WO2014168089A1 - 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 - Google Patents

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 Download PDF

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Publication number
WO2014168089A1
WO2014168089A1 PCT/JP2014/059985 JP2014059985W WO2014168089A1 WO 2014168089 A1 WO2014168089 A1 WO 2014168089A1 JP 2014059985 W JP2014059985 W JP 2014059985W WO 2014168089 A1 WO2014168089 A1 WO 2014168089A1
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WIPO (PCT)
Prior art keywords
sealing material
holding sealing
binder
exhaust gas
inorganic
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PCT/JP2014/059985
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English (en)
French (fr)
Japanese (ja)
Inventor
圭司 熊野
隆彦 岡部
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イビデン株式会社
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Application filed by イビデン株式会社 filed Critical イビデン株式会社
Priority to CN201480019654.7A priority Critical patent/CN105247186B/zh
Priority to KR1020157026881A priority patent/KR101749217B1/ko
Priority to EP14782882.6A priority patent/EP2985435B1/en
Priority to JP2015511241A priority patent/JP6298452B2/ja
Publication of WO2014168089A1 publication Critical patent/WO2014168089A1/ja

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    • 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
    • D04H1/58—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 by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—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 by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/645—Impregnation followed by a solidification process
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • 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
    • F01N3/2871—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 having an additional, e.g. non-insulating or non-cushioning layer, a metal foil or an adhesive layer

Definitions

  • the present invention relates to a holding sealing material, a method for manufacturing the holding sealing material, and an exhaust gas purification apparatus.
  • the exhaust gas discharged from an internal combustion engine such as a diesel engine contains particulate matter (hereinafter also referred to as PM) such as soot.
  • PM particulate matter
  • this PM has a problem that it causes harm to the environment and the human body. It has become.
  • the exhaust gas contains harmful gas components such as CO, HC and NOx, there is a concern about the influence of the harmful gas components on the environment and the human body.
  • an exhaust gas treatment body made of a porous ceramic such as silicon carbide or cordierite, and a casing that houses the exhaust gas treatment body
  • Various types of exhaust gas purifying apparatuses have been proposed, which are composed of an inorganic fiber aggregate disposed between an exhaust gas treating body and a casing.
  • This holding sealing material prevents the exhaust gas treating body from being damaged by contact with the casing covering the outer periphery due to vibrations or impacts caused by traveling of an automobile or the like, or exhaust gas from between the exhaust gas treating body and the casing.
  • the main purpose is to prevent leakage and the like. Therefore, the holding sealing material is required to have a function of increasing the surface pressure generated by the repulsive force caused by being compressed and holding the exhaust gas treating body reliably.
  • a holding sealing material obtained by impregnating a mat made of an inorganic fiber material with an aggregate composed of an organic binder and inorganic particles (for example, see Patent Document 1).
  • the surface pressure of the holding sealing material is derived from the force of returning the original when the inorganic fibers constituting the holding sealing material receive stress. From this, when the friction between inorganic fibers is large, or when the inorganic fibers are bonded together, the surface pressure of the holding sealing material increases.
  • agglomerates are attached only to some of the inorganic fibers constituting the mat. Therefore, the friction between inorganic fibers is small in the portion where the aggregate is not attached, and the effect of improving the surface pressure is not sufficiently exhibited. Therefore, the holding sealing material disclosed in Patent Document 1 has room for improving the surface pressure.
  • the present invention has been made to solve the above problems, and an object of the present invention is to provide a holding sealing material that can sufficiently satisfy the surface pressure characteristics required for the holding sealing material, and a method for manufacturing the holding sealing material. Moreover, an object of this invention is to provide the exhaust gas purification apparatus provided with the said holding sealing material.
  • the holding sealing material of the present invention has an inorganic fiber surface covered with a binder layer, and the binder layer contains an organic binder, inorganic particles, and a polymeric dispersant. It is characterized by including.
  • the holding sealing material of the present invention includes a polymer dispersant in the binder layer, aggregation of the organic binder and the inorganic particles in the binder layer is suppressed.
  • the binder layer containing the organic binder is formed over a wide range of the surface of the inorganic fiber.
  • the binder layer contains inorganic particles, the binder layer is excellent in tensile strength. Since the aggregation of the inorganic particles is suppressed by the polymer dispersant, the strength of the binder layer is increased over a wide range.
  • the inorganic fibers When the strength of the binder layer is weak, when the inorganic fibers come into contact with each other, the inorganic fibers slip with the peeling of the binder layer, and the surface pressure of the holding sealing material becomes low, but the strength of the binder layer is high. And the inorganic fibers are prevented from slipping, and the holding sealing material has a high surface pressure.
  • the inorganic particles of the binder layer are coated on the surface with the polymer dispersant, and the inorganic particles are dispersed in an organic binder component.
  • the inorganic particles are more effectively prevented from aggregating in the binder layer, and the inorganic particles are dispersed in the organic binder component. Therefore, the strength of the binder layer is more uniformly improved over a wide range of the surface of the inorganic fiber. Therefore, the holding sealing material has a higher surface pressure.
  • the inorganic particles and the organic binder are preferably contained in an amount of 0.1 to 10 parts by weight with respect to 100 parts by weight of the inorganic fibers. Further, the inorganic particles and the organic binder are preferably contained in an amount of 0.1 to 3 parts by weight with respect to 100 parts by weight of the inorganic fibers. It is known that when an impact is applied to the holding sealing material, the inorganic fibers are broken by the impact and the broken inorganic fibers are scattered. Controlling such scattering of inorganic fibers is one of the characteristics required for the holding sealing material.
  • the binder layer is formed on the surface of the inorganic fiber, even if the inorganic fiber is broken at the portion where the binder layer is formed, the broken inorganic fiber is held together, so that the fibers are scattered. Is prevented.
  • the content of the inorganic particles and the organic binder is less than 0.1 parts by weight with respect to 100 parts by weight of the inorganic fibers, the portion where the binder layer is formed is small, and the effect of suppressing scattering of the inorganic fibers is small. Become.
  • the content of the inorganic particles and the organic binder exceeds 10 parts by weight with respect to 100 parts by weight of the inorganic fibers, the effect of suppressing scattering of the inorganic fibers and the effect of improving the surface pressure are almost the same. Therefore, the amount of decomposition gas generated by the heat of the exhaust gas increases, which may adversely affect the surrounding environment. Therefore, the content of the organic binder is preferably as small as possible, and more preferably 3 parts by weight or less.
  • the polymer dispersant is preferably an anionic polymer dispersant.
  • the polymer-based dispersant is an anionic polymer-based dispersant, even if the surface of the inorganic particles is positively charged, the inorganic particles are offset by canceling the charge on the surface of the inorganic particles. It becomes easy to disperse.
  • the organic binder is preferably an acrylic resin.
  • the compatibility between the organic binder and the polymeric dispersant is easily increased in the binder layer, and thus the strength of the binder layer is easily improved by the anchor effect. .
  • the holding sealing material of the present invention is preferably subjected to needle punching treatment.
  • the entanglement between the inorganic fibers is strengthened and the surface pressure is easily improved.
  • the organic binder when the organic binder is burned off by heat, it is preferable that irregularities due to the inorganic particles are formed over the entire surface of the inorganic fiber.
  • the inorganic fibers become less slippery and the entanglement between the inorganic fibers becomes stronger. Therefore, it becomes easy to improve the surface pressure of the holding sealing material.
  • the binder layer is preferably formed on the entire surface of the inorganic fiber.
  • the binder layer By forming the binder layer on the entire surface of the inorganic fibers, friction when the inorganic fibers come into contact with each other is increased, and the surface pressure is easily improved. Furthermore, when the binder layer is formed on the entire surface of the inorganic fiber, it is easy to suppress the inorganic fiber from being scattered even if the inorganic fiber breaks at any part.
  • Another aspect of the holding sealing material of the present invention is a mat preparation step for preparing a mat containing inorganic fibers, an inorganic particle solution and a polymer dispersant are mixed, and then mixed with an organic binder dispersed in water.
  • a binder solution preparing step for preparing a binder solution, an applying step for applying the binder solution to the mat, and drying the mat to which the binder solution has been applied to dry the organic binder and the inorganic It is manufactured by a process including a drying process for drying particles.
  • the surface of the inorganic particles is coated with the polymer dispersant.
  • the binder solution dispersed in the organic binder dispersed in water with the inorganic particles coated on the surface of the polymer dispersant It becomes. Since the organic binder and the inorganic particles are dispersed in the binder solution, the organic binder and the inorganic particles easily spread over the entire surface of the inorganic fiber, and a high-strength binder layer is formed on the entire surface of the inorganic fiber. .
  • the holding sealing material has a high surface pressure. Furthermore, since the binder layer is formed on the entire surface of the inorganic fiber, it is easy to prevent the inorganic fiber from scattering even if the inorganic fiber breaks at any location.
  • an organic binder having a glass transition temperature of ⁇ 5 ° C. or lower is preferably used as the organic binder in the binder solution preparation step.
  • a binder layer obtained by a binder solution using an organic binder having a glass transition temperature of ⁇ 5 ° C. or lower has high strength of the binder layer, high film elongation, and excellent flexibility. For this reason, the holding sealing material is unlikely to break when the holding sealing material is wound around the exhaust gas treating body. Moreover, since a binder layer does not become hard too much, it becomes easy to suppress scattering of inorganic fiber.
  • the binder solution in the binder solution preparation step, is prepared so that the tensile strength of the binder layer obtained by drying the binder solution is 5.0 MPa or more. It is preferable.
  • the tensile strength of the binder layer is less than 5.0 MPa, when the inorganic fibers come into contact with each other, the binder layer may be peeled off and the inorganic fibers may slip, making it difficult to improve the surface pressure.
  • the manufacturing method of the holding sealing material of the present invention includes a mat preparation step of preparing a mat containing inorganic fibers, and an inorganic particle solution and a polymer dispersant are mixed, and then mixed with an organic binder dispersed in water.
  • a drying step for drying Since the polymer dispersant suppresses aggregation with the organic binder by coating the inorganic particles, the binder solution prepared in the binder solution preparing step is an organic binder and inorganic in water.
  • a binder solution in which the particles are dispersed is obtained. Since the binder solution in which the organic binder and the inorganic particles are dispersed in water tends to spread over the entire surface of the inorganic fiber, the binder is applied to the entire surface of the inorganic fiber by applying the binder solution to the mat. A layer can be formed. Therefore, in the manufacturing method of the holding sealing material of the present invention, the entire surface of the inorganic fiber is covered with the binder layer, and the sliding of the inorganic fiber is prevented over the entire surface of the inorganic fiber.
  • a holding sealing material that is a sealing material that can suppress scattering of the inorganic fiber even when the inorganic fiber breaks at any location can be manufactured.
  • the exhaust gas purifying apparatus of the present invention includes a metal casing, an exhaust gas treatment body accommodated in the metal casing, and a winding wound around the exhaust gas treatment body and disposed between the exhaust gas treatment body and the metal casing.
  • An exhaust gas purifying apparatus comprising a sealing material, wherein the holding sealing material is the holding sealing material of the present invention.
  • the exhaust gas purifying apparatus of the present invention includes a metal casing, an exhaust gas treatment body accommodated in the metal casing, and a winding wound around the exhaust gas treatment body and disposed between the exhaust gas treatment body and the metal casing.
  • An exhaust gas purification apparatus including a sealing material, wherein the holding sealing material is a holding sealing material manufactured by the method for manufacturing a holding sealing material of the present invention.
  • FIG.1 (a) is the perspective view which showed typically an example of the binder layer which covers the inorganic fiber and inorganic fiber surface which comprise the holding sealing material of this invention
  • FIG.1 (b) is FIG.1 (a).
  • 2 is a cross-sectional view taken along line AA in FIG.
  • FIG.1 (c) is the elements on larger scale of the binder layer of FIG.1 (b).
  • FIG. 2 (a) is a scanning electron microscope (hereinafter also referred to as SEM) photograph of a binder layer formed on the surface of the inorganic fibers constituting the holding sealing material of the present invention
  • FIG. It is a SEM photograph after heat-treating the holding
  • SEM scanning electron microscope
  • FIG. 3 is a perspective view schematically showing an example of the holding sealing material of the present invention.
  • Fig.4 (a) is a side view which shows typically an example of the measuring apparatus for measuring the dispersibility of an inorganic fiber
  • FIG.4 (b) is a measuring apparatus for measuring the dispersibility of an inorganic fiber.
  • FIG. 6 is a plan view schematically showing a part of a sample support arm that constitutes the structure.
  • FIG. 5 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention.
  • FIG. 6 is a perspective view schematically showing an example of the exhaust gas treating body constituting the exhaust gas purifying apparatus of the present invention.
  • FIG. 7 is a perspective view schematically showing an example of a method for producing the exhaust gas purifying apparatus of the present invention.
  • the holding sealing material of the present invention is characterized in that the surface of the inorganic fiber is covered with a binder layer, and the binder layer contains an organic binder, inorganic particles, and a polymer dispersant.
  • the inorganic fiber constituting the holding sealing material of the present invention is not particularly limited, but is composed of at least one selected from the group consisting of alumina fiber, silica fiber, alumina silica fiber, mullite fiber, biosoluble fiber, and glass fiber. It is preferable that In the case where the inorganic fiber is at least one of alumina fiber, silica fiber, alumina silica fiber, and mullite fiber, the heat resistance is excellent, and therefore the exhaust gas treating body is exposed to a sufficiently high temperature. However, no alteration or the like occurs, and the function as the holding sealing material can be sufficiently maintained. In addition, when the inorganic fiber is a biosoluble fiber, when producing an exhaust gas purification device using a holding sealing material, even if the scattered inorganic fiber is inhaled, it is dissolved in the living body. Will not harm your health.
  • the alumina fiber may contain additives such as calcia, magnesia, zirconia, and the like.
  • the average fiber length of the inorganic fibers is preferably 5 to 150 mm, and more preferably 10 to 80 mm. If the average fiber length of the inorganic fiber is less than 5 mm, the fiber length of the inorganic fiber is too short, so that the entanglement between the inorganic fibers becomes insufficient, the wrapping property to the exhaust gas treatment body is lowered, and the holding sealing material is easily broken. Become. On the other hand, if the average fiber length of the inorganic fibers exceeds 150 mm, the fiber length of the inorganic fibers is too long, so the number of fibers constituting the holding sealing material is reduced, and the denseness of the mat is lowered. As a result, the shear strength of the holding sealing material is lowered.
  • FIG.1 (a) is the perspective view which showed typically an example of the binder layer which covers the inorganic fiber and inorganic fiber surface which comprise the holding sealing material of this invention
  • FIG.1 (b) is FIG.1 (a).
  • 2 is a sectional view taken along line AA in FIG.
  • FIG.1 (c) is the elements on larger scale of the binder layer of FIG.1 (b).
  • the surface of the inorganic fiber 10 constituting the holding sealing material is covered with a binder layer 20.
  • the binder layer 20 is preferably formed on the entire surface of the inorganic fiber 10. Furthermore, as shown in FIG. 1B, it is preferable that a plurality of inorganic fibers 10 are bonded through a binder layer 20.
  • the binder layer 20 includes inorganic particles 21, a polymer dispersant 23, and an organic binder component 22. Further, in the binder layer 20, the surface of the inorganic particles 21 is covered with the polymer dispersant 23, and the inorganic particles 21 covered with the polymer dispersant 23 are dispersed in the organic binder component 22. Yes. When the surfaces of the inorganic particles 21 are covered with the polymer dispersant 23, the aggregation of the inorganic particles 21 in the binder layer 20 can be effectively suppressed. Furthermore, since the inorganic particles 21 are dispersed in the organic binder component 22, the tensile strength of the binder layer can be easily kept high.
  • the tensile strength of the binder layer in the present invention is preferably 5.0 MPa or more.
  • the tensile strength of the binder layer is less than 5.0 MPa, when the fibers come into contact with each other, the binder layer may be peeled off and the inorganic fibers may slip, making it difficult to improve the surface pressure.
  • a tensile test is performed at a rate of 300 mm / min with an Instron type tensile tester at room temperature using a dumbbell-shaped test piece having a thickness of 0.4 mm. It is the tensile breaking strength of the above-mentioned specimen measured by this.
  • the said test piece can be produced by pouring the binder solution used as the raw material of a binder layer on a glass plate with a frame, leaving it to dry at room temperature, and making it into a film form.
  • the organic binder constituting the holding sealing material of the present invention is obtained by drying an organic binder (organic binder solution) dispersed in water.
  • the organic binder is not particularly limited, and is an acrylic resin, acrylate latex, rubber latex, water-soluble organic polymer such as carboxymethyl cellulose or polyvinyl alcohol, thermoplastic resin such as styrene resin, thermosetting epoxy resin, etc. Resin etc. are mentioned.
  • the organic binder in the present invention is preferably contained in a solid content of 0.1 to 10 parts by weight, preferably 0.1 to 3 parts by weight, based on 100 parts by weight of the inorganic fibers constituting the holding sealing material. More preferably, it is contained in an amount of 0.1 to 2 parts by weight.
  • content of the said organic binder is less than 0.1 weight part with respect to 100 weight part of said inorganic fibers, the effect which suppresses scattering of inorganic fiber becomes small.
  • the amount exceeds 10 parts by weight the effect of improving the surface pressure is hardly changed, and the amount of decomposition gas generated by the heat of the exhaust gas increases, which may adversely affect the surrounding environment. Therefore, the content of the organic binder is preferably as small as possible, preferably 10 parts by weight or less, more preferably 3 parts by weight or less, and still more preferably 2 parts by weight or less.
  • the glass transition temperature of the organic binder in the present invention is preferably ⁇ 5 ° C. or lower, more preferably ⁇ 10 ° C. or lower, and further preferably ⁇ 30 ° C. or lower.
  • the glass transition temperature of the organic binder is ⁇ 5 ° C. or lower, it is possible to obtain a holding sealing material with high film elongation and excellent flexibility while increasing the strength of the binder layer. Therefore, the holding sealing material is not easily broken when the holding sealing material is wound around the exhaust gas treating body.
  • a binder layer does not become hard too much, it becomes difficult to suppress scattering of inorganic fiber.
  • the inorganic particles constituting the binder layer in the present invention refer to a solid component obtained by removing the solvent from an inorganic particle solution such as an inorganic sol dispersion solution.
  • the inorganic sol dispersion solution is not particularly limited, and examples thereof include alumina sol and silica sol.
  • alumina particles derived from alumina sol and silica particles derived from silica sol are preferable.
  • TEM transmission electron microscope
  • the inorganic particles in the present invention are preferably contained in an amount of 0.1 to 10 parts by weight, more preferably 0.1 to 3 parts by weight, based on 100 parts by weight of inorganic fibers constituting the holding sealing material. More preferably, it is contained in 1 to 2 parts by weight.
  • the content of the inorganic particles is less than 0.1 parts by weight with respect to 100 parts by weight of the inorganic fiber, the effect of improving the surface pressure tends to be small because the content of the inorganic particles is insufficient.
  • the amount exceeds 10 parts by weight the effect of improving the surface pressure is hardly changed, but the binder layer may become too hard and it is difficult to suppress scattering of inorganic fibers.
  • the inorganic particles in the present invention are more preferably contained in 0.1 to 3 parts by weight with respect to 100 parts by weight of the inorganic fibers constituting the holding sealing material of the present invention. preferable.
  • the particle size of the inorganic particles in the present invention is not particularly limited, but the average particle size of the inorganic particles is preferably 0.005 to 0.1 ⁇ m.
  • the number average molecular weight of the polymer dispersant in the present invention is not particularly limited, but is preferably 500 to 100,000.
  • the type of the polymeric dispersant in the present invention is not particularly limited, but polycarboxylic acid and / or salt thereof, naphthalene sulfonate formalin condensate and / or salt thereof, polyacrylic acid and / or salt thereof, polymethacrylic acid And / or salts thereof, hydrophilic synthetic polymers such as anionic polymer dispersants such as polyvinyl sulfonic acid and / or salt thereof, and nonionic polymer dispersants such as polyvinyl alcohol, polyvinyl pyrrolidone, and polyethylene glycol.
  • Natural hydrophilic polymer substances such as gelatin, casein and water-soluble starch; hydrophilic semi-synthetic polymer substances such as carboxymethyl cellulose.
  • hydrophilic synthetic polymer substances are preferable, and anionic polymer dispersants are more preferable.
  • anionic polymer dispersants are more preferable.
  • the organic binder is preferably polar, such as an acrylic resin.
  • the compatibility of the organic binder and the polymeric dispersant is increased in the binder layer, and the strength of the binder layer is improved by the anchor effect.
  • only one type of these polymer dispersants may be used, or a plurality of types may be used in combination. Further, it may be a polymer dispersant having both a structure showing properties as an anionic polymer dispersant and a structure showing properties as a nonionic polymer dispersant.
  • an anionic polymer dispersant having a number average molecular weight of 500 to 100,000 is particularly preferable.
  • the content of the polymeric dispersant is preferably 50 to 1000 ppm based on the weight of the inorganic fibers constituting the holding sealing material.
  • the content of the polymer dispersant is less than 50 ppm with respect to the weight of the inorganic fiber, it is difficult to suppress aggregation of the inorganic particles and the organic binder in the binder solution. If it exceeds 1000 ppm, the effect of dispersing the inorganic particles in the organic binder component does not change, so excessive addition is not preferable.
  • a biosoluble fiber may be used as the inorganic fiber.
  • the biosoluble fiber is, for example, an inorganic fiber containing at least one compound selected from the group consisting of an alkali metal compound, an alkaline earth metal compound, and a boron compound in addition to silica and the like. Since the biosoluble fiber made of these compounds is easily dissolved even when taken into the human body, the mat containing these inorganic fibers is excellent in safety to the human body.
  • the specific composition of the biosoluble fiber includes 60 to 85% by weight of silica and 15 to 40% by weight of at least one compound selected from the group consisting of alkali metal compounds, alkaline earth metal compounds and boron compounds. % Composition.
  • the silica refers to SiO or SiO 2 .
  • alkali metal compound examples include sodium and potassium oxides
  • examples of the alkaline earth metal compound include magnesium, calcium, strontium, and barium oxides
  • examples of the boron compound include boron oxide.
  • the silica content when the silica content is less than 60% by weight, it is difficult to produce by a glass melting method, and it is difficult to fiberize.
  • the content of silica when the content of silica is less than 60% by weight, the content of flexible silica is small, so that it is structurally fragile, and is easily soluble in physiological saline, an alkali metal compound, an alkaline earth metal compound, and Since the ratio of at least one compound selected from the group consisting of boron compounds is relatively high, the biosoluble fiber tends to be too soluble in physiological saline.
  • the content of silica exceeds 85% by weight, the ratio of at least one compound selected from the group consisting of an alkali metal compound, an alkaline earth metal compound, and a boron compound is relatively low, so that it is biosoluble. Fibers tend to be too difficult to dissolve in saline.
  • the silica content is calculated by converting the amounts of SiO and SiO 2 into SiO 2 .
  • the content of at least one compound selected from the group consisting of an alkali metal compound, an alkaline earth metal compound and a boron compound exceeds 40% by weight in the composition of the biosoluble fiber, it is produced by the glass melting method. Difficult to fiberize. Further, when the content of at least one compound selected from the group consisting of an alkali metal compound, an alkaline earth metal compound and a boron compound exceeds 40% by weight, it is structurally fragile and the biosoluble fiber becomes physiological saline. It becomes too easy to dissolve.
  • the solubility of the biosoluble fiber in physiological saline is desirably 30 ppm or more. This is because if the solubility of the biosoluble fiber is less than 30 ppm, it is difficult for the fiber to be discharged from the body when the inorganic fiber is taken into the body, which is not preferable for health.
  • the glass fibers are glassy fibers containing silica and alumina as main components and containing calcia, titania, zinc oxide and the like in addition to alkali metals.
  • FIG. 2 (a) is an SEM photograph of the binder layer formed on the surface of the inorganic fiber constituting the holding sealing material of the present invention
  • FIG. 2 (b) is a heat treatment of the holding sealing material of the present invention. It is a SEM photograph after burning off an organic binder.
  • the organic binder when the organic binder is burned out, it means heating in the atmosphere at 600 ° C. for 1 hour unless otherwise specified.
  • the binder layer is formed in the surface of the inorganic fiber which comprises the holding
  • FIG. 2B innumerable irregularities are formed over the entire surface of the inorganic fiber. This is presumably because the inorganic particles dispersed in the binder layer were exposed due to the burnout of the organic binder.
  • unevenness is formed by inorganic particles over the entire surface of the inorganic fiber, the inorganic fiber is caught by the unevenness when the inorganic fiber comes into contact after the organic binder is burned out, and the surface of the inorganic fiber is prevented from slipping. Therefore, it becomes easy to improve the surface pressure.
  • FIG. 3 is a perspective view schematically showing an example of the holding sealing material of the present invention.
  • the holding sealing material of the present invention has a predetermined longitudinal length (hereinafter, indicated by an arrow L in FIG. 3), a width (indicated by an arrow W in FIG. 3), and a thickness ( 3 may be configured by a flat mat having a substantially rectangular shape in plan view.
  • a convex portion is formed on the first end 111 which is one of the end portions on the length direction side of the holding sealing material, and at the other end.
  • a concave portion is formed in a certain second end portion 112.
  • the convex portion 111 and the concave portion 112 of the holding sealing material are shaped so as to be fitted to each other when the holding sealing material is wound around the exhaust gas treatment body in order to assemble an exhaust gas purification device to be described later.
  • substantially rectangular in plan view is a concept including a convex portion and a concave portion.
  • the substantially rectangular shape in plan view includes a shape whose corners have an angle other than 90 °.
  • the holding sealing material of the present invention is preferably subjected to needle punching treatment.
  • the entanglement between the inorganic fibers is strengthened and the surface pressure is easily improved.
  • the needle punching process can be performed using a needle punching apparatus.
  • the needle punching device is composed of a support plate that supports a sheet of inorganic fiber precursor, and a needle board that is provided above the support plate and can reciprocate in the piercing direction (thickness direction of the base mat). ing. A large number of needles are attached to the needle board.
  • the inorganic fiber precursor is configured by moving the needle board with respect to the sheet-like material of the inorganic fiber precursor placed on the support plate, and inserting and removing a large number of needles with respect to the sheet-like material of the inorganic fiber precursor.
  • the fibers can be intertwined in a complex manner.
  • the number of needle punching processes and the number of needles may be changed according to the target bulk density and the basis weight.
  • the thickness of the holding sealing material is not particularly limited, but is preferably 2.0 to 20 mm.
  • the thickness of the holding sealing material exceeds 20 mm, the flexibility of the holding sealing material is lost, so that it becomes difficult to handle the holding sealing material when it is wound around the exhaust gas treating body. Further, the holding sealing material is likely to cause creases and cracks.
  • the thickness of the holding sealing material is less than 2.0 mm, the surface pressure of the holding sealing material is not sufficient to hold the exhaust gas treating body. For this reason, the exhaust gas treating body is easily dropped off. Further, when a volume change occurs in the exhaust gas treating body, the holding sealing material is difficult to absorb the volume change of the exhaust gas treating body. Therefore, cracks and the like are likely to occur in the exhaust gas treating body.
  • the surface pressure of the holding sealing material of the present invention can be measured by the following method using a surface pressure measuring device.
  • a hot surface pressure measuring device provided with a heater on the portion of the plate that compresses the mat is used, and the bulk density (GBD) of the sample becomes 0.3 g / cm 3 at room temperature. Compress until The contact pressure at that time is defined as the firing front pressure. Thereafter, it was held for 10 minutes.
  • the scattering property of the inorganic fibers constituting the holding sealing material of the present invention can be measured by the following procedure. First, the holding sealing material is cut out to 100 mm ⁇ 100 mm to obtain a scattering property test sample 210. About this sample for a scattering test, the scattering rate of an inorganic fiber can be measured using the measuring apparatus shown to Fig.4 (a) and (b).
  • Fig.4 (a) is a side view which shows typically an example of the measuring apparatus for measuring the scattering property of inorganic fiber. As shown in FIG. 4A, the test apparatus 200 is connected to the upper ends of two support columns 260 vertically provided on a base 250 so that the sample support arm 270 can rotate within a predetermined range. Has been.
  • FIG.4 (b) is the top view which showed typically an example of the sample support arm part which comprises the measuring apparatus for measuring the scattering property of inorganic fiber.
  • the other end of the sample support arm 270 is fixed by a sample fixing member 280 that connects the ends of the sample support arm 270 to each other.
  • the sample support arm 270 is locked by a predetermined locking mechanism, and the scattering test sample 210 is fixed to the sample fixing member 280 by the clip 220.
  • the sample support arm 270 is unlocked, the sample support arm 270 and the test sample 210 start dropping in a direction toward the base 250 to which the support column 260 is fixed.
  • the sample support arm 270 and the column 260 become parallel, the sample support arm 270 collides with the vertical wall member 290. Due to this collision, a part of the inorganic fibers constituting the test sample 290 is broken and scattered.
  • Fiber scattering rate (% by weight) (weight of sample for scattering test before test ⁇ weight of sample for scattering test after test) / (weight of sample for scattering test before test) ⁇ 100 (5)
  • Weight per unit area of the holding sealing material of the present invention is not particularly limited, but is preferably 200 ⁇ 4000g / m 2, and more preferably 1000 ⁇ 3000g / m 2.
  • the basis weight of the holding sealing material is less than 200 g / m 2 , the holding force is not sufficient, and when the basis weight of the holding sealing material exceeds 4000 g / m 2 , the bulk of the holding sealing material is difficult to decrease. Therefore, when manufacturing an exhaust gas purification apparatus using such a holding sealing material, the exhaust gas treating body is likely to drop off.
  • the bulk density of the holding sealing material of the present invention is not particularly limited, but is preferably 0.10 to 0.30 g / cm 3 .
  • the bulk density of the holding sealing material is less than 0.10 g / cm 3 , the entanglement of the inorganic fibers is weak and the inorganic fibers are easily peeled off, so that it is difficult to keep the shape of the holding sealing material in a predetermined shape.
  • the bulk density of the holding sealing material exceeds 0.30 g / cm 3 , the holding sealing material becomes hard, the wrapping property around the exhaust gas treating body is lowered, and the holding sealing material is easily broken.
  • the holding sealing material of the present invention may further contain an expansion material.
  • the expansion material preferably has a characteristic of expanding in the range of 400 to 800 ° C. If the holding sealing material contains an expanding material, the holding sealing material expands in the range of 400 to 800 ° C. Therefore, the holding sealing material can be held even in a high temperature range exceeding 700 ° C where the strength of the glass fiber is reduced. The holding force at the time of using as a sealing material can be improved.
  • the expanding material examples include vermiculite, bentonite, phlogopite, pearlite, expandable graphite, and expandable fluoride mica. These expanding materials may be used alone or in combination of two or more.
  • the addition amount of the expansion material is not particularly limited, but is preferably 10 to 50% by weight, more preferably 20 to 30% by weight with respect to the total weight of the holding sealing material.
  • the holding sealing material of the present invention is used as a holding sealing material for an exhaust gas purification device
  • the number of holding sealing materials constituting the exhaust gas purification device is not particularly limited, and may be a single holding sealing material or coupled to each other.
  • a plurality of holding sealing materials may be used.
  • the method for bonding a plurality of holding sealing materials is not particularly limited, and examples thereof include a method of bonding holding sealing materials by sewing and a method of bonding holding sealing materials with an adhesive tape or an adhesive. .
  • the manufacturing method of the holding sealing material of the present invention is suitable for the method of manufacturing the holding sealing material of the present invention.
  • the manufacturing method of the holding sealing material of the present invention includes a mat preparing step of preparing a mat containing inorganic fibers, an organic binder dispersed in water after preparing a solution in which inorganic particles and a polymeric dispersant are mixed.
  • the mat preparation process which prepares the mat containing an inorganic fiber first is performed.
  • the mat constituting the holding sealing material can be obtained by various methods.
  • the mat can be produced by a needling method or a papermaking method.
  • the needling method for example, it can be produced by the following method. That is, first, an inorganic fiber precursor having an average fiber diameter of 3 to 10 ⁇ m is produced by spinning a spinning mixture using, for example, a basic aqueous aluminum chloride solution and silica sol as a raw material. Subsequently, the inorganic fiber precursor is compressed to produce a continuous sheet-like material having a predetermined size, subjected to a needle punching process, and then subjected to a firing process to complete the preparation of the mat.
  • inorganic fibers such as alumina fibers and silica fibers, inorganic particles, and water are mixed so that the content of the inorganic fibers in the raw material liquid becomes a predetermined value, and mixed by stirring with a stirrer.
  • the mixed solution may contain a colloidal solution made of a polymer compound or a resin as necessary.
  • seat is produced by spin-dry
  • the preparation of the mat is completed by heating and compressing the raw material sheet under predetermined conditions.
  • Binder solution preparation step Next, after preparing a solution in which an inorganic particle solution and a polymer dispersant are mixed, the binder is mixed with an organic binder (organic binder solution) dispersed in water.
  • a binder solution preparation step for preparing a solution is performed. First, by preparing a solution in which inorganic particles and a polymer dispersant are mixed, the surface of the inorganic particles is coated with the polymer dispersant. Subsequently, by mixing with an organic binder dispersed in water, the inorganic particles and the organic binder coated with the polymer dispersant can be dispersed in water.
  • the inorganic particle solution used in the binder solution preparation step of the present invention is not particularly limited, and those described in the explanation of the holding sealing material of the present invention can be used, and alumina sol, silica sol and the like can be used.
  • the concentration of the inorganic particle solution is not particularly limited, but it is preferable to use a solution in which the concentration of the inorganic particles is diluted to about 0.2 to 20% by weight in terms of solid content.
  • the polymer dispersant to be mixed with the inorganic particle solution is not particularly limited, and those described in the explanation of the holding sealing material of the present invention can be used. Detailed description is omitted. The preferred range and type of number average molecular weight are also the same.
  • the concentration of the polymer dispersant in the binder solution prepared in the binder solution preparation step of the present invention is not particularly limited, but is preferably 50 to 1000 ppm.
  • concentration of the polymeric dispersant is less than 50 ppm, the amount of the polymeric dispersant is insufficient, so that it is difficult to suppress aggregation of the inorganic particles and the organic binder in the binder solution. Since the effect of dispersing is not changed, excessive addition is not preferable.
  • the concentration of the organic binder solution is not particularly limited, but it is preferable to use a solution diluted to about 0.2 to 20% by weight in terms of solid content.
  • the glass transition temperature of the organic binder is not particularly limited, but is preferably ⁇ 5 ° C. or lower, more preferably ⁇ 10 ° C. or lower, and more preferably ⁇ 30 ° C. or lower. More preferably it is.
  • the mixing ratio of the solution obtained by mixing the inorganic particles and the polymer dispersant and the organic binder solution is not particularly limited, but the inorganic particle solution and the polymer dispersant
  • the solid content weight of the inorganic particles in the mixed solution is preferably mixed at a weight ratio of 3: 1 to 1: 3.
  • a pH adjuster for adjusting the pH of the binder solution may be added.
  • the method of bringing the mat into contact with the binder solution is not particularly limited.
  • the binder solution may be applied to the inorganic fibers in the mat by impregnating the mat with the binder solution.
  • the binder solution may be applied to the inorganic fibers in the mat by dropping the binder solution onto the mat by a method such as curtain coating, and the binder solution is sprayed onto the mat and sprayed onto the mat as in spray coating. May be attached.
  • a cutting step of cutting the holding sealing material into a predetermined shape may be further performed.
  • a binder solution prepared by mixing with an organic binder dispersed in water is applied to a mat composed of inorganic fibers.
  • a binder solution prepared by mixing with an organic binder dispersed in water is applied to a mat composed of inorganic fibers.
  • a binder solution is provided to the whole surface of an inorganic fiber by an application
  • the binder layer formed by the steps (a) to (d) has high tensile strength because it contains an organic binder, inorganic particles, and a polymeric dispersant. Therefore, the surface pressure of the holding sealing material manufactured by the manufacturing method of the holding sealing material of the present invention is high. Furthermore, since the binder layer is formed on the entire surface of the inorganic fiber, the scattering of the inorganic fiber can be suppressed even if the inorganic fiber breaks at any part.
  • Another aspect of the sealing material of the present invention is a holding sealing material manufactured by the method for manufacturing a holding sealing material of the present invention, a mat preparation step of preparing a mat containing inorganic fibers, an inorganic particle solution, and a polymer system
  • the mat provided with the solution is dried to produce the organic binder and the inorganic particles, and the drying step is performed.
  • each process described in the column of the manufacturing method of the holding sealing material of the present invention may be the same unless otherwise specified. it can.
  • an anionic polymer dispersant as the polymer dispersant in the binder solution preparation step.
  • the binder solution is preferably prepared so that the solid weight content of the inorganic particles is 0.1 to 10 parts by weight in the binder solution preparation step.
  • the binder solution is more preferably adjusted to 1 to 3 parts by weight, and more preferably the binder solution is adjusted to be 0.1 to 2 parts by weight.
  • the binder solution is preferably prepared so that the solid content weight of the organic binder is 0.1 to 10 parts by weight, and the binder solution is adjusted so as to be 0.1 to 3 parts by weight. More preferably, the binder solution is further adjusted to be 0.1 to 2 parts by weight.
  • an organic binder having a glass transition temperature of ⁇ 5 ° C.
  • the binder solution is preferably prepared such that the tensile strength of the binder layer obtained by drying the binder solution is 5.0 MPa or more.
  • the surface of the inorganic fiber is covered with a binder layer, and the binder layer preferably contains an organic binder, inorganic particles, and a polymer dispersant.
  • the binder layer is organic binder, inorganic particles, and high A holding sealing material containing a molecular dispersant can be obtained.
  • the binder layer is preferably formed on the entire surface of the inorganic fiber. Moreover, it is preferable that the surface of the inorganic particles is coated with a polymer dispersant and that the inorganic particles are dispersed in the organic binder component. Moreover, when the organic binder is burned out by heat, it is preferable that the unevenness
  • the polymer dispersant is a binder in which the organic binder and the inorganic particles are dispersed in water. Become a solution.
  • the binder solution in which the organic binder and the inorganic particles are dispersed in water is likely to spread over the entire surface of the inorganic fiber
  • the binder is applied to the entire surface of the inorganic fiber by applying the binder solution to the mat.
  • a layer can be formed.
  • a holding sealing material in which the binder layer is formed on the entire surface of the inorganic fiber can be obtained.
  • the surface of the inorganic particles is coated with the polymer dispersant by mixing the inorganic particles and the polymer dispersant, the surface of the inorganic particles is coated with the polymer dispersant, and the inorganic It can be a holding sealing material in which particles are dispersed in an organic binder component.
  • the inorganic particles have a structure that spreads over the entire surface of the inorganic fiber, when the organic binder is burned off by heat, a holding sealing material in which irregularities due to the inorganic particles are formed over the entire surface of the inorganic fiber; can do.
  • the holding sealing material of the present invention can be used as a holding sealing material for an exhaust gas purification device.
  • the exhaust gas purifying apparatus of the present invention includes a metal casing, an exhaust gas treatment body accommodated in the metal casing, and a winding wound around the exhaust gas treatment body and disposed between the exhaust gas treatment body and the metal casing.
  • An exhaust gas purifying apparatus comprising a sealing material, wherein the holding sealing material is manufactured by the holding sealing material of the present invention, another aspect of the holding sealing material of the present invention, or the method of manufacturing a holding sealing material of the present invention. Holding seal material.
  • FIG. 5 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention.
  • the exhaust gas purification apparatus 100 of the present invention includes a metal casing 130, an exhaust gas treatment body 120 accommodated in the metal casing 130, and a holding disposed between the exhaust gas treatment body 120 and the metal casing 130. And a sealing material 110.
  • the exhaust gas treatment body 120 has a columnar shape in which a large number of cells 125 are arranged in parallel in the longitudinal direction with a cell wall 126 therebetween.
  • an end of the metal casing 130 is connected to an introduction pipe for introducing the exhaust gas discharged from the internal combustion engine and an exhaust pipe for discharging the exhaust gas that has passed through the exhaust gas purification device to the outside, if necessary. It will be.
  • the material of the metal casing constituting the exhaust gas purifying apparatus of the present invention is not particularly limited as long as it is a metal having heat resistance, and specifically, metals such as stainless steel, aluminum, iron and the like can be mentioned.
  • a clamshell shape, a downsizing shape or the like can be suitably used in addition to a substantially cylindrical shape.
  • FIG. 5 is a perspective view schematically showing an example of the exhaust gas treating body constituting the exhaust gas purifying apparatus of the present invention.
  • An exhaust gas treatment body 120 shown in FIG. 5 is a honeycomb structure made of a columnar ceramic material in which a large number of cells 125 are provided side by side with cell walls 126 therebetween. One end of each cell 125 is sealed with a sealing material 128.
  • the cross-sectional shape obtained by cutting the exhaust gas treatment body 120 in a direction perpendicular to the longitudinal direction is not particularly limited, and may be a substantially circular shape or a substantially elliptical shape, or a substantially polygonal shape such as a substantially triangular shape, a substantially rectangular shape, a substantially pentagonal shape, or a substantially hexagonal shape. There may be.
  • the cross-sectional shape of the cells 125 constituting the exhaust gas treating body 120 may be a substantially triangular shape, a substantially quadrangular shape, a substantially pentagonal shape, a substantially hexagonal shape or the like, or may be a substantially circular shape or a substantially elliptical shape. Further, the exhaust gas treating body 120 may be a combination of cells having a plurality of cross-sectional shapes.
  • the material constituting the exhaust gas treatment body 120 is not particularly limited, and non-oxides such as silicon carbide and silicon nitride, and oxides such as cordierite and aluminum titanate can be used. Of these, non-oxide porous fired bodies such as silicon carbide or silicon nitride are particularly preferable. Since these porous fired bodies are brittle materials, they are easily broken by a mechanical impact or the like. However, in the exhaust gas purifying apparatus of the present invention, the holding sealing material 110 is interposed around the side surface of the exhaust gas treatment body 120 to absorb the impact, so that the exhaust gas treatment body 120 is cracked by a mechanical impact or a thermal shock. It can be prevented from occurring.
  • the exhaust gas treating body constituting the exhaust gas purifying apparatus of the present invention may carry a catalyst for purifying exhaust gas, and the supported catalyst is preferably a noble metal such as platinum, palladium, rhodium, etc. Then, platinum is more desirable.
  • a noble metal such as platinum, palladium, rhodium, etc.
  • platinum is more desirable.
  • alkali metals such as potassium and sodium
  • alkaline earth metals such as barium can be used. These catalysts may be used alone or in combination of two or more. When these catalysts are supported, it is easy to burn and remove PM, and toxic exhaust gas can be purified.
  • the exhaust gas treatment body constituting the exhaust gas purification apparatus of the present invention may be an integrally formed honeycomb structure made of cordierite or the like, or may be made of silicon carbide or the like, and has a large number of through holes. May be a collective honeycomb structure in which a plurality of columnar honeycomb fired bodies arranged in parallel in the longitudinal direction with partition walls are bundled together through a paste mainly containing ceramic.
  • the end of the cell may not be sealed without providing the cell with the sealing material.
  • the exhaust gas treating body functions as a catalyst carrier that purifies harmful gas components such as CO, HC, or NOx contained in the exhaust gas by supporting a catalyst such as platinum.
  • an outer peripheral coat layer may be formed on the outer peripheral surface.
  • the outer peripheral portion of the exhaust gas treating body can be reinforced, the shape can be adjusted, and the heat insulation can be improved.
  • the outer peripheral surface of the exhaust gas treatment body refers to a side surface portion of the exhaust gas treatment body that is columnar.
  • the exhaust gas discharged from the internal combustion engine and flowing into the exhaust gas purification device 100 (in FIG. 5, the exhaust gas is indicated by G and the flow of the exhaust gas is indicated by an arrow) is an exhaust gas treatment body (honeycomb filter) 120.
  • the exhaust gas treatment body 120 Flows into one cell 125 opened in the exhaust gas inflow end face 120a and passes through the cell wall 126 separating the cells 125.
  • PM in the exhaust gas is collected by the cell wall 126, and the exhaust gas is purified.
  • the purified exhaust gas flows out from another cell 125 opened in the exhaust gas treatment side end face 120b and is discharged to the outside.
  • FIG. 7 is a perspective view schematically showing an example of the manufacturing method of the exhaust gas purifying apparatus of the present invention.
  • the exhaust gas treating body and the holding sealing material constituting the exhaust gas purifying apparatus of the present invention are wound around the exhaust gas treating body 120 to form a wound body 140.
  • the exhaust gas purifying apparatus of the present invention is obtained.
  • a press-fitting method in which the exhaust gas treatment body 120 having the holding sealing material 110 disposed around it to a predetermined position inside the metal casing 130 is press-fitted ( Stuffing method), a sizing method (swaging type) that compresses from the outer peripheral side so as to reduce the inner diameter of the metal casing 130, and a shape in which the metal casing is separable into parts of the first casing and the second casing,
  • Stuffing method Stuffing method
  • a sizing method swaging type
  • the inner diameter of the metal casing (the inner diameter of the portion accommodating the exhaust gas treating body) may be slightly smaller than the outer diameter of the wound body. preferable.
  • the exhaust gas purifying apparatus of the present invention may be composed of a plurality of holding sealing materials of two or more layers joined together.
  • the method for bonding a plurality of holding sealing materials is not particularly limited, and examples thereof include a method for bonding holding sealing materials by sewing and a method for bonding holding sealing materials with an adhesive tape or an adhesive. .
  • the exhaust gas purification apparatus of the present invention is manufactured.
  • a holding sealing material is interposed between the exhaust gas treating body and the metal casing, and the holding sealing material is different from the holding sealing material of the present invention and the holding sealing material of the present invention. It is the holding sealing material manufactured by the manufacturing method of the aspect or this invention. Therefore, the holding sealing material can exhibit a high surface pressure, and the exhaust gas treating body can be stably held. Furthermore, when the organic binder in the binder layer is burned out by the heat of the exhaust gas, irregularities due to inorganic particles are formed on the entire surface of the inorganic fiber.
  • the fibers are not easily slipped, a high surface pressure can be maintained, and damage to the exhaust gas treating body can be suppressed. Furthermore, even if the inorganic fiber which comprises a holding
  • the holding sealing material of the present invention the manufacturing method of the holding sealing material, another aspect of the holding sealing material, and the effect of the exhaust gas purifying apparatus will be described.
  • the binder layer contains a polymer dispersant, aggregation of the organic binder and inorganic particles in the binder layer is suppressed.
  • the binder layer containing the organic binder is formed over a wide range of the surface of the inorganic fiber.
  • the binder layer contains inorganic particles, the binder layer is excellent in tensile strength. Since the aggregation of the inorganic particles is suppressed by the polymer dispersant, the strength of the binder layer is increased over a wide range.
  • the holding sealing material of the present invention since the binder layer is formed in a wide range on the surface of the inorganic fiber, the organic binder and the polymer dispersant in the binder layer are decomposed by the heat of the exhaust gas. In this case, the inorganic particles constituting the binder layer are exposed, and irregularities are formed in a wide range of the surface of the inorganic fiber. Therefore, the unevenness due to the inorganic particles increases the friction between the inorganic fibers, and even after the binder layer is decomposed by the heat of the exhaust gas, it becomes a holding sealing material having a high surface pressure.
  • the holding sealing material having the above configuration can be easily manufactured.
  • the holding sealing material is interposed between the exhaust gas treating body and the metal casing, it is possible to prevent the exhaust gas from leaking and to form the holding sealing material. Since the binder layer containing the polymer dispersant is formed on the fiber surface, the surface pressure of the holding sealing material is high, and the exhaust gas treating body can be stably held.
  • the binder layer is burned out by the exhaust gas flowing through the exhaust gas treating body constituting the exhaust gas purifying apparatus.
  • the binder layer burns out, the inorganic particles constituting the binder layer are exposed and the friction between the inorganic fibers is improved, so that the surface pressure can be kept high.
  • Example 1 (A) Mat preparation step First, a mat containing inorganic fibers was prepared by the following procedure.
  • the obtained mixed solution was concentrated to obtain a spinning mixture, and the spinning mixture was spun by a blowing method to prepare an inorganic fiber precursor having an average fiber diameter of 5.1 ⁇ m.
  • (A-2) Compression step The inorganic fiber precursor obtained in the above step (a-1) was compressed to produce a continuous sheet.
  • (A-3) Needle punching process The sheet-like material obtained in the above step (a-2) was continuously subjected to needle punching using the conditions shown below to produce a needle punched body.
  • a needle board to which needles were attached at a density of 21 pieces / cm 2 was prepared.
  • the needle board is disposed above the one surface of the sheet-like material, and the needle board is moved up and down once along the thickness direction of the sheet-like material to perform needle punching treatment. Was made. At this time, the needle was penetrated until the barb formed at the tip of the needle completely penetrated the surface on the opposite side of the sheet-like material.
  • (A-4) Firing step An inorganic fiber containing 72 parts by weight and 28 parts by weight of alumina and silica, which is obtained by continuously firing the needle punched body obtained in the above step (a-3) at a maximum temperature of 1250 ° C.
  • the baked sheet-like material which consists of was manufactured.
  • the average fiber diameter of the inorganic fibers was 5.1 ⁇ m, and the minimum value of the inorganic fiber diameter was 3.2 ⁇ m.
  • the fired sheet material thus obtained has a bulk density of 0.15 g / cm 3 and a basis weight of 1500 g / m 2 .
  • Binder solution preparation step (b-1) Organic binder solution preparation step Acrylate latex in which an acrylic rubber having a glass transition temperature of ⁇ 10 ° C. is dispersed in water (Nipol LX854E manufactured by Nippon Zeon Co., Ltd. (solid content concentration) : 45 wt%)) and diluted with water to prepare an organic binder solution having a solid content concentration of 2 wt%.
  • Alumina colloid solution (alumina sol) (Alumina sol 550 (solid content concentration: 15 wt%) manufactured by Nissan Chemical Industries, Ltd.) was diluted with water, and an anionic polymer dispersant (San Nopco) Nopcosanto RFA) was added and stirred sufficiently to prepare an inorganic binder solution having a solid content concentration of inorganic particles of 2% by weight and a concentration of the anionic polymer dispersant of 500 ppm.
  • step (D) Drying step (d-1) Dehydration step
  • the mat provided with the binder solution obtained in the above step (c) applying step is sucked and dehydrated with a dehydrator so that the binder solution becomes an inorganic fiber. It was prepared so that 100 parts by weight was applied to 100 parts by weight.
  • Example 2 Example 1 except that an acrylate latex (Nipol LX874 (solid content concentration: 45 wt%) manufactured by Nippon Zeon Co., Ltd.) in which acrylic rubber having a glass transition temperature of ⁇ 31 ° C. was dispersed in water was used as the organic binder. A holding sealing material was produced in the same manner as described above.
  • an acrylate latex Nipol LX874 (solid content concentration: 45 wt%) manufactured by Nippon Zeon Co., Ltd.) in which acrylic rubber having a glass transition temperature of ⁇ 31 ° C. was dispersed in water was used as the organic binder.
  • a holding sealing material was produced in the same manner as described above.
  • Example 3 (B-1) In the organic binder solution preparation step, the solid content concentration of the organic binder solution is 1.0% by weight; and (b-2) Inorganic particle solids in the inorganic particle solution are prepared in the inorganic particle solution preparation step.
  • a holding sealing material was produced in the same manner as in Example 2 except that the partial concentration was changed to 3.0% by weight.
  • the amount of the inorganic particles contained in the binder layer constituting the holding sealing material is 1.5 parts by weight with respect to 100 parts by weight of the inorganic fibers, and the amount of the organic binder is 100 parts by weight of the inorganic fibers. The amount was 0.5 part by weight.
  • Example 4 A holding sealing material was produced in the same manner as in Example 1 except that a polyethylene glycol dispersant (Emanon 1112 manufactured by Kao Corporation) was used as the polymer dispersant.
  • a polyethylene glycol dispersant (Emanon 1112 manufactured by Kao Corporation) was used as the polymer dispersant.
  • Example 5 A holding sealing material was produced in the same manner as in Example 1 except that a naphthalenesulfonic acid formalin condensate-based dispersant (Demol N manufactured by Kao Corporation) was used as the polymer dispersant.
  • a naphthalenesulfonic acid formalin condensate-based dispersant (Demol N manufactured by Kao Corporation) was used as the polymer dispersant.
  • Example 6 A holding sealing material was produced in the same manner as in Example 1 except that a polyvinyl alcohol dispersant (Denkapoval B-24N manufactured by Denki Kagaku Kogyo Co., Ltd.) was used as the polymer dispersant.
  • a polyvinyl alcohol dispersant (Denkapoval B-24N manufactured by Denki Kagaku Kogyo Co., Ltd.) was used as the polymer dispersant.
  • Binder layer tensile strength test The binder solution prepared in each example and comparative example was poured into a glass plate with a frame, left to dry at room temperature, and then punched to prepare a dumbbell-shaped test piece having a thickness of 0.4 mm. Using this test piece, the tensile strength (tensile breaking strength) of the binder layer was measured by conducting a tensile test at a speed of 300 mm / min with an Instron type tensile tester. The results are shown in Table 1.
  • the binder layer could not be formed because the binder solution did not contain an organic binder. Therefore, scattering of inorganic fibers could not be suppressed. Further, in the holding sealing material of Comparative Example 3, since the binder layer did not contain inorganic particles, the tensile strength of the binder layer was low, and the surface pressure was also low.

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PCT/JP2014/059985 2013-04-12 2014-04-04 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 WO2014168089A1 (ja)

Priority Applications (4)

Application Number Priority Date Filing Date Title
CN201480019654.7A CN105247186B (zh) 2013-04-12 2014-04-04 保持密封件、保持密封件的制造方法及废气净化装置
KR1020157026881A KR101749217B1 (ko) 2013-04-12 2014-04-04 유지 시일재, 유지 시일재의 제조 방법 및 배기 가스 정화 장치
EP14782882.6A EP2985435B1 (en) 2013-04-12 2014-04-04 Holding seal member, method for producing holding seal member, and exhaust gas purification device
JP2015511241A JP6298452B2 (ja) 2013-04-12 2014-04-04 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

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JP2016089776A (ja) * 2014-11-07 2016-05-23 イビデン株式会社 保持シール材及び保持シール材の製造方法。
JP2021121701A (ja) * 2016-07-11 2021-08-26 三菱ケミカル株式会社 アルミナ繊維集合体及びその製造方法
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