WO2015170610A1 - Matériau d'étanchéité de fixation, procédé de production de matériau d'étanchéité de fixation, et purificateur de gaz d'échappement - Google Patents

Matériau d'étanchéité de fixation, procédé de production de matériau d'étanchéité de fixation, et purificateur de gaz d'échappement Download PDF

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Publication number
WO2015170610A1
WO2015170610A1 PCT/JP2015/062498 JP2015062498W WO2015170610A1 WO 2015170610 A1 WO2015170610 A1 WO 2015170610A1 JP 2015062498 W JP2015062498 W JP 2015062498W WO 2015170610 A1 WO2015170610 A1 WO 2015170610A1
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Prior art keywords
binder
sealing material
holding sealing
inorganic
exhaust gas
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PCT/JP2015/062498
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English (en)
Japanese (ja)
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圭司 熊野
隆彦 岡部
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イビデン株式会社
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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
    • 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

Definitions

  • the present invention relates to a holding sealing material, a manufacturing method of the holding sealing material, and an exhaust gas purification device.
  • 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.
  • 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. Furthermore, it is known that when the exhaust gas treating body is accommodated in the casing, the inorganic fibers constituting the holding sealing material are broken and scattered in the atmosphere. Due to such scattering of the inorganic fibers, there is a problem that the inorganic fibers scattered in the atmosphere adversely affect the working environment of the worker handling the holding sealing material.
  • Patent Document 1 a method of impregnating a holding sealing material with an aggregate composed of an organic binder and an inorganic binder is known (for example, see Patent Document 1).
  • Patent Document 1 uses only an aggregate composed of an organic binder and inorganic particles as an inorganic binder, and the effect of suppressing the scattering of inorganic fibers is applied to the portion where the aggregate is attached. Limited. Therefore, when the inorganic fiber is broken at a portion where no aggregate is present, the scattering of the inorganic fiber cannot be suppressed.
  • the organic binder is burned down by the heat of the exhaust gas, the inorganic binder remaining on the surface of the inorganic fibers improves the surface pressure by preventing the fibers from slipping, but the remaining inorganic binder is Since it exists only on a part of the surface of the inorganic fiber, the effect of improving the surface pressure is small. Therefore, there has been a problem that the effect of improving the surface pressure and the effect of suppressing the scattering of inorganic fibers have not been sufficiently achieved.
  • the present invention has been made in order to solve the above-described problem, and can effectively suppress the scattering amount of the inorganic fibers and can sufficiently satisfy the surface pressure characteristics required for the holding sealing material. It aims at providing a sealing material and its manufacturing method. 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 is a holding sealing material made of inorganic fibers, and a binder film made of a first organic binder is formed on the surface of the inorganic fibers.
  • An aggregate composed of the second organic binder and the inorganic binder protrudes from the binder film to form a plurality of convex portions.
  • the inorganic fiber is scattered by the binder film even when the inorganic fiber is broken. Can be suppressed. Therefore, when manufacturing the exhaust gas purification device by press-fitting the exhaust gas treating body around which the holding sealing material of the present invention is wound into a metal casing, scattering of inorganic fibers can be suppressed.
  • the binder film is formed with protrusions by protruding aggregates composed of the second organic binder and the inorganic binder. For this reason, when the inorganic fibers are in contact with each other, the protrusions are hooked to cause frictional resistance, and the inorganic fibers are less likely to slip. As a result, the surface pressure of the holding sealing material is improved.
  • the holding sealing material of the present invention can reduce the surface pressure of the holding sealing material even when high-temperature exhaust gas flows into the exhaust gas purification device and the first organic binder and the second organic binder are burned out. Can be kept high. This is because when the second organic binder in the aggregate is burned off at a high temperature, the inorganic particles as the inorganic binder adhere to and bind to the surface of the inorganic fiber and are maintained as convex portions. Therefore, when the said convex part is caught, it becomes frictional resistance and it becomes difficult to occur that inorganic fiber slips. As a result, the surface pressure of the holding sealing material is improved, and the exhaust gas treating body can be stably held.
  • the aggregate is preferably configured by dispersing inorganic particles as the inorganic binder in the polymer resin component as the second organic binder. Dispersing the inorganic particles as the inorganic binder in the polymer resin component as the second organic binder improves the mechanical strength of the aggregate and contributes to the improvement of the surface pressure.
  • the average height of the convex portions is smaller than the average fiber diameter of the inorganic fibers including the binder film. If the average height of the protrusions is equal to or greater than the average fiber diameter of the inorganic fibers including the binder film, the protrusions may be caught too strongly, and the binder film may peel from the inorganic fibers or form protrusions. In some cases, the agglomerated particles may fall off the binder film.
  • the total content of the first organic binder and the second organic binder is preferably 2% by weight or less of the entire holding sealing material.
  • the total content of the first organic binder and the second organic binder exceeds 2% by weight of the entire holding sealing material, the effect of suppressing the scattering of inorganic fibers and the effect of improving the surface pressure are Almost the same, the amount of cracked gas generated by the heat of the exhaust gas increases, which may adversely affect the surrounding environment.
  • the content of the inorganic binder is preferably 2% by weight or less of the entire holding sealing material.
  • the content of the inorganic binder exceeds 2% by weight, the effect of improving the surface pressure is hardly changed. Therefore, excessive use of an inorganic binder is not preferable from the viewpoint of manufacturing cost.
  • the polymer resin component as the first organic binder and the polymer resin component as the second organic binder are preferably acrylic resins.
  • the polymer resin component as the first organic binder and the polymer resin component as the second organic binder are acrylic resins, it is easy to improve the strength of the binder film.
  • the glass transition point (T g ) of the polymer resin component as the first organic binder and the polymer resin component as the second organic binder is 5 ° C. or less. It is preferable.
  • the glass transition point of the polymer resin component as the first organic binder is 5 ° C. or less, the binder film covering the surface of the inorganic fiber does not become too hard and is highly flexible.
  • the holding sealing material is easily bent when wound around the exhaust gas treatment body.
  • the glass transition point of the polymer resin component as the second organic binder is 5 ° C. or less, the strength can be increased while maintaining the flexibility of the aggregate. Therefore, while maintaining the flexibility of the holding sealing material, when the inorganic fibers are in contact with each other, the aggregates are less likely to fall off and the inorganic fibers are less likely to slip, and the surface pressure is easily improved.
  • 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 manufacturing method of the holding sealing material of the present invention includes a mat preparation step for preparing a mat made of inorganic fibers, and a binder solution for forming a binder film made of a first organic binder on the surface of the inorganic fibers.
  • a binder solution preparation step to prepare an aggregate solution preparation step of mixing the second organic binder and the inorganic binder to form an aggregate composed of the second organic binder and the inorganic binder, and the above
  • a binder film composed of the first organic binder is formed on the surface of the inorganic fiber, and the aggregate is formed on the binder film. It comprises a solution contact step for forming a convex portion and a drying step for drying the mat in contact with the binder solution and the aggregate solution.
  • a binder solution preparing step of preparing a binder solution composed of a first organic binder, a second organic binder and an inorganic binder are mixed to produce a second organic
  • An aggregate solution preparation step for forming an aggregate composed of a binder and an inorganic binder is performed.
  • a binder film made of the first organic binder is formed on the surface of the inorganic fiber.
  • a convex portion made of an aggregate in which the second organic binder and the inorganic binder are aggregated is formed. Therefore, it is suitable as a method for producing the holding sealing material of the present invention.
  • the exhaust gas purification apparatus of the present invention is wound around a metal casing, an exhaust gas treatment body accommodated in the metal casing, and the exhaust gas treatment body, and is disposed between the exhaust gas treatment body and the metal casing.
  • An exhaust gas purification apparatus comprising a holding sealing material, wherein the holding sealing material is the holding sealing material of the present invention.
  • the holding sealing material manufactured by the above manufacturing method is used as the holding sealing material. Therefore, the first organic binder and the second organic binder are heated by introducing exhaust gas or the like.
  • the inorganic fibers contact each other because the inorganic binder that formed the aggregates firmly binds to the surface of the inorganic fibers and many irregularities are formed on the surface of the inorganic fibers.
  • the surface pressure of the holding sealing material can be improved.
  • FIG.1 (a) is the perspective view which showed typically an example of the aggregate which protrudes from the inorganic fiber which comprises the holding
  • 1 (b) is a cross-sectional view taken along line AA in FIG. 1 (a)
  • FIG. 1 (c) is an enlarged cross-sectional view of the aggregate in FIG. 1 (b).
  • FIG. 2A is a cross-sectional view schematically showing another example of an aggregate constituting the holding sealing material of the present invention
  • FIG. 2B is an aggregate constituting the holding sealing material of the present invention.
  • FIG. 2C is a cross-sectional view schematically showing still another example of the aggregate constituting the holding sealing material of the present invention.
  • FIG. 3A is an SEM photograph before firing of the holding sealing material of the present invention
  • FIG. 3B is an SEM photograph after firing of the holding sealing material of the present invention.
  • FIG. 4 is a perspective view schematically showing an example of the holding sealing material of the present invention.
  • Fig.5 (a) is a side view which shows typically an example of the measuring apparatus for measuring the dispersibility of an inorganic fiber
  • FIG.5 (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. 6 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention.
  • FIG. 7 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. 8 is a perspective view schematically showing an example of the manufacturing method of the exhaust gas purifying apparatus of the present invention.
  • the surface of the inorganic fiber is covered with the binder film made of the first organic binder, and the aggregate made of the second organic binder and the inorganic binder is further bonded to the binder. It protrudes from the film.
  • Fig.1 (a) is the perspective view which showed typically an example of the aggregate which protrudes from the inorganic fiber which comprises the holding
  • 1 (b) is a cross-sectional view taken along line AA in FIG. 1 (a)
  • FIG. 1 (c) is an enlarged cross-sectional view of the aggregate in FIG. 1 (b).
  • FIG. 1A in the holding sealing material of the present invention, the surface of the inorganic fiber 10 constituting the holding sealing material is covered with a binder film 20. Further, as shown in FIG. 1B, the aggregate 30 protrudes from the binder film 20.
  • maintenance sealing material of this invention even if the aggregate 30 may be contacting the inorganic fiber 10, it may not be contacting the inorganic fiber 10 Good.
  • the aggregate protrudes from the binder film, a convex portion is formed on the surface of the inorganic fiber. By this convex part, the frictional resistance between inorganic fibers increases, and the surface pressure of the holding sealing material can be improved.
  • FIG. 1C is a cross-sectional view schematically showing that the inorganic particles 32 as the inorganic binder are dispersed in the polymer resin component 31 as the second organic binder in the aggregate 30. is there.
  • the mechanical strength of the aggregate is improved. Therefore, when the inorganic fibers are in contact with each other, it is difficult for the aggregates to drop and the inorganic fibers to slip, and the surface pressure is easily improved.
  • the aggregate 30 protrudes from the binder film 20 made of the polymer resin component 21 as the first organic binder, but its height (FIG. 1C). ),
  • the average value of the distance indicated by the double arrow a) (hereinafter also referred to as the average height of the convex portion) is the fiber diameter of the inorganic fiber 10 including the binder film 20 (double arrow in FIG. 1B). It is preferable that it is smaller than the average value of (length indicated by b).
  • the average height of the protrusions is equal to or greater than the average fiber diameter of the inorganic fibers including the binder film, the protrusions may be caught too strongly, and the binder film may peel from the inorganic fibers or form protrusions. In some cases, the agglomerated particles may fall off the binder film.
  • the average height of a convex part be an average value of the height of ten convex parts selected at random from the SEM image of a holding sealing material.
  • FIG. 2A is a cross-sectional view schematically showing another example of an aggregate constituting the holding sealing material of the present invention
  • FIG. 2B is an aggregate constituting the holding sealing material of the present invention
  • FIG. 2 (c) is a cross-sectional view schematically showing yet another example of the aggregate constituting the holding sealing material of the present invention.
  • the aggregation form of the polymer resin component as the second organic binder and the inorganic particles as the inorganic binder is not particularly limited.
  • the aggregate 35 may be formed so that the polymer resin component 31 as the second organic binder surrounds the periphery of the inorganic particles 32 as at least one inorganic binder as shown in FIG.
  • the aggregate 36 may be formed so that the inorganic particles 32 as the inorganic binder surround the polymer resin component 31 as the second organic binder.
  • the inorganic particles 32 as the inorganic binder are one large particle, and the periphery is surrounded by the polymer resin component 31 as the second organic binder.
  • the collection body 37 may be formed. 1C, FIG. 2A, FIG. 2B, and FIG. 2C are cross-sectional views of the polymer resin component (for example, latex) as the second organic binder.
  • Particle) and inorganic particles as an inorganic binder schematically show the formation of aggregates, the shape of the polymer resin component as the second organic binder constituting the aggregates, and the inorganic binder as The shape of the inorganic particles and the shape of the aggregate are not particularly limited.
  • the aggregate can be formed, for example, by aggregating a second organic binder and an inorganic binder in a solvent, but the shape of the polymer resin component as the second organic binder in the solvent.
  • the shape of the inorganic particles as the inorganic binder is not particularly limited.
  • the binder film constituting the holding sealing material of the present invention is obtained by drying the first organic binder (binder solution) dispersed in a solvent.
  • the polymer resin component as the first organic binder is not particularly limited, and water-soluble organic polymers such as acrylic resins, acrylate latexes, rubber latexes, carboxymethyl cellulose or polyvinyl alcohol, and thermoplastic resins such as styrene resins. And thermosetting resins such as epoxy resins, and acrylic resins are particularly preferable.
  • the glass transition point of the polymer resin component as the first 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. preferable.
  • the glass transition point of the first organic binder is 5 ° C. or less, the binder film made of the first organic binder covering the surface of the inorganic fibers becomes soft, and the holding sealing material having excellent flexibility and can do. Therefore, the holding sealing material is easily bent when the holding sealing material is wound around the exhaust gas treating body.
  • membrane which consists of a 1st organic binder is formed in the surface of an inorganic fiber, even if it is a case where an inorganic fiber fractures
  • the aggregate constituting the holding sealing material of the present invention is obtained by aggregating the second organic binder and the inorganic binder.
  • the polymeric resin component as a 2nd organic binder is not specifically limited, The thing similar to the polymeric resin component as a 1st organic binder can be used suitably.
  • the glass transition point of the polymer resin component as the second organic binder is preferably 5 ° C. or less, more preferably ⁇ 10 ° C. or less, and further preferably ⁇ 30 ° C. or less. .
  • the strength of the aggregate can be increased while maintaining the flexibility of the aggregate to which inorganic particles as the inorganic binder are added. Therefore, when the inorganic fibers are in contact with each other, it is difficult for the aggregates to drop and the inorganic fibers to slip, and the surface pressure is easily improved.
  • the inorganic binder constituting the aggregate in the present invention refers to a solid component obtained by removing a 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.
  • the particle size and particle size distribution of the inorganic particles constituting the inorganic binder are not particularly limited, but the particle size of the inorganic particles is preferably smaller than the fiber size of the inorganic fibers. Specifically, the particle diameter of the inorganic particles is preferably 0.005 to 10 ⁇ m, more preferably 0.01 to 5 ⁇ m, and still more preferably 0.01 to 1 ⁇ m.
  • the total content of the first organic binder and the second organic binder is preferably 2% by weight or less, and more preferably 0.1 to 2% by weight of the entire holding sealing material.
  • the total content of the first organic binder and the second organic binder exceeds 2% by weight of the entire holding sealing material, the effect of improving the surface pressure and suppressing fiber scattering is almost unchanged, and the heat of exhaust gas The amount of cracked gas generated by the gas increases, which may adversely affect the surrounding environment.
  • the content of the inorganic binder is preferably 2% by weight or less, more preferably 0.1 to 2% by weight, based on the entire holding sealing material.
  • the holding sealing material gradually becomes hard and the flexibility is lowered.
  • the holding sealing material is bent and wound around the exhaust gas treatment body, the holding sealing material is bent, so that the winding property cannot be wound along the outer periphery of the exhaust gas treatment body or the surface of the holding sealing material is cracked. Concerned.
  • the content of the inorganic binder exceeds 2% by weight of the entire holding sealing material, the effect of improving the surface pressure is hardly observed. Further, excessive use of the inorganic binder is not preferable from the viewpoint of manufacturing cost.
  • the average height of the protrusions formed by the aggregates constituting the holding sealing material of the present invention is preferably smaller than the average fiber diameter of the inorganic fibers including the binder film.
  • the average height of the convex portions is preferably 0.05 to 11 ⁇ m, more preferably 0.1 to 6 ⁇ m, and further preferably 0.2 to 4 ⁇ m.
  • the size of the aggregate constituting the holding sealing material of the present invention in the aggregate solution is preferably 0.1 to 11 ⁇ m, more preferably 0.2 to 6 ⁇ m, and preferably 0.2 to 4 ⁇ m. More preferably it is.
  • the size of the aggregate exceeds 11 ⁇ m, when the aggregate solution is brought into contact with the mat in the step of applying the aggregate to the mat, the aggregate is too large and is clogged on the surface of the mat. It becomes difficult to make the aggregate contact evenly on the surface of each inorganic fiber present in the direction.
  • the aggregate is too large, the number of aggregates is reduced, and the convex portion formed by the aggregate formed on the surface of the inorganic fiber may be formed on only a part of the inorganic fiber.
  • the effect of improving the surface pressure of the holding sealing material may be insufficient.
  • the size of the aggregate is less than 0.1 ⁇ m, the aggregate is too small, the catch between the inorganic fibers becomes weak, and the surface pressure of the holding sealing material may not be improved.
  • 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 it be changed according to the characteristics required for the mat, such as heat resistance and wind erosion resistance, and use large diameter fibers or fiber lengths that can meet the environmental regulations of each country. Is preferred. 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.
  • 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.
  • low crystalline alumina inorganic fibers are desirable, and low crystalline alumina inorganic fibers having a mullite composition are more preferable.
  • inorganic fibers containing a spinel compound are more preferable.
  • a highly crystalline alumina material is hard and brittle, so it is not suitable for a mat used as a cushioning material.
  • the crystallization ratio is preferably in the range of 0.1 to 30%, and more preferably in the range of the crystallization rate of 0.4 to 20%.
  • Mats made of inorganic fibers in this range have a high rebound force and a high restoration surface pressure after a durability test.
  • the crystallization ratio is less than 0.1% or exceeds 30%, the repulsive force and the restoring surface pressure are rapidly decreased.
  • the mat constituting the holding sealing material can be obtained by various methods, and for example, can be produced by a needling method or a papermaking method.
  • the inorganic fibers constituting the mat obtained by the needling method have a certain average fiber length.
  • the average fiber length of the inorganic fibers is preferably 1 to 150 mm, More preferably, it is 10 to 80 mm. If the average fiber length of the inorganic fiber is less than 1 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 treating body is lowered, and the holding sealing material is easily broken. Become.
  • 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.
  • the average fiber length of the inorganic fibers constituting the mat obtained by the papermaking method is preferably 0.1 to 20 mm.
  • the average fiber length of the inorganic fiber is less than 0.1 mm, the fiber length of the inorganic fiber is too short, so that the characteristics as a fiber are no longer substantially exhibited. Entanglement does not occur and it becomes difficult to obtain sufficient surface pressure.
  • the average fiber length of the inorganic fibers exceeds 20 mm, the fiber length of the inorganic fibers is too long, so that the entanglement between the inorganic fibers in the slurry solution in which the inorganic fibers are dispersed in the water in the paper making process becomes too strong.
  • Inorganic fiber tends to accumulate non-uniformly when formed into a fiber-like aggregate.
  • the fiber length is measured by using tweezers for both the needling method and the papermaking method so that the inorganic fiber is not broken from the mat, and the fiber length is measured using an optical microscope.
  • the average fiber length was determined by extracting 300 inorganic fibers and measuring the fiber length. If the inorganic fibers cannot be removed from the mat without breaking, the mat is degreased, the degreased mat is put into water, and the inorganic fibers are collected so as not to break while loosening the entanglement between the inorganic fibers. .
  • a biosoluble fiber may be used as the inorganic fiber.
  • the biosoluble fiber is, for example, an inorganic fiber made of 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 biologically soluble fiber in physiological saline is preferably 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 mainly composed of silica and alumina and made of calcia, titania, zinc oxide or the like in addition to alkali metals.
  • FIG. 3A is an SEM photograph before firing of the holding sealing material of the present invention
  • FIG. 3B is an SEM photograph after firing of the holding sealing material of the present invention.
  • the binder film when the binder film is burned out, it means heating in the atmosphere at 600 ° C. for 1 hour unless otherwise specified.
  • a binder film and an aggregate are formed on the surface of the inorganic fiber constituting the holding sealing material of the present invention, and a convex portion is formed by the aggregate. Since the binder film is formed on the surface of the inorganic fiber, the binder film can prevent scattering of the inorganic fiber even when the inorganic fiber is broken. Furthermore, aggregates protrude from the binder film. Therefore, when the inorganic fibers are in contact with each other, the convex portions due to the aggregates are caught, and the surface pressure of the holding sealing material can be improved by increasing the frictional resistance between the inorganic fibers.
  • FIG. 3 (b) The structure having the convex portions shown in FIG. 3A is maintained in FIG.
  • a convex portion is formed on the entire surface of the inorganic fiber, and this convex portion is the one in which the inorganic binder constituting the aggregate remains without being decomposed by firing. Accordingly, even after the first organic binder and the second organic binder are burned out, the convex portions on the surface of the inorganic fibers are maintained by the inorganic binder in the aggregate, and the inorganic fibers can slip. Therefore, it is easy to improve the surface pressure.
  • FIG. 4 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. 4), a width (indicated by an arrow W in FIG. 4), and a thickness ( In FIG. 4, it may be composed of a flat plate-like mat having a substantially rectangular shape in plan view having an arrow T).
  • the convex portion 111 is formed on the first end which is one of the end portions on the length direction side of the holding sealing material, and the other end A recess 112 is formed at a certain second end.
  • 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 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 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 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 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.5 (a) and (b).
  • Fig.5 (a) is a side view which shows typically an example of the measuring apparatus for measuring the dispersibility of an inorganic fiber
  • FIG.5 (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. As shown in FIG.
  • the test apparatus 200 is connected to the upper ends of two support columns 260 provided vertically on a base 250 so that the sample support arm 270 can rotate within a predetermined range.
  • a vertical wall member 290 is fixed between the two support columns at a position where it can collide with the sample support arm.
  • FIG.5 (b) is the top view which showed typically an example of the sample support arm part of 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 and the scattering test sample 210 start dropping in the direction toward the base 250 to which the support column 260 is fixed. Connection between the sample support arm 270 and the support column 260 When 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 scattering test sample 210 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 (1)
  • 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 (the bulk density of the holding sealing material before winding) is not particularly limited, but is preferably 0.1 to 0.3 g / cm 3 .
  • the bulk density of the holding sealing material is less than 0.1 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 0.3 g / cm 3 , the holding sealing material becomes hard, so that the winding 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, so that the holding strength can be maintained even in a high temperature range exceeding 700 ° C where the strength of the glass fiber decreases. 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 amount of the expansion material added is not particularly limited, but is preferably 10 to 50% by weight, and preferably 20 to 30% by weight, based on 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 for bonding holding sealing materials by sewing and a method for bonding holding sealing materials with an adhesive tape or an adhesive. .
  • the method for producing a holding sealing material of the present invention includes a mat preparing step for preparing a mat made of inorganic fibers, a binder solution preparing step for preparing a binder solution consisting of a first organic binder, and a second organic bond.
  • the mat preparation process which prepares the mat which consists of 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, for example, an inorganic fiber precursor is prepared by spinning a spinning mixture using a basic aluminum chloride aqueous solution and silica sol as raw materials by a blowing method.
  • the inorganic fiber precursor is compressed to produce a continuous sheet-like material having a predetermined size, which is subjected to a needle punching treatment, and then subjected to a firing treatment to obtain an average fiber diameter of 3 to 10 ⁇ m.
  • the preparation of the mat made of the alumina silica fiber is completed.
  • 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 dehydrating the water in a liquid mixture through a mesh. Thereafter, the preparation of the mat is completed by heat-compressing and drying the raw material sheet under predetermined conditions.
  • the fiber length of the inorganic fiber is shorter than that of the needling method, and therefore it is necessary to maintain the sheet strength with a binder such as an inorganic binder or an organic binder.
  • a binder such as an inorganic binder or an organic binder.
  • an organic binder, an inorganic binder, or the like may be appropriately added to the mixed liquid before molding. .
  • Binder Solution Preparation Step a step of preparing a binder solution by dispersing the first organic binder in a solvent is performed.
  • a binder solution in which the first organic binder is dispersed in the solvent can be prepared by adding the first organic binder to the solvent and stirring sufficiently.
  • the first organic binder used in the above (b) binder solution preparation step is not particularly limited, and those described in the explanation of the holding sealing material of the present invention can be used. Omitted.
  • the solvent used in the binder solution preparation step is not particularly limited, and examples thereof include aqueous organic solvents such as methanol and ethanol, water, and the like. From the viewpoint of production cost, it is preferable to use water.
  • the concentration of the first organic binder 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 point of the first organic binder is not particularly limited, but is preferably 5 ° C. or less, more preferably ⁇ 10 ° C. or less, and ⁇ 30 More preferably, it is not higher than ° C.
  • a pH adjuster for adjusting the pH of the binder solution may be added as necessary.
  • (C) Aggregate solution preparation step an aggregate solution preparation for preparing a solution containing an aggregate in which the second organic binder and the inorganic binder are aggregated by mixing the second organic binder and the inorganic binder. Perform the process.
  • the method for preparing the aggregate solution is not particularly limited as long as the second organic binder and the inorganic binder can be aggregated.
  • a solution in which the second organic binder is dispersed in a solvent (second The organic binder solution can be prepared by adding a solution (inorganic binder solution) in which an inorganic binder is dispersed in a solvent, and adding an aggregating agent as necessary.
  • the inorganic binder solution used in the above (c) aggregate solution preparation step 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 or the like can be used. it can.
  • the concentration of the inorganic binder is not particularly limited, but it is preferable to use a solution in which the concentration of the inorganic binder is diluted to about 0.2 to 20% by weight in terms of solid content.
  • the second organic binder used in the above (c) aggregate solution preparation step is not particularly limited, and since the one described in the explanation of the holding sealing material of the present invention can be used, the detailed explanation thereof is as follows. Omitted.
  • the concentration of the second organic binder solution in the (c) aggregate solution preparation step is not particularly limited, but the concentration of the second organic binder is 0.2 to 20% by weight in terms of solid content. preferable.
  • the solvent used in the (c) aggregate solution preparation step is not particularly limited, and for example, the same solvent as that used in the (b) binder solution preparation step can be used.
  • the glass transition point of the second organic binder is not particularly limited, but is preferably 5 ° C. or less, more preferably ⁇ 10 ° C. or less, and ⁇ 30 More preferably, it is not higher than ° C.
  • a pH adjuster for adjusting the pH of the aggregate solution may be added as necessary.
  • the solution contact process which makes the said binder solution and the said aggregate solution contact with the said mat is performed.
  • the method of bringing the mat into contact with the binder solution and the aggregate solution is not particularly limited.
  • the mat is bonded to the inorganic fibers in the mat by impregnating the mat with the binder solution and the aggregate solution.
  • the binder solution and the aggregate solution may be contacted, and the binder solution and the aggregate solution are dropped onto the inorganic fibers in the mat by dropping the binder solution and the aggregate solution on the mat by a method such as curtain coating. They may be contacted, and the binder solution and the agglomerate solution may be sprayed and sprayed onto the mat as in spray coating.
  • the order of contacting the binder solution and the aggregate solution is not particularly limited, and the aggregate solution may be contacted after the binder solution is contacted and the inorganic fibers are dried, or after the contact with the binder solution.
  • the inorganic fibers may not be dried and subsequently contacted with the aggregate solution, or the mixture of the binder solution and the aggregate solution may be contacted at once.
  • By removing the solvent from the mat that has been brought into contact with the binder solution and the aggregate solution it is possible to form a convex portion and a binder film on the inorganic fibers constituting the mat.
  • it is preferable to adjust the amount of the binder solution applied to 100 parts by weight of the inorganic fibers constituting the mat so as to be 50 to 200 parts by weight.
  • the inorganic fiber When contacting the aggregate solution, it is preferable to contact the inorganic fiber while dispersing the aggregate in the solution by stirring the aggregate solution. By bringing the aggregate solution into contact with the inorganic fibers while stirring, precipitation of the aggregate can be prevented, and further, the size of the aggregate can be suppressed from becoming too large.
  • a solvent removal treatment for removing the solvent in the binder solution and the aggregate solution is performed. May be.
  • the solvent removal treatment is not particularly limited as long as the solvent contained in the mat can be removed.
  • the solvent can be removed by means such as compression, rotation, suction, and reduced pressure.
  • (E) Drying step Thereafter, a drying step is performed in which the mat that has been brought into contact with the binder solution and the aggregate solution is dried at a temperature of about 110 to 140 ° C., and the first organic binder, the second organic binder, By drying the organic binder and the inorganic binder, and removing the solvent in the binder solution and the aggregate solution, a binder film made of the first organic binder is formed on the surface of the inorganic fiber, and further, Aggregates made of the second organic binder and the inorganic binder protrude from the binder film to form convex portions. Therefore, the holding sealing material of the present invention can be manufactured by such a manufacturing method.
  • the mat can be dried using a method such as hot air drying, ventilation drying, or compression drying with a hot plate. If drying with a hot plate is performed, the distribution of the binder solution and the aggregate solution impregnated in the mat becomes uniform in the thickness direction, which is advantageous for a mat for papermaking with poor thickness formability.
  • a cutting step of cutting the holding sealing material into a predetermined shape may be further performed.
  • the cutting of the holding sealing material can be performed with a Thomson blade, a guillotine blade, a laser, a water jet, or the like.
  • the above cutting method may be used as appropriate depending on the situation, but a Thomson blade or a guillotine blade is preferable if mass processing is important, and a laser or a water jet is preferable if cutting accuracy is important.
  • a binder solution made of a first organic binder and an aggregate solution containing an aggregate made of a second organic binder and an inorganic binder are brought into contact with the mat.
  • a binder film made of the first organic binder is formed on the inorganic fiber surface.
  • an aggregate composed of the second organic binder and the inorganic binder is formed so as to protrude from the binder film. Therefore, even if the inorganic fiber is broken, the scattering of the inorganic fiber can be suppressed by the binder film.
  • a convex part is formed in the binder film
  • 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 holding member that is wound around the exhaust gas treatment body and disposed between the exhaust gas treatment body and the metal casing.
  • An exhaust gas purifying apparatus including a sealing material, wherein the holding sealing material is a holding sealing material manufactured by the holding sealing material of the present invention or the manufacturing method of the holding sealing material of the present invention.
  • FIG. 6 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 specific examples include metals such as stainless steel, aluminum, and iron.
  • a clamshell shape or the like can be suitably used in addition to a substantially cylindrical shape.
  • FIG. 7 is a perspective view schematically showing an example of the exhaust gas treating body constituting the exhaust gas purifying apparatus of the present invention.
  • the exhaust gas treatment body 120 shown in FIG. 7 is a honeycomb structure made of a columnar ceramic material in which a large number of cells 125 are provided side by side with a cell wall 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 cell 125 constituting the exhaust gas treatment body 120 may be a substantially polygonal shape such as a substantially triangular shape, a substantially square shape, a substantially pentagonal shape or a substantially hexagonal shape, 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 preferable.
  • the supported catalyst is preferably a noble metal such as platinum, palladium, rhodium, etc. Then, platinum is more preferable.
  • alkali metals such as potassium and sodium, and 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.
  • the exhaust gas treating body constituting the exhaust gas purifying apparatus of the present invention may have an outer peripheral coat layer formed on the outer peripheral surface.
  • the outer peripheral coating layer is formed on the outer peripheral surface of the exhaust gas treating body, 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. 6, 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. 8 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), sizing method (swaging type) that compresses from the outer peripheral side so as to reduce the inner diameter of the metal casing 130, and the metal casing in a shape that can be separated into parts of the first casing and the second casing,
  • Stuffing method Stuffing method
  • 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 having 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.
  • a binder film made of the first organic binder is formed on the surface of the inorganic fiber. Therefore, even if the inorganic fiber is broken, the scattering of the inorganic fiber can be suppressed by the binder film.
  • the aggregate protrudes from the binder film, when the inorganic fibers are brought into contact with each other, the convex portion due to the aggregate is caught and the frictional resistance between the inorganic fibers is increased. As a result, the surface pressure of the holding sealing material can be improved.
  • a convex portion derived from the inorganic binder in the aggregate is formed on almost the entire surface of the inorganic fiber. Since the convex portion derived from the inorganic binder is formed on the entire surface of the inorganic fiber, the fibers are less likely to slip, can maintain a high surface pressure, and suppress damage to the exhaust gas treating body. Can do.
  • a binder film made of the first organic binder is formed on the surface of the inorganic fiber. Therefore, even if the inorganic fiber is broken, the scattering of the inorganic fiber can be suppressed by the binder film. Therefore, when manufacturing the exhaust gas purification device by press-fitting the exhaust gas treatment body around which the holding sealing material of the present invention is wound into a metal casing, scattering of inorganic fibers can be suppressed.
  • an aggregate composed of the second organic binder and the inorganic binder protrudes from the binder film to form a plurality of convex portions. For this reason, when the inorganic fibers come into contact with each other, the convex portions are hooked to cause frictional resistance, and the inorganic fibers are difficult to slip. As a result, the surface pressure of the holding sealing material is improved.
  • 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. Aggregates composed of the second organic binder and inorganic binder protrude from the surface of the fiber to form a plurality of convex portions, so the surface pressure of the holding sealing material is high, and the exhaust gas treatment body is stably held. can do.
  • the first organic binder in the binder film and the first in the aggregate are obtained by circulating high-temperature exhaust gas through the exhaust gas treatment body constituting the exhaust gas purification apparatus. 2 organic binder burns out. Even if the first organic binder in the binder film and the second organic binder in the aggregate are burned out, the inorganic binder in the aggregate is not burned out. Since the convex part derived from the agent is formed and the frictional resistance between the inorganic fibers is increased, the surface pressure can be kept high.
  • Example 1 (A) Mat preparation step First, a mat made of 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.
  • A-3) Needle punching process The needle-punched body was produced by continuously performing the needle punching process on the sheet-like material obtained in the above-mentioned process (a-2) using the conditions shown below. First, a needle board to which needles were attached at a density of 21 pieces / cm 2 was prepared. Next, 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 Inorganic fiber containing 72 parts by weight: 28 parts by weight of alumina and silica 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 Acrylate latex in which acrylic rubber having a glass transition point of ⁇ 10 ° C. is dispersed in water as a first organic binder solution (Nipol LX854E (solid content concentration: 45 wt. %)) was added to water to prepare a binder solution prepared such that the first organic binder was 1% by weight in terms of solid content with respect to the total amount of the binder solution.
  • a first organic binder solution Napol LX854E (solid content concentration: 45 wt. %)
  • acrylate latex Nipol LX854E manufactured by Nippon Zeon Co., Ltd., solid content concentration: 45
  • acrylic rubber having a glass transition point of ⁇ 10 ° C. is dispersed in water.
  • an inorganic binder solution an alumina colloid solution (alumina sol) (Alumina sol 550 (solid content concentration: 15% by weight) manufactured by Nissan Chemical Industries, Ltd.) is used as a solid content conversion with respect to the whole solution.
  • (D-3) Solvent removal step The mat with the aggregate solution and the binder solution obtained in the above (d-2) solution contact step is set in a suction dehydrator and dehydrated, whereby the first organic
  • the contents of the binder, the second organic binder, and the inorganic binder are 0.5% by weight, 0.5% by weight, and 1% by weight, respectively, of the entire holding sealing material after the completion of the drying step (e) described later. It adjusted so that it might become.
  • step (E) Drying step The mat obtained in the step (d) solution contact step was dried with hot air by blowing hot air at a temperature of 130 ° C. and a wind speed of 2 m / s to obtain a holding sealing material.
  • the organic solvent composed of the organic binder and the inorganic binder was placed in a crucible, and the organic solvent was evaporated and removed by heating.
  • the residue remaining in the crucible was regarded as the total weight of the organic binder and the inorganic binder relative to the holding sealing material, and the content (% by weight) relative to the weight of the holding sealing material was calculated.
  • the crucible was heat-treated at 600 ° C. for 1 hour to burn off the organic binder. Since the inorganic binder remained in the crucible, this was regarded as the content (% by weight) of the inorganic binder with respect to the total of the organic binder and the inorganic binder, and the content was calculated. The remainder is the content of the organic binder (the total content of the first organic binder and the second organic binder) (% by weight).
  • the content of the organic binder and the inorganic binder can be measured by the above method.
  • the organic binder is a crosslinkable resin
  • all the crosslinkable resin is eluted with an organic solvent. Difficult to do. Therefore, in that case, the inorganic fibers constituting the mat (those in which the binder film and aggregates are not formed) are collected and the weight (A1) is measured, and the same conditions as in this example and this comparative example are obtained.
  • After adhering the organic binder and the inorganic binder to the inorganic fiber it is sufficiently dried and the weight is measured (A2). Thereafter, heat treatment is performed at 600 ° C. for 1 hour, and the weight is further measured (A3). Since A2-A3 is the weight of the organic binder and A3-A1 is the weight of the inorganic binder, the content (% by weight) of the organic binder and the inorganic binder relative to the weight of the sample can be calculated.
  • Example 1 (Confirmation of binder film) About Example 1 and each comparative example, the surface of the inorganic fiber which comprises the holding sealing material before baking is observed with a fluorescent X-ray analyzer, and the binder film is the one in which carbon is detected from most of the surface of the inorganic fiber. was determined to be formed. The results are shown in Table 1. In Table 1, the case where it was determined that the binder film was formed was indicated by ⁇ , and the case where it was not formed was indicated by ⁇ .
  • Example 1 (Confirmation of aggregates) About Example 1 and each comparative example, the inorganic fiber which comprises the holding sealing material before baking was observed with the scanning electron microscope, and it was confirmed whether the convex part was formed with the aggregate. The results are shown in Table 1. In Table 1, the case where the convex portion is formed by the aggregate is indicated by ⁇ , and the case where the convex portion is not formed is indicated by ⁇ .
  • the holding sealing material according to Example 1 when the holding sealing material according to Example 1 is used, a high surface pressure of 170 kPa or more before firing and 30 kPa or more after firing can be secured, and the fiber scattering rate is 0.1 weight. % could be suppressed.
  • a binder film was not formed, and scattering of inorganic fibers could not be sufficiently suppressed. Furthermore, the surface pressure before and after firing was not sufficient.
  • the holding sealing material of Comparative Example 2 since no inorganic binder was added, aggregates were not formed. Therefore, the scattering of inorganic fibers could be sufficiently suppressed, but the surface pressure after firing was greatly reduced. From the above, the holding sealing material of the present invention having the binder film and the protrusions from which the aggregates protruded from the binder film is excellent in suppressing the scattering of fibers and in the surface pressure before and after firing. I found out.

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Abstract

La présente invention concerne : un matériau d'étanchéité de fixation qui peut être empêché efficacement de libérer des fibres inorganiques et qui peut suffisamment satisfaire aux caractéristiques de pression surfacique requises par les matériaux d'étanchéité de fixation ; et un procédé de production du matériau d'étanchéité de fixation. Le matériau d'étanchéité de fixation comprend des fibres inorganiques, et est caractérisé en ce qu'un film de revêtement de liant comprenant un premier liant organique a été formé sur la surface des fibres inorganiques et en ce que des agrégats composés d'un second liant organique et un liant inorganique sont en saillie du film de revêtement de liant pour former une pluralité de saillies.
PCT/JP2015/062498 2014-05-08 2015-04-24 Matériau d'étanchéité de fixation, procédé de production de matériau d'étanchéité de fixation, et purificateur de gaz d'échappement WO2015170610A1 (fr)

Applications Claiming Priority (2)

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JP2014097199A JP6294147B2 (ja) 2014-05-08 2014-05-08 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
JP2014-097199 2014-05-08

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WO2015170610A1 true WO2015170610A1 (fr) 2015-11-12

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WO2023163009A1 (fr) * 2022-02-28 2023-08-31 イビデン株式会社 Matériau de matelas, dispositif de purification de gaz d'échappement et procédé de production de matériau de matelas

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JP2002206421A (ja) * 2001-01-11 2002-07-26 Ibiden Co Ltd 触媒コンバータ用保持シール材、セラミック繊維及びセラミック繊維の製造方法
JP2006342774A (ja) * 2005-06-10 2006-12-21 Ibiden Co Ltd 保持シール材及びその製造方法
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* Cited by examiner, † Cited by third party
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WO2023163007A1 (fr) * 2022-02-28 2023-08-31 イビデン株式会社 Matériau de matelas, dispositif de purification de gaz d'échappement et procédé de production de matériau de matelas
WO2023163009A1 (fr) * 2022-02-28 2023-08-31 イビデン株式会社 Matériau de matelas, dispositif de purification de gaz d'échappement et procédé de production de matériau de matelas

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