US20060278323A1 - Holding and sealing material and manufacturing method thereof - Google Patents

Holding and sealing material and manufacturing method thereof Download PDF

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Publication number
US20060278323A1
US20060278323A1 US11/444,484 US44448406A US2006278323A1 US 20060278323 A1 US20060278323 A1 US 20060278323A1 US 44448406 A US44448406 A US 44448406A US 2006278323 A1 US2006278323 A1 US 2006278323A1
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Prior art keywords
holding
organic binder
sealing material
mat
emulsion
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US11/444,484
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English (en)
Inventor
Masayuki Eguchi
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Ibiden Co Ltd
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Ibiden Co Ltd
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Application filed by Ibiden Co Ltd filed Critical Ibiden Co Ltd
Assigned to IBIDEN CO., LTD. reassignment IBIDEN CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EGUCHI, MASAYUKI
Publication of US20060278323A1 publication Critical patent/US20060278323A1/en
Priority to US12/257,459 priority Critical patent/US8533950B2/en
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    • 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
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/9454—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific device
    • 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
    • F01N3/18—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 methods of operation; Control
    • F01N3/20—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 methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • 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
    • 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
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies
    • 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
    • Y10T29/49345—Catalytic device making
    • 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
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
    • Y10T428/249964—Fibers of defined composition
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2926—Coated or impregnated inorganic fiber fabric

Definitions

  • the present invention relates to a holding and sealing material of a catalytic converter for purifying an exhaust gas discharged from an internal combustion engine or the like.
  • a catalytic converter 90 for purifying an exhaust gas has been used for purifying an exhaust gas discharged from an internal combustion engine 92 or the like.
  • the catalytic converter 90 has a catalyst carrier 1 , a shell 95 made of metal and covering the outside of the catalyst carrier, and a holding and sealing material 91 which is set between the both.
  • the holding and sealing material 91 can prevent the exhaust gas from leaking out from between the catalyst carrier 1 and the shell 95 , and also, it can prevent the catalyst carrier 1 from damage in contact with the shell 95 .
  • the holding and sealing material 91 is wound around the catalyst carrier 1 , and the wound unit is set within the shell 95 . Then, an inlet connection 97 and an outlet connection 98 are respectively connected to both ends of the shell 95 by welding.
  • the catalytic converter 90 manufactured in the manner mentioned above is set in the middle of a pipe 99 for an exhaust gas discharged from the engine 92 .
  • the holding and sealing material 91 As the holding and sealing material 91 , the material made by infiltrating a mat-like material 911 made of alumina-silica based ceramic fibers (inorganic fibers) or the like with an organic binder 912 has been used. Because the holding and sealing material 91 is an aggregate of filaments and its specific gravity is small, there is a risk that a part of the inorganic fibers flies in all directions in the air from a surface of the holding and sealing material 91 at a time of manufacturing the catalytic converter 90 by mounting the holding and sealing material 91 in the catalyst carrier 1 and the shell 95 ,. Therefore, there is a risk of deteriorating a working environment of a working area for the mounting work, and it is necessary for a worker to work with wearing an antidust mask or the like.
  • alumina fibers aggregate whose average fiber diameter and minimum fiber diameter are controlled to specific range has been developed so far (refer to Patent document 1).
  • the alumina fibers aggregate is assembled to the catalyst carrier 1 and the shell 95 as the holding and sealing material 91 , it is possible to reduce a flying amount of inorganic fibers (alumina).
  • a manufacturing method of a holding and sealing material which is configured to be set between a catalyst carrier and a shell covering the outside of the catalyst carrier in a catalytic converter for purifying an exhaust gas comprising:
  • a infiltrating step for infiltrating a mat-like material formed by arranging inorganic fibers in a mat shape with emulsion made by dispersing a organic binder into water;
  • a drying step for attaching the organic binder to the mat-like material by means of drying the mat-like material containing the emulsion and obtaining the holding and sealing material
  • the organic binder has a glass transition point Tg (° C.) of less than or equal to approximately 5° C.
  • the infiltrating step and the drying step are conducted as described above.
  • the mat-like material formed by arranging inorganic fibers in a mat shape is infiltrated with emulsion made by dispersing the organic binder into water.
  • the drying step by drying the mat-like material containing the emulsion, liquid ingredient in the emulsion is evaporated.
  • the organic binder is attached to a surface and inside and the like of the mat-like material, and the holding and sealing material is obtained.
  • an organic binder with a low glass transition point Tg (° C.) of less than or equal to 5° C. is used as the organic fiber. Therefore, the organic binder attached to the holding and sealing material can exhibit high motility rubbery state at room temperature (e.g. temperature which is equal to or more than glass transition point of the organic binder). Accordingly, at a time of mounting the holding and sealing material in the catalyst carrier and the shell, the organic binder can combine the inorganic fibers each other of the mat-like material and also can exhibit excellent extensity, and it is possible to absorb damage such as a shock or the like given to the holding and sealing material.
  • Tg glass transition point
  • the organic binder can suppress a break of the inorganic fibers of the mat-like material and can hold the inorganic fibers. Therefore, the holding and sealing material can prevent the inorganic fibers from flying in all directions without increasing an amount of an inorganic binder.
  • a holding and sealing material which is configured to be set between a catalyst carrier and a shell covering the outside of the catalyst carrier in a catalytic converter for purifying an exhaust gas comprising:
  • the organic binder with the glass transition point Tg (° C.) of less than or equal to approximately 5° C. is attached to the mat-like material.
  • FIG. 1 is a perspective view which shows a state of mounting a holding and sealing material in a catalyst carrier and a shell, in accordance with an embodiment 1;
  • FIG. 2 is an explanatory drawing which shows a state of setting a catalytic converter for purifying an exhaust gas built-in a holding and sealing material in the middle of the exhaust pipe of the engine, in accordance with the embodiment 1 ;
  • FIG. 3 is an explanatory drawing which (A) shows a state prior to winding the holding and sealing material around the catalyst carrier and (B) shows a state of winding the holding and sealing material around the catalyst carrier, in accordance with the embodiment 1;
  • FIG. 4 is an explanatory drawing which shows a state of setting a unit formed by winding the holding and sealing material around the catalyst carrier within the shell, in accordance with the embodiment 1;
  • FIG. 5 is an explanatory drawing which shows a state of setting a conventional catalytic converter for purifying an exhaust gas assembled in the middle of the exhaust pipe of the engine.
  • the holding and sealing material can be manufactured.
  • the mat-like material formed by arranging inorganic fibers in a mat shape is infiltrated with emulsion made by dispersing the organic binder into water.
  • the one with the glass transition point Tg (° C.) of less than or equal to approximately 5° C. is employed.
  • the glass transition point Tg (° C.) exceeds approximately 5° C., it is impossible that the organic binder adequately suppresses a break of the inorganic fibers of the mat-like material at a time of mounting the holding and sealing material, and there is a risk that a part of the inorganic fibers flies in all directions in the air while at assembling work.
  • the glass transition point Tg (° C.) of the organic binder is equal to or more than approximately ⁇ 20° C.
  • the organic binder is hardly to exude outside from the holding and sealing material at the mounting work, and there is almost no risk that the working environment around the mounting jig or the like is polluted by the organic binder.
  • the organic binder is a rubber on which is not conducted a crosslinking process.
  • the organic binder in the infiltrating step, is easy to adapt to a surface of the mat-like material, and it is possible to equally infiltrate a surface of the inorganic fibers of the mat-like material with the emulsion. Accordingly, in the drying step, the organic binder is attached almost equally on the surface or inside of the mat-like material, it is possible to suppress a flying ratio more of the inorganic fibers from the holding and sealing material.
  • organic binder for example, acrylic based rubber, styrene-butadiene rubber (SBR), acrylate based rubber, methacrylate based rubber or the like can be employed.
  • SBR styrene-butadiene rubber
  • acrylate based rubber methacrylate based rubber or the like
  • the organic binder is an acrylate based rubber or a methacrylate based rubber.
  • the organic binder is more equally attached on the surface or the like of the inorganic fibers of mat-like material.
  • the elongation of the organic binder becomes better after the drying step, and it is possible to prevent the fibers from being tied up constrainedly. Therefore, it is possible to prevent the inorganic fibers from breaking at a time of mounting in the catalyst carrier and the shell, and to prevent the inorganic fibers from flying in all directions further.
  • the emulsion has a surface tension of less than or equal to approximately 60 mN/M at the room temperature.
  • a surface tension of the emulsion is less than or equal to approximately 60 mN/M, the emulsion is easy to adapt to a surface of the mat-like material, and thus, organic binder is easily to be attached equally in the mat-like material.
  • surface tension of the emulsion should be equal to or more than approximately 20 mN/m.
  • the emulsion with less than or equal to approximately 60 mN/m of surface tension can be manufactured by, for example, using rubber on which is not conducted a crosslinking process as described above.
  • Surface tension of the emulsion can be measured, for example, by a ring method.
  • the emulsion has an emulsion particle diameter of less than or equal to approximately 300 nm.
  • the emulsion particle diameter is less than or equal to approximately 300 nm, in the infiltrating step, it is easy to infiltrate the surface of the mat-like material with the emulsion. More preferably, the emulsion particle diameter is not greater than approximately 150 nm, and much more preferably, not greater than approximately 100 nm.
  • the the emulsion particle diameter can be measured by evaluating average value of the particle diameter of, for example, 100 pieces of the emulsion by measured by using a transmission electron microscope.
  • the drying step by drying the mat-like material containing the emulsion, the organic binder is attached to the mat-like material and then the holding and sealing material is manufactured.
  • the mat-like material containing the emulsion is dried with heating and pressing.
  • the drying step is conducted under the temperature between approximately 95 to 155° C.
  • the drying temperature is equal to or greater than 95° C., there is almost no risk that the drying time gets longer and manufacturing efficiency decreases. On the other hand, in the case the drying temperature is lower than or equal to 155° C., there is almost no risk that dissolution of the organic binder starts and the adhesion property of the organic binder is spoiled. In addition, it is preferable that the drying time is equal to or more than 100 minutes. If the drying time is more than 100 minutes, enough drying is performed easily.
  • compression is performed under the compression interval of 4 to 15 mm.
  • the compression interval is equal to or longer than approximately 4 mm, damage of the inorganic fibers hardly occurs.
  • the compression interval is smaller than or equal to approximately 15 mm, it is easy to obtain the above described effect by the compression sufficiently.
  • crosslinking reaction of the organic binder can be proceeded by heating at the drying step.
  • the crosslinking reaction is too proceeded, there is a risk that extensity of the organic binder is spoiled. Therefore, in the drying step, it is preferable to making the crosslinking degree of the organic binder lower than or equal to approximately 70%. Since the crosslinking degree of the organic binder is varies, for example, by composition or the like of the organic binder, the organic binder whose final the crosslinking degree after the drying step is less than or equal to approximately 70% can be chosen.
  • the crosslinking degree of the organic binder can be measured, for example, by gel content measurement method.
  • attached ratio of the organic binder in the holding and sealing material is preferably in the range of 0.5 wt % to 1.5 wt %.
  • the attached ratio is equal to or more than approximately 0.5 wt %, it is easy to prevent the inorganic fibers fully from flying in all directions from a surface of the holding and sealing material.
  • the attached ratio is less than or equal to approximately 1.5 wt %, amount of the organic binder increases, and there is almost no risk that the poisonous gas such as nonmethane hydrocarbons, nitrogen oxide or the like might be occurred from the holding and sealing material.
  • a solid content removal step for removing extra solid content of the organic binder attached in the mat-like material.
  • a solid content removal step can be conducted, for example, by suction or the like.
  • the holding and sealing material is comprised by attaching the organic binder into the mat-like material which is formed by arranging the inorganic fibers in a mat shape.
  • the material similar to the one in the first aspect of the present invention can be used.
  • the one with a glass transition point Tg (° C.) of less than or equal to 5° C. is employed.
  • the reason for the critical point is similar to the one in the first aspect of the present invention and it is preferable that the glass transition Tg of the organic binder is equal to or more than ⁇ 20° C.
  • organic binder as same as the first aspect of the present invention, for example, acrylic based rubber, styrene-butadiene rubber (SBR), acrylate based rubber, methacrylate based rubber or the like can be employed.
  • SBR styrene-butadiene rubber
  • acrylate based rubber methacrylate based rubber or the like
  • the organic binder is an acrylate based rubber or a methacrylate based rubber.
  • the elongation of the organic binder becomes better and it is possible to prevent the fibers from being tied up constrainedly. Therefore, it is possible to prevent the inorganic fibers from breaking at a time of mounting in the catalyst carrier and the shell, and to prevent the inorganic fibers from flying in all directions further.
  • a flying ratio of the inorganic fibers is less than or equal to 0.15 wt %.
  • a flying ratio of the inorganic fibers is more preferably less than or equal to 0.10 wt %.
  • the flying ratio of the inorganic fibers can be defined by a pace of decrease of weight when a device according to Japanese Industrial Standards K6830-1996-26 low temperature resistant test•26.2 test device (4) impact testing machine is used.
  • the crosslinking degree of the organic binder attached in the holding and sealing material is less than or equal to approximately 70%.
  • crosslinking degree is less than or equal to approximately 70%, extensity of the organic binder is lowered and there is almost no risk that the prevention effect for the flying of the inorganic fibers from the holding and sealing material is reduced.
  • FIG. 1 to FIG. 4 the holding and sealing material relates to the embodiment in the present invention is explained with FIG. 1 to FIG. 4 .
  • the holding and sealing material 2 of the present embodiment is used as being disposed on between the catalyst carrier 1 and the shell 95 which covers outer of the catalyst carrier 1 in the catalytic converter for purifying an exhaust gas 10 .
  • the mat-like material is formed by arranging the inorganic fibers in mat shape, and the organic binder 22 with the glass transition point Tg (° C.) of less than or equal to 5° C. is attached to the mat-like material 21 (refer to FIGS. 3 (A) and (B)).
  • the catalyst carrier 1 As the catalyst carrier 1 , a cordierite carrier whose a transverse sectional surface is formed in a honeycomb shape. A lot of rectangular holes 11 are provided along an axial direction in this catalyst carrier 1 . Further, a lot of honeycomb walls 12 which is the partition walls of the rectangular holes 11 are formed between the rectangular holes 11 (refer to FIG. 1 ). Further, a catalyst mainly composed of a platinum or a palladium is supported on the catalyst carrier 1 .
  • inorganic fibers constituting the mat-like material 21 crystalline alumina fibers which is non-expansible fibers arranged so as not to expand so much by heat.
  • the infiltrating step and the drying step are conducted.
  • the infiltrating step the emulsion made by dispersing the organic binder 22 into water is infiltrated into the mat-like material 21 formed by arranging inorganic fibers in a mat shape.
  • the drying step the holding and sealing material 2 is obtained by attaching the organic binder 22 to the mat-like material 21 by means of drying the mat-like material 21 containing the emulsion.
  • the organic binder the one with a glass transition point Tg (° C.) of less than or equal to 5° C. is used.
  • a solid content removal step for removing extra solid content of the organic binder 22 attached in the mat-like material 21 is conducted in between the infiltrating step and the drying step.
  • the mat-like material 21 with dimensions of lengthwise 500 to 1400 mm ⁇ crosswise 51,000 to 52,500 mm, and thickness 1.5 to 12 m was prepared.
  • the mat-like material 21 was infiltrated with the emulsion containing the organic binder.
  • acrylonitrile-butadiene copolymer latex (the emulsion particle diameter: 50 nm, the glass transition point of the organic binder: ⁇ 21° C., the density of the organic binder: 1 wt %) made by dispersing acrylonitrile-butadiene copolymer rubber to water was prepared.
  • This emulsion was infiltrated by pouring method into the mat-like material 21 set on the conveyer.
  • suction for equal to or more than 1 minute was conducted to remove solid content of the extra organic binder attaching to the mat-like material 21 .
  • the suction when the impregnated rate of the emulsion was measured by weighing instrument, the emulsion 22 of 100 parts by weight was impregnated against the mat-like material 21 of 100 parts by weight.
  • Heating, compressing, and drying of the mat-like material 21 was conducted. Heating, compressing, and drying was conducted under the condition of temperature of 95 to 155° C., drying time of equal to or more than 100 minutes, and interval pressurisation at the time of drying of 4 to 15 mm.
  • the holding and sealing material 2 with the attached rate of the organic binder of 1.0 wt % and thickness of 3 to 15 mm was obtained.
  • the catalyst was supported on the catalyst carrier 1 in advance.
  • the holding and sealing material 2 was wound (refer to FIGS. 3 (A) and (B)) onto the catalyst carrier 1 and the wound unit 20 was set into the inside of the shell 95 (refer to FIG. 4 ).
  • mounting of the holding and sealing material 2 was conducted, an inlet connection 97 and an outlet connection 98 were respectively connected to the both ends of the shell 95 by welding (refer to FIG. 2 ).
  • the catalytic converter for purifying an exhaust gas 10 manufactured by this means can be used by setting in the midstream of a pipe for exhaust gas discharged by an engine.
  • the one with glass transition point Tg (° C.) of less than or equal to 5° C. is used (refer to FIG. 1 ).
  • the organic binder 22 attached to the holding and sealing material 2 can exhibit the rubber state with high motility at room temperature.
  • the organic binder exhibits an excellent extensity and making it possible to absorb damages such as impacts or the like given to the inorganic fibers of the holding and sealing material 2 .
  • the workers can comfortably work without wearing the antidust mask or the like and it is possible to keep the working environment of working area for the amounting work good.
  • a drop test was conducted as described below in order to make sure of difficulty of flying the inorganic fibers contained in the holding and sealing material in all directions in the air.
  • a plural number of holding and sealing materials (sample E 1 to sample E 4 , sample C 1 to sample C 4 ) was manufactured by using the emulsion containing the organic binders having different glass transition point (Tg). And then, they were dropped from the specific height and difficulty of flying the inorganic fibers in all directions in the air at this time was evaluated.
  • Sample E 1 was manufactured by infiltrating with acrylonitrile-butadiene copolymer latex (the glass transition point Tg of the organic binder: ⁇ 21° C., the emulsion particle diameter: 50 nm, the density of the organic binder: about 1 wt %) made by dispersing acrylonitrile-butadiene copolymer rubber into water as the emulsion, and then, by conducting suction, heating, compressing, and drying as well as embodiment 1.
  • the holding and sealing material in sample E 1 is the same as the one in embodiment 1.
  • Sample E 2 was manufactured by infiltrating with denatured acrylic ester copolymer latex (the glass transition point Tg of the organic binder: ⁇ 5° C., the emulsion particle diameter: 80 nm, the density of the organic binder: about 1 wt %) made by dispersing denatured acrylic ester copolymer rubber into water as the emulsion, and then, by conducting suction, heating, compressing, and drying as well as embodiment 1.
  • denatured acrylic ester copolymer latex the glass transition point Tg of the organic binder: ⁇ 5° C., the emulsion particle diameter: 80 nm, the density of the organic binder: about 1 wt %
  • sample E 3 is manufactured by infiltrating with denatured acrylic ester copolymer latex (the glass transition point Tg of the organic binder: 1° C., the emulsion particle diameter: 110 nm, the density of the organic binder: about 1 wt %), and then, by conducting suction, heating, compressing, and drying as well as embodiment 1.
  • denatured acrylic ester copolymer latex the glass transition point Tg of the organic binder: 1° C., the emulsion particle diameter: 110 nm, the density of the organic binder: about 1 wt %
  • sample E 4 is manufactured by infiltrating with denatured acrylic ester copolymer latex (the glass transition point Tg of the organic binder: ⁇ 10° C., the emulsion particle diameter: 260 nm, the density of the organic binder: about 1 wt %), and then, by conducting suction, heating, compressing, and drying as well as embodiment 1.
  • denatured acrylic ester copolymer latex the glass transition point Tg of the organic binder: ⁇ 10° C., the emulsion particle diameter: 260 nm, the density of the organic binder: about 1 wt %
  • sample C 1 is manufactured by infiltrating with acrylonitrile-butadiene-styrene three dimension copolymer latex (the glass transition point Tg of the organic binder: 26° C., the emulsion particle diameter: 40 nm, the density of the organic binder: about 1 wt %) made by dispersing acrylonitrile-butadiene-styrene three dimension copolymer rubber into water as the emulsion, and then, by conducting suction, heating, compressing, and drying as well as embodiment 1.
  • acrylonitrile-butadiene-styrene three dimension copolymer latex the glass transition point Tg of the organic binder: 26° C., the emulsion particle diameter: 40 nm, the density of the organic binder: about 1 wt % made by dispersing acrylonitrile-butadiene-styrene three dimension copolymer rubber into water as the emulsion, and then, by conducting suction,
  • sample C 2 is manufactured by infiltrating with denatured styrene-butadiene copolymer latex (glass transition point Tg of the organic binder: 12° C., the emulsion particle diameter: 80 nm, density of the organic binder: about 1 wt %) made by dispersing denatured styrene-butadiene copolymer rubber into water as the emulsion, and then, by conducting suction, heating, compressing, and drying as well as embodiment 1.
  • denatured styrene-butadiene copolymer latex glass transition point Tg of the organic binder: 12° C., the emulsion particle diameter: 80 nm, density of the organic binder: about 1 wt % made by dispersing denatured styrene-butadiene copolymer rubber into water as the emulsion, and then, by conducting suction, heating, compressing, and drying as well as embodiment 1.
  • sample C 3 is manufactured by infiltrating with denatured styrene-butadiene copolymer latex (glass transition point Tg of the organic binder: 20° C., the emulsion particle diameter: 160 nm, density of the organic binder: about 1 wt %), and then, by conducting suction, heating, compressing, and drying as well as embodiment 1.
  • sample C 4 is manufactured by infiltrating with denatured acrylic ester copolymer latex (the glass transition point Tg of the organic binder: 25° C., the emulsion particle diameter: 110 nm, the density of the organic binder: about 1 wt %), and then, by conducting suction, heating, compressing, and drying as well as embodiment 1.
  • denatured acrylic ester copolymer latex the glass transition point Tg of the organic binder: 25° C., the emulsion particle diameter: 110 nm, the density of the organic binder: about 1 wt %
  • the organic binder of approximately 1.0 wt % was attached to the mat-like material as is the case with the embodiment 2.
  • the holding and sealing material of sample E 1 to sample E 4 manufactured by using the emulsion containing the organic binder with low glass transition point Tg shows very low flying ratio of more than 0.116 wt % at the maximum.
  • the holding and sealing material of sample C 1 to sample C 4 manufactured by using the emulsion containing the organic binder with high glass transition point Tg shows high flying ratio. This is because the organic binder shows the rubber state with high motility at room temperature and exhibits excellent extensity, and impacts given to the inorganic fibers of the holding and sealing material can be sufficiently absorbed in the sample E 1 to sample E 4 .
  • sample E 1 to sample E 4 and sample C 1 to sample C 4 small amount of about 1.0 wt % of the organic binder is attached.
  • Sample E 1 to sample E 4 can exhibits low flying ratio as described above even if such as a small amount of the organic binder is used. Accordingly, sample E 1 to sample E 4 is safe for the environment and it is possible to sufficiently prevent the inorganic fibers from flying in all directions at the time of handling.
  • JP 2003-105658 and Japanese Industrial Standards K6830-1996•26 are incorporated herein by reference.

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  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Toxicology (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Biomedical Technology (AREA)
  • Environmental & Geological Engineering (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Catalysts (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
US11/444,484 2005-06-10 2006-06-01 Holding and sealing material and manufacturing method thereof Abandoned US20060278323A1 (en)

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US8533950B2 (en) 2013-09-17
KR100762116B1 (ko) 2007-10-02
CN1876748A (zh) 2006-12-13
KR20060128742A (ko) 2006-12-14
CN1876748B (zh) 2010-11-17
US20090049690A1 (en) 2009-02-26
JP2006342774A (ja) 2006-12-21
EP1731729A1 (en) 2006-12-13
EP1731729B2 (en) 2023-03-08
JP4665618B2 (ja) 2011-04-06
EP1731729B1 (en) 2012-12-26

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