US20070140929A1 - Pollution control device and mat for mounting a pollution control element - Google Patents

Pollution control device and mat for mounting a pollution control element Download PDF

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Publication number
US20070140929A1
US20070140929A1 US10/534,893 US53489303A US2007140929A1 US 20070140929 A1 US20070140929 A1 US 20070140929A1 US 53489303 A US53489303 A US 53489303A US 2007140929 A1 US2007140929 A1 US 2007140929A1
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Prior art keywords
fiber layer
mat
pollution control
alumina
control device
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US10/534,893
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English (en)
Inventor
Toshiyuki Watanabe
Muneki Miyasaka
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3M Innovative Properties Co
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3M Innovative Properties Co
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Assigned to 3M INNOVATIVE PROPERTIES COMPANY reassignment 3M INNOVATIVE PROPERTIES COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MIYASAKA, MUNEKI, WATANABE, TOSHIYUKI
Publication of US20070140929A1 publication Critical patent/US20070140929A1/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
    • F01N3/18—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
    • 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
    • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86—Catalytic processes
    • B01D53/88—Handling or mounting catalysts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/008—Producing shaped prefabricated articles from the material made from two or more materials having different characteristics or properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/527—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement by delivering the materials on a rotating drum, e.g. a sieve drum, from which the materials are picked up by a felt
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B30/00—Compositions for artificial stone, not containing binders
    • C04B30/02—Compositions for artificial stone, not containing binders containing fibrous materials
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • 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
    • F01N3/24—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
    • 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
    • F01N3/2864—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 the mats or gaskets comprising two or more insulation layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2265/00—Casings, housings or mounting for filters specially adapted for separating dispersed particles from gases or vapours
    • B01D2265/06—Details of supporting structures for filtering material, e.g. cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2279/00—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses
    • B01D2279/30—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses for treatment of exhaust gases from IC Engines
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00793—Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms
    • 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
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/02—Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
    • 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
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/06—Ceramic, e.g. monoliths
    • 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
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/0211—Arrangements for mounting filtering elements in housing, e.g. with means for compensating thermal expansion or vibration
    • 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
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
    • Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
    • 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

Definitions

  • the present invention relates to pollution control devices (e.g., catalytic converters, diesel particulate filters, etc.), to mats for mounting pollution control elements in such devices and, in particular, to catalytic converters used in exhaust gas purification devices and, more particularly, to a mat for mounting a catalyst support in a catalytic converter housing.
  • pollution control devices e.g., catalytic converters, diesel particulate filters, etc.
  • Catalytic converters used in the exhaust gas purification devices of automobile and diesel engines normally contain a catalyst support composed of a monolith having a so-called “honeycomb structure” in which through holes are arranged in the shape of honeycombs, in a metal housing.
  • This monolith is loaded with a catalyst such as a precious metal, and purifies exhaust gas by oxidizing carbon monoxide and hydrocarbons and reducing nitrogen oxides.
  • This monolith catalyst support is formed from a metal or ceramic material.
  • a mat for mounting the catalyst support composed of alumina-silica-based fibers or other ceramic fibers is arranged between the metal housing and catalyst support, and the catalyst support is held and protected from damage.
  • the coefficient of thermal expansion of ceramic catalyst support is typically nearly a power of ten smaller than the coefficient of thermal expansion of the metal housing.
  • catalytic converters are normally exposed to high temperatures of several hundred degrees, under such high temperatures, the thermal expansion of the metal housing exceeds the thermal expansion of the ceramic catalyst support due to the difference in the coefficients of thermal expansion between the metal housing and ceramic catalyst support.
  • gaps expand between the metal housing and catalyst support resulting in a decrease in the holding strength of the catalyst support, leading to problems such as the occurrence of rattling in the catalyst support.
  • a mat for mounting a pollution control element like a catalyst support, can be provided that maintains support holding strength without impairing elasticity even when exposed to temperatures in excess of 800° C. for long periods of time.
  • the present invention can provide a mat for mounting a pollution control element (e.g., a catalyst support, diesel particulate filter, etc.), and the pollution control device containing such a mat, where the mat comprises at least two layers, an alumina fiber layer and a ceramic fiber layer. These layers can be provided in the form a single sheet without the use of an auxiliary bonding means.
  • a pollution control element e.g., a catalyst support, diesel particulate filter, etc.
  • FIG. 1 is an exploded perspective view of a catalytic purification device.
  • FIG. 2 is a cross-sectional view showing the constitution of a mat for mounting a catalyst support of the present invention.
  • FIG. 3 is a graph showing the changes over time in the bearing pressure of the mat for mounting a catalyst support of Sample 3.
  • FIG. 4 is a graph showing the extrapolated values of bearing pressure after 10 years of samples of Examples 1 and 2 and Comparative Example 1.
  • FIG. 1 is an exploded perspective view of a typical catalytic converter.
  • Catalytic converter 10 contains catalyst support 20 , composed of a monolith having a so-called “honeycomb structure” in which through holes are arranged in the shape of honeycombs, in a metal housing 11 .
  • This monolith is loaded with a catalyst that purifies exhaust gas by oxidizing carbon dioxide and hydrocarbons and reducing nitrogen oxides.
  • Catalyst support 20 is normally formed from a ceramic material, and is frequently extremely brittle. Consequently, a mat 3 for mounting a catalyst support is arranged between metal housing 11 and catalyst support 20 to protect catalyst support 20 from damage.
  • mat 30 for mounting a catalyst support of the present invention contains at least two layers consisting of an alumina fiber layer 31 and a ceramic fiber layer 32 , and these layers form a single sheet without the use of an auxiliary bonding means.
  • Alumina fiber layer 31 is formed from alumina fibers prepared by a precursor fibering process and ceramic fiber layer 32 is formed from ceramic fibers prepared by melting a mixture of alumina (Al 2 O 3 ), silica (SiO 2 ) and other oxides followed by melt blowing or melt spanning. These fibers are formed from 80-95 wt % of fibers and 5-20 wt % of binder.
  • the alumina fibers that compose alumina fiber layer 31 are crystalline fibers that contain 50 wt % or more, and preferably 70 wt % or more, of alumina.
  • the ceramic fibers that compose ceramic fiber layer 32 are RCF (Refractory Ceramic Fiber) that contain 45 wt % or more of silica.
  • examples of other oxides besides alumina and silica include zirconia (ZrO 2 ), magnesia (MgO), calcia (CaO), chromium oxide (Cr 2 O 3 ), yttrium oxide (Y 2 O 3 ) and lanthanum oxide (La 2 O 3 ).
  • the ceramic fibers that compose ceramic fiber layer 32 are preferably annealed. Annealing improved elasticity and improves the holding strength and durability of the mat. This annealing is carried out at a temperature of 700-1200° C., and preferably 950-1100° C., and the annealing time is preferably 0.5-2 hours.
  • Acrylic resin styrene-butadiene, vinyl pyridine, acrylonitrile, vinyl chloride or polyurethane and so forth is used for the binder.
  • an inorganic binder e.g., glass particles, calcium carbonate, mica or magnesium hydroxide
  • flexible thermosetting resin e.g., unsaturated polyester, epoxy resin or polyvinyl ester
  • the mat for mounting a catalyst support of the present invention is formed by forming a single sheet without the use of an auxiliary bonding means, such as by simultaneously forming a ceramic fiber layer on the upper surface of an alumina fiber layer.
  • This “auxiliary bonding means” refers to an externally used adhesive means such as resin, adhesive, adhesive tape, stitches or staples.
  • Mats for mounting a catalyst support of the prior art that are composed of a multi-layered laminate were formed by first individually forming each layer followed by mutually adhering the layers using adhesive, adhesive film, stitches or staples.
  • multi-layered mats in which the individual layers were adhered with adhesive or adhesive film may typically produce undesirable smoke or odor when used in a catalytic converter.
  • this adhesive or adhesive film has an effect on the heat resistance of the mat.
  • the production costs of such a mat increase due to the cost of mutually adhering each layer as well as the cost of the adhesive or adhesive film used.
  • the mechanical strength of the mat decreases at those sites where the stitches penetrate the mat, and there are problems with costs of the additional steps and materials required.
  • the present invention eliminates the above problems since a single sheet is formed from an alumina fiber layer and ceramic fiber layer without the use of such auxiliary bonding means.
  • the mat for mounting a catalyst support of the present invention is formed by preparing a slurry containing alumina fibers and a slurry containing ceramic fibers (the solid portion of these slurries are preferably 5 wt % or less), adhering the first slurry to a screen or wire and so forth of a rolling machine, forming a lower layer by partially dehydrating this first slurry by gravity and/or vacuum, adhering the second slurry to the above partially dehydrated lower layer, forming an upper layer by similarly partially dehydrating, and then pressing using a pressing roller to increase the densities of both layers followed by drying completely with a heated roller.
  • the alumina fiber layer or ceramic fiber layer may be initially formed as the lower layer, it is preferable during drying that the thickest layer be the lower layer that is formed first.
  • the weight ratio between the alumina fiber layer and the ceramic fiber layer is preferably 3:11-11:3.
  • the mat for mounting a catalyst support of the present invention may employ a structure of three or more layers that include other layers composed of these materials or other materials. In this case, however, at least one of the outermost layers must be an alumina fiber layer.
  • a catalytic purification device can be completed by wrapping the mat for mounting a catalyst support obtained in this manner around a catalyst support to that an alumina fiber layer is in contact with the catalyst support, and then containing it in a metal housing.
  • 92 wt % of alumina fibers composed of 72 wt % of alumina and 28 wt % of silica, were mixed with 8 wt % of binder (acrylic latex, Nippon Zeon: Nippore LX-816) followed by the addition of water to prepare a first slurry.
  • binder acrylic latex, Nippon Zeon: Nippore LX-8166
  • silica fibers Shinnikka Thermal Ceramics: SC-1260D1
  • Samples 1 through 5 of mats for mounting a catalyst support having the weighing capacity ratios between the alumina fiber layer and ceramic fiber layer shown in Table 1 were obtained by the above ordinary rolling method using these slurries.
  • samples 6 through 8 of mats for mounting a catalyst support shown in Table 2 were obtained in the same manner as Example 1.
  • each sample was cut to a diameter of 45 mm, and each cut sample was then clamped between two plates above and below of a compression tester so that the alumina fiber layer was on the high-temperature (900° C.) side.
  • the samples were compressed and the pressure was adjusted to 130 kPa after 5 minutes.
  • the two upper and lower plates were heated and the times when the plates reached 900° C. and 700° C., respectively, were taken to be time 0.
  • the changes in bearing pressure were then recorded every hour for 20 hours.
  • the results for sample 3 are shown in FIG. 3 .
  • FIG. 4 A graph containing a plot of extrapolated bearing pressure values after ten years is shown in FIG. 4 .
  • the high-temperature holding strength after 10 years of the mat for mounting a catalyst support of the present invention is improved by about 40% over a mat containing an expanding agent of the prior art at alumina fiber layer to ceramic fiber layer ratios of 7:7-3:1.
  • high-temperature holding strength after 10 years was improved by about 4-5 times at an alumina fiber layer to ceramic fiber layer ratio of 3:11, and by about two times at an alumina fiber layer to ceramic fiber layer ratio of 7:7.
  • the mat for mounting a catalyst support of the present invention maintains support holding strength without impairing elasticity even if exposed to high temperatures in excess of 800° C. for long periods of time.

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  • Organic Chemistry (AREA)
  • Exhaust Gas After Treatment (AREA)
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US10/534,893 2002-12-26 2003-11-17 Pollution control device and mat for mounting a pollution control element Abandoned US20070140929A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2002377557A JP2004204819A (ja) 2002-12-26 2002-12-26 触媒担体保持用マット
JP2002-377557 2002-12-26
PCT/US2003/036478 WO2004061279A1 (en) 2002-12-26 2003-11-17 Pollution control device and mat for mounting a pollution control element

Publications (1)

Publication Number Publication Date
US20070140929A1 true US20070140929A1 (en) 2007-06-21

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US10/534,893 Abandoned US20070140929A1 (en) 2002-12-26 2003-11-17 Pollution control device and mat for mounting a pollution control element

Country Status (10)

Country Link
US (1) US20070140929A1 (ja)
EP (1) EP1588033B1 (ja)
JP (1) JP2004204819A (ja)
KR (1) KR101009886B1 (ja)
CN (1) CN100371566C (ja)
AT (1) ATE399257T1 (ja)
AU (1) AU2003297272A1 (ja)
DE (1) DE60321828D1 (ja)
WO (1) WO2004061279A1 (ja)
ZA (1) ZA200505966B (ja)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050232827A1 (en) * 2004-04-14 2005-10-20 3M Innovative Properties Company Multilayer mats for use in pollution control devices
US20080078150A1 (en) * 2006-09-29 2008-04-03 Ibiden Co., Ltd. Laminated sheet, method of producing the sheet, exhaust gas processing device, and method of producing the device
US20080206114A1 (en) * 2005-10-19 2008-08-28 Hornback Loyd R Multilayer Mounting Mats and Pollution Control Devices Containing Same
US20080253939A1 (en) * 2005-10-13 2008-10-16 Hornback Loyd R Multilayer Mounting Mats and Pollution Control Devices Containing Same
US20090257925A1 (en) * 2008-04-15 2009-10-15 Ibiden Co., Ltd. Holding sealing material, exhaust gas purifying apparatus, and method for manufacturing holding sealing material
US20090304560A1 (en) * 2006-06-01 2009-12-10 3M Innovative Properties Company Multilayer mounting mat
US20100233464A1 (en) * 2006-01-13 2010-09-16 Mitsuo Unno Composition for friction material and friction material using same
US20130118138A1 (en) * 2011-11-16 2013-05-16 Ibiden Co., Ltd. Holding sealing material, method for producing holding sealing material, and exhaust gas purifying apparatus
US9605576B2 (en) 2009-09-18 2017-03-28 3M Innovative Properties Company Mounting mat

Families Citing this family (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5068452B2 (ja) * 2005-10-07 2012-11-07 イビデン株式会社 保持シール材および排気ガス処理装置
CN101443090B (zh) * 2006-03-31 2013-05-15 阿尔贡尼德公司 结合超细或纳米尺寸粉末的无纺介质
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
JP2013204424A (ja) 2012-03-27 2013-10-07 Honda Motor Co Ltd 排気ガス浄化用触媒コンバーター装置及び鞍乗り型車両
JP5999980B2 (ja) * 2012-05-23 2016-09-28 スリーエム イノベイティブ プロパティズ カンパニー 取付システム及び汚染制御装置
CN105829606B (zh) * 2013-12-19 2020-03-20 3M创新有限公司 使用可再循环的废水来制备适用于污染控制设备或挡火物中的非织造纤维材料
EP2993323B1 (en) * 2014-09-04 2017-07-19 3M Innovative Properties Company Mounting mat for a pollution control element or a chemical reactor
CN115680847A (zh) 2018-06-21 2023-02-03 3M创新有限公司 垫材料、其制造方法、污染控制装置和隔热结构
JP2020033935A (ja) 2018-08-30 2020-03-05 スリーエム イノベイティブ プロパティズ カンパニー 保持材及びその製造方法、並びに、汚染コントロール装置
JP7224156B2 (ja) 2018-11-30 2023-02-17 スリーエム イノベイティブ プロパティズ カンパニー マット材及びその製造方法、並びに、無機接着シート、汚染コントロール装置及び断熱構造体
EP4077892A1 (en) 2019-12-17 2022-10-26 3M Innovative Properties Company Thermal insulation structure and method of making same

Citations (4)

* Cited by examiner, † Cited by third party
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US4863700A (en) * 1985-04-16 1989-09-05 Stemcor Monolithic catalytic converter mounting arrangement
US5094074A (en) * 1990-02-23 1992-03-10 Nissan Motor Co., Ltd. Catalytic converter with metallic carrier and method for producing same
US5250269A (en) * 1992-05-21 1993-10-05 Minnesota Mining And Manufacturing Company Catalytic converter having a metallic monolith mounted by a heat-insulating mat of refractory ceramic fibers
US6051193A (en) * 1997-02-06 2000-04-18 3M Innovative Properties Company Multilayer intumescent sheet

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JPS60187712A (ja) * 1984-03-08 1985-09-25 Nissan Motor Co Ltd 内燃機関の排気マニホ−ルド
JP3919034B2 (ja) * 1997-04-10 2007-05-23 三菱化学株式会社 無機繊維成形体および触媒コンバーター
CA2371116C (en) * 1999-06-08 2007-09-25 3M Innovative Properties Company High temperature mat for a pollution control device
WO2003050397A2 (en) * 2001-12-07 2003-06-19 Dan T. Moore Company Insulated exhaust manifold having internal catalyst support body

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4863700A (en) * 1985-04-16 1989-09-05 Stemcor Monolithic catalytic converter mounting arrangement
US5094074A (en) * 1990-02-23 1992-03-10 Nissan Motor Co., Ltd. Catalytic converter with metallic carrier and method for producing same
US5250269A (en) * 1992-05-21 1993-10-05 Minnesota Mining And Manufacturing Company Catalytic converter having a metallic monolith mounted by a heat-insulating mat of refractory ceramic fibers
US6051193A (en) * 1997-02-06 2000-04-18 3M Innovative Properties Company Multilayer intumescent sheet
US6224835B1 (en) * 1997-02-06 2001-05-01 3M Innovative Properties Company Multilayer intumescent sheet
US6365267B1 (en) * 1997-02-06 2002-04-02 3M Innovative Properties Company Multilayer intumescent sheet and pollution control device

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050232827A1 (en) * 2004-04-14 2005-10-20 3M Innovative Properties Company Multilayer mats for use in pollution control devices
US7550118B2 (en) * 2004-04-14 2009-06-23 3M Innovative Properties Company Multilayer mats for use in pollution control devices
US20080253939A1 (en) * 2005-10-13 2008-10-16 Hornback Loyd R Multilayer Mounting Mats and Pollution Control Devices Containing Same
US8071039B2 (en) 2005-10-13 2011-12-06 3M Innovative Properties Company Multilayer mounting mats and pollution control devices containing same
US8080210B2 (en) 2005-10-19 2011-12-20 3M Innovative Properties Company Multilayer mounting mats and pollution control devices containing same
US20080206114A1 (en) * 2005-10-19 2008-08-28 Hornback Loyd R Multilayer Mounting Mats and Pollution Control Devices Containing Same
US20100233464A1 (en) * 2006-01-13 2010-09-16 Mitsuo Unno Composition for friction material and friction material using same
US7914871B2 (en) * 2006-01-13 2011-03-29 Hitachi Chemical Co., Ltd. Composition for friction material and friction material using same
US20090304560A1 (en) * 2006-06-01 2009-12-10 3M Innovative Properties Company Multilayer mounting mat
US8277925B2 (en) * 2006-06-01 2012-10-02 Dietz Peter T Multilayer mounting mat
US20100040513A1 (en) * 2006-09-29 2010-02-18 Ibiden Co., Ltd. Laminated sheet, method of producing the sheet, exhaust gas processing device, and method of producing the device
US20080078150A1 (en) * 2006-09-29 2008-04-03 Ibiden Co., Ltd. Laminated sheet, method of producing the sheet, exhaust gas processing device, and method of producing the device
US8328986B2 (en) 2006-09-29 2012-12-11 Ibiden Co., Ltd. Laminated sheet, method of producing the sheet, exhaust gas processing device, and method of producing the device
US20090257925A1 (en) * 2008-04-15 2009-10-15 Ibiden Co., Ltd. Holding sealing material, exhaust gas purifying apparatus, and method for manufacturing holding sealing material
US8580207B2 (en) * 2008-04-15 2013-11-12 Ibiden Co., Ltd. Holding sealing material, exhaust gas purifying apparatus, and method for manufacturing holding sealing material
US9605576B2 (en) 2009-09-18 2017-03-28 3M Innovative Properties Company Mounting mat
US20130118138A1 (en) * 2011-11-16 2013-05-16 Ibiden Co., Ltd. Holding sealing material, method for producing holding sealing material, and exhaust gas purifying apparatus
US8945269B2 (en) * 2011-11-16 2015-02-03 Ibiden Co., Ltd. Holding sealing material, method for producing holding sealing material, and exhaust gas purifying apparatus

Also Published As

Publication number Publication date
ATE399257T1 (de) 2008-07-15
EP1588033B1 (en) 2008-06-25
KR101009886B1 (ko) 2011-01-19
EP1588033A1 (en) 2005-10-26
CN100371566C (zh) 2008-02-27
ZA200505966B (en) 2006-10-25
DE60321828D1 (de) 2008-08-07
AU2003297272A1 (en) 2004-07-29
KR20050091751A (ko) 2005-09-15
CN1732331A (zh) 2006-02-08
JP2004204819A (ja) 2004-07-22
WO2004061279A1 (en) 2004-07-22

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Owner name: 3M INNOVATIVE PROPERTIES COMPANY, MINNESOTA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:WATANABE, TOSHIYUKI;MIYASAKA, MUNEKI;REEL/FRAME:018373/0555

Effective date: 20050623

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION