, since the adhesive 3 containing the colored powder is used for joining the sheets, the color tone of the adhesive 3 is different from that of the sheets, and the joining of the sheets by the adhesive 3 is visually observed. Since it can be easily confirmed, the workability is improved and the yield is increased. Further, since the adhesive 3 containing starch is used, the bonding strength between the sheets after drying is high, and the mechanical strength of the molded body is improved. Therefore, even if an impact is applied to the molded body, it does not lose its shape as in the conventional case, and the handling becomes easy and the productivity is improved.

The exhaust gas filter for a diesel vehicle according to this example also has a high porosity as in (Example 2).
It had low pressure loss, high collection efficiency, and light weight.

In the present embodiment, it is desirable that the firing temperature range of the molded body is 1430 to 1470 ° C. 143
If the temperature is 0 ° C. or lower, the firing will be insufficient, the mechanical strength will be weak, and the thermal expansion coefficient will be large. Further, there is a possibility of melting at 1470 ° C or higher.

Although color powder, for example, was used as the pigment in each of the above-mentioned embodiments, liquid pigment or the like may be used.

Further, although the coloring powder serving as a pigment is added to the adhesive, it may be added to the sheet.

[0039]

EFFECTS OF THE INVENTION The present invention uses the adhesive agent in which the ceramic powder, the starch and the color powder are mixed for the joining between the sheets, so that the color tone of the adhesive and the sheet is different and the joining between the sheets by the adhesive is visible. You can easily check with
Workability is improved and the yield can be increased. In addition, by using an adhesive containing starch for joining the sheets, it is possible to increase the joining force between the sheets of the dried formed body, so that the mechanical strength of the formed body is improved,
Since it is easier to handle, productivity is improved.

[Brief description of drawings]

FIG. 1 is a partially enlarged view showing a molded body manufactured by a method for manufacturing an exhaust gas filter according to a first embodiment of the present invention.

FIG. 2 is a perspective view showing a molded body manufactured by the method for manufacturing an exhaust gas filter according to the first embodiment of the present invention.

[Explanation of symbols]

 1, 2 sheet 3 adhesive 4 plug material 5 through hole 6 molded body

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI Technical display location C04B 38/00 ZAB 303 Z 304 Z 38/06 ZAB B F01N 3/02 ZAB 301 B (72) Invention Makoto Ogawa 1006 Kadoma, Kadoma, Osaka Prefecture Matsushita Electric Industrial Co., Ltd. (72) Inventor, Yukinori Ikeda 1006 Kadoma, Kadoma City, Osaka Matsushita Electric Industrial Co., Ltd.

Claims (11)

[Claims] 1. An exhaust gas filter adhesive which is used for joining sheets when a laminated sheet is rolled up to form a molded article, and which contains a dye. 2. The adhesive for exhaust gas filters according to claim 1, which contains a ceramic material, starch and a pigment. 3. The starch comprises at least one of corn starch and potato starch.
The adhesive for exhaust gas filters described. 4. The adhesive for exhaust gas filters according to claim 2, wherein the ceramic material is a clay powder containing sericite alone, or a clay powder containing sericite is mixed with another ceramic powder. 5. A ceramic material, an inorganic fiber, and pulp are dispersed and mixed, respectively, and then paper-made to prepare a sheet, the sheet is laminated with an adhesive to form a laminated body, and the laminated body is rolled up. A method of manufacturing an exhaust gas filter, comprising forming a molded article by drying and firing the molded article, wherein the adhesive contains a ceramic material and a pigment, and a ceramic material forming a sheet and a ceramic material forming the adhesive. An exhaust gas filter manufacturing method, characterized in that the same material is used. 6. The method for producing an exhaust gas filter according to claim 5, which contains a ceramic material, starch and a pigment. 7. The starch comprises at least one of corn starch and potato starch.
A method for producing the exhaust gas filter described. 8. The production of an exhaust gas filter according to claim 6, wherein the ceramic material forming the sheet material is a sericite-containing clay-based powder alone or a mixture of the sericite-containing clay-based powder and another ceramic powder. Method. 9. An exhaust gas filter in which laminated sheets are joined with an adhesive, wherein the sheets and the adhesive have different colors. 10. The exhaust gas filter according to claim 9, wherein a color is added to the adhesive so that the sheet and the adhesive have different colors. 11. The exhaust gas filter according to claim 10, wherein the adhesive contains a ceramic material, starch and a pigment.