WO2016080388A1 - バインダー含有無機繊維成形体の製造方法 - Google Patents
バインダー含有無機繊維成形体の製造方法 Download PDFInfo
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- WO2016080388A1 WO2016080388A1 PCT/JP2015/082252 JP2015082252W WO2016080388A1 WO 2016080388 A1 WO2016080388 A1 WO 2016080388A1 JP 2015082252 W JP2015082252 W JP 2015082252W WO 2016080388 A1 WO2016080388 A1 WO 2016080388A1
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- binder
- liquid
- inorganic fiber
- molded body
- fiber molded
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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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/18—Processes for applying liquids or other fluent materials performed by dipping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/30—Processes for applying liquids or other fluent materials performed by gravity only, i.e. flow coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/30—Processes for applying liquids or other fluent materials performed by gravity only, i.e. flow coating
- B05D1/305—Curtain coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
- B05D3/0254—After-treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/04—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases
- B05D3/0406—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases the gas being air
- B05D3/0413—Heating with air
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/04—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases
- B05D3/0493—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases using vacuum
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
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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
- D04H1/42—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
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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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2203/00—Other substrates
- B05D2203/30—Other inorganic substrates, e.g. ceramics, silicon
Definitions
- the present invention relates to a method for producing an inorganic fiber molded body containing a binder. More specifically, the present invention relates to a method for producing a binder-containing inorganic fiber molded body useful as a catalyst carrier for an exhaust gas purification device or a holding material for a particle filter.
- a molded body of inorganic fiber typified by ceramic fiber is exposed to a high temperature state such as industrial heat insulating material, refractory material, packing material, etc., and when the catalyst carrier or particle filter is accommodated in a metal casing, It is also used as a holding material for an exhaust gas purification device wound around a particle filter and interposed between a catalyst carrier or a particle filter and a casing.
- the inorganic fiber molded body contains an organic binder or an inorganic binder in order to prevent fiber scattering during the assembly operation.
- Patent Document 1 after impregnating an inorganic fiber mat with an organic binder liquid, the inorganic fiber mat is compressed in the thickness direction, and the medium liquid of the organic binder liquid is removed in a state where the thickness of the inorganic fiber mat is constrained.
- Patent Document 2 discloses a method for producing a resin-impregnated inorganic fiber mat in which an inorganic fiber mat is impregnated with a resin solution and then dried by passing hot air through the inorganic fiber mat in the thickness direction.
- Patent Document 3 discloses a method for producing a holding material in which a fiber material mat is impregnated with latex (organic binder liquid), wherein the organic binder content on the inner peripheral side of the mat is the organic binder content on the outer peripheral side of the mat. Is larger and is in the range of 15 to 50 g / m 2 .
- the inorganic fiber molded body in which the binder is localized on the surface is deformed by applying an excessive external force, delamination occurs on the surface where the binder concentration difference is large in the thickness direction. May cause destruction.
- a method for assembling an exhaust gas purification apparatus a method of press-fitting a catalyst carrier or a particle filter wound with an inorganic fiber molded body into a casing is generally employed. In this press-fitting method, an inorganic fiber molded body is employed. Since a large shearing force is applied, the problem of delamination becomes significant.
- the binder when the binder is localized on the surface of the inorganic fiber molded body, when the inorganic fiber molded body is wound around the catalyst carrier or the particle filter, the surface layer containing the binder of the inorganic fiber molded body is formed. There is also a possibility that cracks and wrinkles may occur and it may be difficult to suppress the bulkiness of the inorganic fiber molded body. If the inorganic fiber molded body and the catalyst carrier or the particle filter are not accommodated in a predetermined position in the casing, good performance cannot be exhibited.
- Patent Documents 1 to 3 None of the techniques described in Patent Documents 1 to 3 are intended to suppress the localization of the binder, and the above-described problems remain.
- the present invention has been made in view of the above problems, and has as its main object to provide a method for producing a binder-containing inorganic fiber molded body capable of suppressing the localization of the binder.
- the present inventors have intensively studied, and as a result, after applying a binder liquid to an inorganic fiber molded body, the localization of the binder is suppressed by applying a predetermined liquid.
- the headline and the present invention were completed.
- the present invention includes a binder liquid application process for applying a binder liquid to an inorganic fiber molded body, and a liquid application process for applying a liquid having a boiling point of less than 120 ° C. to the inorganic fiber molded body on which the binder liquid is applied. And a method for producing a binder-containing inorganic fiber molded article.
- the binder by applying a predetermined liquid to the inorganic fiber molded body coated with the binder liquid and impregnating the liquid into the inorganic fiber molded body, the binder is opposite to the surface of the inorganic fiber molded body from which the binder liquid is applied. It can be moved to the inside or the inside of the substrate, and the localization of the binder can be suppressed.
- the liquid application step it is preferable to apply the liquid to the application surface of the binder liquid of the inorganic fiber molded body.
- the binder concentration can be lowered on the surface of the inorganic fiber molded body to which the binder liquid is applied, and as a result, segregation of the binder on the surface of the inorganic fiber molded body can be suppressed in the drying step.
- the binder liquid can also permeate, and the binder can be uniformly contained throughout the thickness direction of the inorganic fiber molded body.
- the inorganic fiber molded body after the liquid application step, it is preferable to have a drying step of drying the inorganic fiber molded body, and in the drying step, the inorganic fiber molded body is preferably air-dried. This is because binder migration during drying can be suppressed.
- the binder liquid application step in the binder liquid application step, the binder liquid is applied to one side of the inorganic fiber molded body, and in the liquid application step, the liquid is applied to the application surface of the binder liquid of the inorganic fiber molded body.
- the liquid removal step includes removing the liquid from the inorganic fiber molded body. In the liquid removal step, the binder liquid and the liquid application surface of the inorganic fiber molded body The liquid is preferably sucked from the opposite surface.
- the liquid moves from the surface of the inorganic fiber molded body to the opposite side of the binder liquid and liquid application, and at the same time, the binder liquid is removed from the surface of the inorganic fiber molded body to which the binder liquid and liquid are applied. This is because it can be moved to the side surface and the binder can be made uniform.
- the method of applying the binder liquid is a non-contact coating method in which the binder liquid is non-contact coated on the inorganic fiber molded body. It is more difficult to penetrate the binder liquid into the inorganic fiber molded body only by a non-contact coating method such as a spray method.
- a non-contact coating method such as a spray method.
- the present invention since the localization of the binder can be suppressed as described above, the present invention is useful in the case of the non-contact coating method.
- the coating amount of the liquid is within a range of 3.0 to 50 with respect to the solid amount of the binder on the coating surface of the binder liquid of the inorganic fiber molded body. If the coating amount of the liquid is too small, it is difficult to make the binder uniform. Moreover, when there is too much application quantity of a liquid, there exists a possibility that drying conditions may become an excessive load.
- the amount of the liquid applied is preferably in the range of 7.5% to 80% with respect to the mass per inorganic fiber in the inorganic fiber molded body.
- the coating amount of the liquid is within the above range, the amount of dust generation of the produced binder-containing inorganic fiber molded body is reduced, the shear coefficient is increased, the friction coefficient is decreased, and the drying condition is excessively loaded. This is preferable because it is not necessary.
- the binder liquid after applying the binder liquid to the inorganic fiber molded body, by applying a predetermined liquid, localization of the binder can be suppressed, the shear strength is high, and the friction resistance against the metal casing is high. There exists an effect that a small binder content inorganic fiber fabrication object can be obtained.
- the method for producing a binder-containing inorganic fiber molded body of the present invention includes a binder liquid coating step of applying a binder liquid to the inorganic fiber molded body, and a boiling point of less than 120 ° C. in the inorganic fiber molded body coated with the binder liquid. And a liquid application step of applying a certain liquid.
- FIG. 1A to 1E are process diagrams showing an example of a method for producing a binder-containing inorganic fiber molded body of the present invention.
- a sheet-like inorganic fiber molded body 1 is prepared as shown in FIG. 1 (a), and a binder liquid 2 is applied to one side of the inorganic fiber molded body 1 as shown in FIG. 1 (b).
- the predetermined liquid 3 is sprayed on the application surface of the binder liquid 2 of the inorganic fiber molded object 1, and the inorganic fiber molded object 1 is impregnated with the liquid 3.
- FIG. 1 are process diagrams showing an example of a method for producing a binder-containing inorganic fiber molded body of the present invention.
- the liquid 3 is applied to the application surface 4a of the binder liquid 2 of the inorganic fiber molded body 1.
- the application surface 4a of the binder liquid 2 of the inorganic fiber molded body 1 and Even when the liquid 3 is applied to the opposite surface 4b, when the liquid 3 is applied and impregnated into the inorganic fiber molded body 1, the binder is separated from the application surface 4a of the binder liquid 2 on the opposite side by the concentration gradient. Move to surface 4b.
- a binder when apply
- a predetermined liquid is applied to the inorganic fiber molded body to which the binder liquid has been applied, and the inorganic fiber molded body is impregnated with the liquid, whereby the binder is applied to the binder liquid of the inorganic fiber molded body.
- concentration can be reduced in the application surface of the binder liquid of an inorganic fiber molded object. Segregation of the binder on the surface of the molded body can be suppressed.
- the binder-containing inorganic fiber molded body in the present invention is used as a holding material for an exhaust gas purifying apparatus, it is excellent in assemblability, and the binder-containing inorganic fiber molded body and the catalyst carrier or the particle filter are displaced during press-fitting. And the holding power of the binder-containing inorganic fiber molded body can be increased.
- FIG. 2 is a schematic view showing another example of the method for producing a binder-containing inorganic fiber molded body of the present invention.
- This example is a roll-to-roll manufacturing method using a long inorganic fiber molded body 1.
- the spraying device 13 is disposed on the spray nozzle 14 for spraying the binder liquid 2 and the surface of the inorganic fiber molded body 1 opposite to the surface on which the binder liquid 2 is applied, and collects the sprayed excess binder liquid 2.
- the binder liquid 2 is sprayed by the spray nozzle 14 on one surface of the inorganic fiber molded body 1.
- the spray device 18 includes a spray nozzle 19 that sprays the liquid 3 and a suction device 20 that sucks the liquid 3 from the surface opposite to the liquid 3 application surface of the inorganic fiber molded body 1.
- the liquid 3 is sprayed by the spray nozzle 19 on the application surface of the binder liquid 2 of the molded body 1.
- the sprayed liquid 3 can be moved into the inorganic fiber molded body 1 by the suction device 20.
- coated is conveyed to the drying apparatus 21 with the guide roll 12a, and the inorganic fiber molded object 1 is dried. Thereby, the binder containing inorganic fiber molded object 6 in which the binder 5 was contained in the inorganic fiber molded object 1 is obtained. Thereafter, the binder-containing inorganic fiber molded body 6 is conveyed by the guide roll 12 b and taken up by the take-up roll 22.
- the inorganic fiber molded body is a non-woven aggregate of inorganic fibers, and is called, for example, a mat, a blanket or a block.
- the inorganic fiber constituting the inorganic fiber molded body is not particularly limited, and examples thereof include silica, alumina / silica, zirconia containing these, spinel, titania alone, or composite fibers. Of these, alumina / silica fibers are preferable, and crystalline alumina / silica fibers are particularly preferable.
- the composition ratio (mass ratio) of alumina / silica of the alumina / silica fiber is preferably in the range of 60 to 98/40 to 2, and more preferably in the range of 70 to 74/30 to 26.
- the average fiber diameter of the inorganic fibers is preferably in the range of 3 ⁇ m to 8 ⁇ m, particularly preferably in the range of 5 ⁇ m to 7 ⁇ m. If the average fiber diameter of the inorganic fibers is too large, the repulsive force of the inorganic fiber molded body is lost, and if it is too small, the amount of dust generated floating in the air may increase.
- the method for producing the inorganic fiber molded body is not particularly limited, and any known method can be employed. Especially, it is preferable that the inorganic fiber molded object is a thing in which the needling process was performed. By the needling treatment, not only a strong inorganic fiber molded body in which inorganic fibers constituting the inorganic fiber molded body are entangled but also the thickness of the inorganic fiber molded body can be adjusted.
- the thickness of the inorganic fiber molded body is not particularly limited, and is appropriately selected depending on the application.
- the thickness of the inorganic fiber molded body can be about 2 mm to 50 mm.
- the inorganic fiber molded body may be a single sheet or a long sheet.
- a binder-containing inorganic fiber molded body can be manufactured by a roll-to-roll method, and productivity can be improved.
- Binder liquid application process In this invention, the binder liquid application process which apply
- an organic binder or an inorganic binder can be used as the binder contained in the binder liquid.
- only an organic binder may be used, or an organic binder and an inorganic binder may be used in combination. Since the organic binder can be decomposed and removed by heating, the repulsive force of the inorganic fiber molded body can be restored by decomposing and removing the organic binder by heating when using the binder-containing inorganic fiber molded body.
- the fiber molded body can be suitably used as a holding material for an exhaust gas purifying apparatus, for example.
- organic binder for example, various rubbers, water-soluble polymer compounds, thermoplastic resins, thermosetting resins and the like can be used.
- synthetic rubbers such as acrylic rubber and nitrile rubber; water-soluble polymer compounds such as carboxymethyl cellulose and polyvinyl alcohol; or acrylic resins are preferable.
- acrylic rubber, nitrile rubber, carboxymethyl cellulose, polyvinyl alcohol, and acrylic resin not contained in acrylic rubber are preferable.
- These organic binders are easy to prepare or obtain an organic binder liquid, and are easy to apply to an inorganic fiber molded body, exhibiting sufficient thickness restraining force even with a relatively low content, and obtained.
- the molded body is flexible and excellent in strength, and can be suitably used because it is easily decomposed or burnt off under the operating temperature conditions.
- An organic binder may be used individually by 1 type, and 2 or more types may be mixed and used for it.
- the inorganic binder examples include inorganic oxides, and specifically include alumina, spinel, zirconia, magnesia, titania, calcia, and materials having the same composition as the inorganic fibers.
- An inorganic binder may be used individually by 1 type, and 2 or more types may be mixed and used for it.
- the particle size of the inorganic oxide can be, for example, 1 ⁇ m or less.
- the solvent or dispersion medium contained in the binder liquid is appropriately selected according to the type of the binder or binder liquid, and examples thereof include water and organic solvents.
- a solvent and a dispersion medium may be used individually by 1 type, and 2 or more types may be mixed and used for them.
- the binder liquid in the case of an organic binder, an aqueous solution containing the above organic binder, a water-dispersed emulsion, latex, or an organic solvent solution can be used. These are commercially available, and these organic binder liquids can be used as they are or diluted with water or the like, and can be suitably used for applying an organic binder liquid to an inorganic fiber molded body. An emulsion is particularly preferable.
- the organic binder liquid may contain an inorganic binder. In the case of an inorganic binder, a sol, colloid, slurry, or solution containing the inorganic binder can be used as the binder liquid.
- the inorganic binder liquid may contain an organic binder.
- a dispersion stabilizer may be added to the inorganic binder liquid in order to increase the stability of the inorganic binder.
- examples of the dispersion stabilizer include acetic acid, lactic acid, hydrochloric acid, nitric acid and the like.
- the binder concentration in the binder liquid is not limited as long as the binder liquid can be uniformly applied to the inorganic fiber molded body, and is appropriately adjusted according to the type and application method of the binder.
- the binder concentration in the binder liquid is preferably in the range of 3% by mass to 50% by mass.
- the binder concentration is too low, it becomes difficult to bring the content of the binder in the binder-containing inorganic fiber molded body into a desired range.
- the binder concentration is too high, it becomes difficult for the binder to impregnate the inorganic fiber molded article, and the physical properties such as workability and thermal properties and strength of the binder-containing inorganic fiber molded article may be deteriorated.
- the method for applying the binder liquid is not particularly limited as long as the binder liquid can be uniformly applied to the inorganic fiber molded body.
- the kiss coating method, the spray method, the dipping method, the roll coating method, and the gravure method can be appropriately selected from general coating methods such as a coating method, a die coating method, and a curtain coating method.
- the application of the binder liquid may be repeated a plurality of times.
- the coating method is preferably a contact coating method in which a binder liquid is applied to an inorganic fiber molded body by contact or a non-contact coating method in which a binder liquid is applied in a non-contact manner to an inorganic fiber molded body, and a non-contact coating method is particularly preferable.
- the contact coating method is a method in which a binder liquid is applied by, for example, a coating member such as a coating roll supplied with the binder liquid coming into contact with the surface of the inorganic fiber molded body. In the contact coating method, if the viscosity of the binder liquid is low, uneven coating may occur, and therefore a binder liquid having a certain degree of viscosity is used.
- the non-contact coating method is a method in which an application member such as a nozzle is not brought into contact with the inorganic fiber molded body.
- a non-contact coating method such as a spray method
- the liquid is applied to and impregnated into the inorganic fiber molded body in the liquid coating step described later, whereby the binder is transferred from the surface of the inorganic fiber molded body to the opposite side or inside of the binder liquid. Can be moved. Therefore, the present invention is useful when the contact coating method and the non-contact coating method are applied.
- Examples of the contact coating method include a kiss coating method, a roll coating method, and a gravure coating method. Of these, the kiss coat method is preferable. This is because the kiss roll can be slid and applied, and the coating amount of the binder liquid can be easily controlled by the ratio of the surface speed of the roller to the line speed of the inorganic fiber molded body.
- Examples of the non-contact coating method include a spray method, a die coating method, and a curtain coating method. Of these, the spray method is preferred. This is because when the binder liquid is applied to the inorganic fiber molded body by the roll-to-roll method, the coating amount of the binder liquid can be controlled without controlling the transport speed and tension of the inorganic fiber molded body.
- the binder liquid When applying the binder liquid to the inorganic fiber molded body, the binder liquid may be applied on one side or both sides of the inorganic fiber molded body, but it is preferable to apply only on one side.
- the binder liquid In the case where the binder liquid is applied only to one side of the inorganic fiber molded body, the inorganic fiber is sucked from the surface opposite to the surface of the inorganic fiber molded body on which the binder liquid is applied in the liquid removal step described later.
- the binder liquid can be moved from the surface of the molded body to which the binder liquid is applied to the opposite surface, and the binder can be further suppressed from being localized on the surface of the inorganic fiber molded body to which the binder liquid is applied.
- the migration of the binder at the time of drying can be suppressed by letting hot air pass from the application surface of the binder liquid of an inorganic fiber molded object at the below-mentioned drying process.
- the amount of the binder liquid applied to the inorganic fiber molded body is appropriately selected according to the type of inorganic fiber or binder liquid, the binder concentration in the binder liquid, the thickness of the binder-containing inorganic fiber molded body, the application, and the like.
- the binder solid content with respect to the inorganic fibers in the inorganic fiber molded body described later is appropriately adjusted so as to be in a desired range.
- liquid application process the liquid application process of apply
- the boiling point of the liquid is less than 120 ° C, preferably in the range of 60 ° C to 110 ° C.
- the liquid can be easily removed in the drying step described later.
- the boiling point is too high, it becomes difficult to completely remove the liquid in the drying step described later.
- the evaporation rate of the liquid is increased, and it becomes difficult to sufficiently penetrate the liquid into the inorganic fiber molded body. As a result, it is difficult to contain the binder inside the inorganic fiber molded body. There is a risk of becoming.
- the vapor pressure of the liquid at room temperature (25 ° C.) is preferably low, specifically 5 kPa or less.
- the viscosity of the liquid is preferably lower than the viscosity of the binder liquid.
- the viscosity is preferably 3.5 mPa ⁇ s or less, and particularly within the range of 3.0 mPa ⁇ s to 0.5 mPa ⁇ s, particularly It is preferably in the range of 2.0 mPa ⁇ s to 0.5 mPa ⁇ s. If the viscosity of the liquid is lower than the viscosity of the binder liquid, the liquid is more easily impregnated into the inorganic fiber molded body than the binder liquid, so that the binder is easily moved when the liquid is applied to the inorganic fiber molded body.
- the viscosity of the liquid refers to a viscosity at 20 ° C., and is a value measured using a rotational viscometer in accordance with JIS Z8803 (liquid viscosity measuring method).
- the liquid is not particularly limited as long as it penetrates into the inorganic fiber molded body, but preferably satisfies the above boiling point and viscosity.
- a liquid is a thing which does not impair the state of a binder liquid, etc.
- it is more preferable that it is a solvent or a dispersion medium contained in a binder liquid. This is because the binder can be easily moved when the liquid is applied and impregnated into the inorganic fiber molded body.
- examples of such a liquid include water and lower alcohols such as ethanol.
- water-dispersed emulsion is used as the binder liquid, it is preferable to use water as the liquid. Water is also suitable from the environmental aspect. As water, for example, pure water can be used.
- a liquid may be used individually by 1 type, and 2 or more types may be mixed and used for it.
- the impurities contained in the liquid are as small as possible, and it is more preferable that the liquid does not contain impurities. It is preferable that the liquid is completely removed in a drying step described later and does not remain in the obtained binder-containing inorganic fiber molded body, and therefore it is preferable that no impurities are contained.
- that the liquid does not contain impurities means that the concentration of impurities contained in the liquid is 0.1% by mass or less.
- the method for applying the liquid is not particularly limited as long as the method can uniformly apply the liquid to the inorganic fiber molded body, and examples thereof include a spray method, a curtain coating method, a die coating method, and a brush coating method. It is done.
- the liquid application method is preferably a non-contact application method. The liquid application may be repeated a plurality of times.
- the liquid when applying a liquid to the inorganic fiber molded body, the liquid may be applied to one side or both sides of the inorganic fiber molded body. Especially, it is preferable to apply
- the binder liquid can also permeate into the inorganic fiber molded body, and the binder extends throughout the thickness direction of the inorganic fiber molded body. Can be contained uniformly.
- the inorganic fiber molded body when applying a liquid to one side of the inorganic fiber molded body, it is preferable to suck the liquid from the surface opposite to the liquid application surface of the inorganic fiber molded body simultaneously with the application. It is preferable to apply the liquid to the surface of the body on which the binder liquid is applied and simultaneously suck the liquid from the surface of the inorganic fiber molded body opposite to the surface on which the binder liquid and liquid are applied. The penetration speed of the liquid can be increased. Further, as the liquid moves from the surface of the inorganic fiber molded body to the opposite side of the binder liquid and liquid applied surface, the binder liquid can also be moved, and the binder can be made uniform.
- the amount of application of the liquid is not particularly limited as long as the binder can be moved in the entire thickness direction of the inorganic fiber molded body.
- the type of inorganic fiber, binder liquid and liquid, and binder-containing inorganic fiber molding It is appropriately selected according to the thickness of the body, the use and the like.
- the coating amount of the liquid is preferably in the range of 3.0 to 50, more preferably in the range of 4.0 to 40, with respect to the solid amount of the binder on the coating surface of the binder liquid of the inorganic fiber molded body. And particularly preferably within the range of 5.0 to 30. If the coating amount of the liquid is too small, it is difficult to make the binder uniform.
- the binder solid content in the binder-containing inorganic fiber molded body is 5 parts by mass or less with respect to 100 parts by mass of the inorganic fibers in the inorganic fiber molded body
- the amount of liquid applied is the inorganic content in the inorganic fiber molded body. It is preferably in the range of 7.5% to 80%, more preferably in the range of 10% to 60%, and still more preferably in the range of 12% to 40% with respect to the mass per fiber.
- the coating amount of the liquid is within the above range with respect to the mass per inorganic fiber in the inorganic fiber molded body, the dust generation amount of the binder-containing inorganic fiber molded body to be produced is reduced, and the shear coefficient is increased. This is preferable because the friction coefficient is lowered and the drying condition does not become an excessive load.
- Liquid removal process it is preferable to perform the liquid removal process which removes a liquid from the inorganic fiber molded object to which the binder liquid and the liquid were apply
- Examples of the liquid removal method include suction, pressurization, and compression.
- suction liquid removal is preferable, and the binder liquid and the liquid are respectively applied to the same side of the inorganic fiber molded body, and the liquid can be sucked from the surface opposite to the surface of the inorganic fiber molded body on which the binder liquid and liquid are applied.
- the binder liquid can be moved as the liquid moves from the surface to which the binder liquid and liquid of the inorganic fiber molded body are applied to the opposite side, and the binder can be made uniform.
- the method of sucking and draining is not particularly limited as long as it is a method capable of sucking a liquid, and examples thereof include a method of reducing the pressure on the surface opposite to the liquid application surface of the inorganic fiber molded body. Further, in the case of pressure drainage, the liquid application surface of the inorganic fiber molded body may be pressurized. This is because the binder liquid can be moved as the liquid moves from the liquid application surface of the inorganic fiber molded body to the opposite surface.
- the liquid removal conditions such as the pressure during liquid removal and the liquid removal time are appropriately adjusted so that the binder in the binder liquid is not removed.
- drying process In this invention, the drying process which dries the inorganic fiber molded object to which the binder liquid and the liquid were apply
- drying method examples include heat drying, ventilation drying, reduced pressure drying, centrifugal drying, suction drying, pressure drying, and natural drying. Among these, aeration drying is preferable. This is because the drying time can be shortened.
- hot air is usually passed in the thickness direction of the inorganic fiber molded body. Especially, it is preferable to let a hot air pass from the application surface of the binder liquid of an inorganic fiber molded object.
- hot air is passed in the thickness direction from the coating surface of the binder liquid of the inorganic fiber molded body, when the solvent, dispersion medium, and liquid of the binder liquid are vaporized, they move in the thickness direction together with the hot air. it can. Therefore, the binder can be kept contained in the inorganic fiber molded body.
- the inorganic fiber molded body is preferably air-dried by being sandwiched between a pair of air-permeable members having air holes. This is because the inorganic fiber molded body can be dried uniformly.
- the material of the ventilation member include metals and resins. Among these, it is preferable to use a metal ventilation member. This is because the thermal conductivity is high, so that it can be dried efficiently. Moreover, it is preferable that a ventilation member has many through-holes. Drying time can be shortened.
- the inorganic fiber molded body in the case of aeration drying, it is preferable to compress the inorganic fiber molded body by sandwiching it between the aeration members. This is because the bulk density of the inorganic fiber molded body can be increased.
- the drying temperature is appropriately selected according to the drying method, the type of binder liquid and liquid, and the like.
- the drying temperature may be higher than the boiling point of the liquid, specifically, preferably in the range of 80 ° C to 160 ° C, and particularly preferably in the range of 120 ° C to 160 ° C. It is. If the drying temperature is too low, sufficient drying cannot be achieved, and crosslinking of the binder may be insufficient. On the other hand, if the drying temperature is too high, the binder may be altered, or the solvent or dispersion medium of the binder liquid may be used. There is a risk of rapid evaporation and migration.
- drying conditions such as aeration amount and drying time during drying are appropriately adjusted so that the liquid can be removed from the inorganic fiber molded body and the binder in the binder liquid is not removed.
- the drying time can be about 10 seconds to 60 seconds.
- Firing conditions can be appropriately selected from general firing conditions in the method for producing a binder-containing inorganic fiber molded body containing an inorganic binder.
- Binder-containing inorganic fiber molded body In the present invention, a binder-containing inorganic fiber molded body having an inorganic fiber molded body and a binder contained in the inorganic fiber molded body can be obtained. It does not specifically limit as content of the binder in a binder containing inorganic fiber molded object, It selects suitably according to the kind of inorganic fiber and a binder, the thickness of a binder containing inorganic fiber molded object, a use, etc.
- the binder solid content in the binder-containing inorganic fiber molded body is preferably in the range of 0.5 to 10.0 parts by mass with respect to 100 parts by mass of the inorganic fibers in the inorganic fiber molded body.
- the binder-containing inorganic fiber molded body can be applied to, for example, a heat insulating material, a refractory material, a cushion material (holding material), a sealing material, and the like.
- the binder-containing inorganic fiber molded body is suitable as a holding material for an exhaust gas purification device.
- the binder-containing inorganic fiber molded body has a high shear strength and a small frictional force against the casing, so that it is excellent in assemblability and suppresses deviation of the binder-containing inorganic fiber molded body and the catalyst carrier or particle filter during press-fitting. And the retention strength of a binder containing inorganic fiber molded object can be improved.
- the exhaust gas purification apparatus includes, for example, a catalyst carrier or particle filter, a metal casing that houses the catalyst carrier or particle filter, and a holding member interposed between the catalyst carrier or particle filter and the casing.
- a catalyst carrier or particle filter for example, a catalyst carrier or particle filter, a metal casing that houses the catalyst carrier or particle filter, and a holding member interposed between the catalyst carrier or particle filter and the casing.
- Specific examples include a catalytic converter and a diesel particulate filter (DPF).
- DPF diesel particulate filter
- the configuration of the exhaust gas purification device is not particularly limited, and the binder-containing inorganic fiber molded body in the present invention can be applied to a general exhaust gas purification device having the above configuration.
- the present invention is not limited to the above embodiment.
- the above-described embodiment is an exemplification, and the present invention has substantially the same configuration as the technical idea described in the claims of the present invention, and any device that exhibits the same function and effect is the present invention. It is included in the technical scope of the invention.
- FIG. 3 is a side view schematically showing a friction coefficient measuring apparatus.
- a 40 mm ⁇ 40 mm test piece was punched out from the produced binder-containing inorganic fiber molded body, and two samples (31) for friction coefficient measurement were produced.
- the friction coefficient measurement sample (31) was adhered to the pair of stainless steel plates (32) with an adhesive tape (33) (manufactured by Nichiban Co., Ltd., Nystack NW-40 (ordinary)).
- the stainless steel plate (32) was installed so that the stainless steel sheet for tension test (34) (EN 1.4509 surface treatment 2B finish) was sandwiched between the friction coefficient measurement samples (31).
- the width of the stainless steel plate was appropriately adjusted with the width adjusting fastener (35) so that the bulk density of the inorganic fibers of the friction coefficient measurement sample (31) was 0.375 g / cm 3 . Thereafter, the stainless steel sheet for tensile test (34) was connected to a measuring device (Technograph, TG) at room temperature (25 ° C.), pulled at a speed of 1000 mm / min, and the peak load F was measured.
- a measuring device Technograph, TG
- Binder solid content Regarding the amount of binder solid content per inorganic fiber in the inorganic fiber molded body, the binder-containing inorganic fiber molded body was fired at 800 ° C. for 1 hour to burn out the binder, and the mass after firing was compared with the mass before firing. The binder content was determined.
- the amount of binder solid adhering is “(mass of binder-containing inorganic fiber molded body before firing ⁇ mass of binder burned inorganic fiber molded body after firing) / mass of binder burned inorganic fiber molded body after firing ⁇ 100”. Calculated.
- the amount of the binder solid content attached corresponds to the amount of the binder solid content in the inorganic fiber molded body of the binder liquid of the inorganic fiber molded body when the binder-containing inorganic fiber molded body is produced.
- Example 1 Alumina fiber molded body roll (trade name: Maftec (registered trademark), manufactured by Mitsubishi Plastics Co., Ltd., basis weight 1200 g / m 2 ), by the production method shown in FIG. Latex (trade name: Nipol (registered trademark), manufactured by Nippon Zeon Co., Ltd., concentration 10%) is sprayed, and the amount of binder solid adhering to 1.0% of the mass per inorganic fiber in the inorganic fiber molded body (target value) It sprayed so that it might become.
- Maftec registered trademark
- Nipol registered trademark
- concentration 10% concentration 10%
- Example 2 In the liquid application step, Example was performed except that water was sprayed from the latex coating surface so that the amount of water applied was 30.0% with respect to the mass per inorganic fiber in the inorganic fiber molded body. In the same manner as in Example 1, a binder-containing inorganic fiber molded body was prepared and evaluated. The results are shown in Table 1.
- Example 3 In the binder liquid coating process, it was carried out except that the latex was sprayed by spraying so that the amount of binder solid content was 2.0% (target value) with respect to the mass per inorganic fiber in the inorganic fiber molded body. In the same manner as in Example 2, a binder-containing inorganic fiber molded body was prepared and evaluated. The results are shown in Table 1.
- Example 4 In the liquid application step, Example was performed except that water was sprayed from the coated surface of the latex so that the amount of water applied was 60.0% with respect to the mass per inorganic fiber in the inorganic fiber molded body. In the same manner as in No. 3, a binder-containing inorganic fiber molded body was prepared and evaluated. The results are shown in Table 1.
- Example 5 In the binder liquid coating step, the latex is sprayed by spraying so that the amount of the binder solid content is 4.0% (target value) with respect to the mass per inorganic fiber in the inorganic fiber molded body, and the liquid coating step In Example 1, except that water was sprayed from the latex coated surface so that the amount of water applied was 22.7% with respect to the mass per inorganic fiber in the inorganic fiber molded body.
- a binder-containing inorganic fiber molded body was prepared and evaluated. The results are shown in Table 1.
- Example 6 In the binder liquid coating process, it was carried out except that the latex was sprayed so that the amount of binder solid content was 2.5% (target value) with respect to the mass per inorganic fiber in the inorganic fiber molded body. A binder-containing inorganic fiber molded body was prepared and evaluated in the same manner as in Example 5. The results are shown in Table 1.
- Example 1 A binder-containing inorganic fiber molded body was prepared and evaluated in the same manner as in Example 1 except that the liquid coating process was not performed and the drying process was performed by static drying (160 ° C., 30 seconds). The results are shown in Table 1.
- Example 2 A binder-containing inorganic fiber molded body was prepared and evaluated in the same manner as in Example 3 except that the liquid coating process was not performed and the drying process was performed by static drying (160 ° C., 30 seconds). The results are shown in Table 1.
- Example 3 A binder-containing inorganic fiber molded body was prepared and evaluated in the same manner as in Example 5 except that the liquid coating process was not performed and the drying process was performed by static drying (160 ° C., 30 seconds). The results are shown in Table 1.
- Example 4 A binder-containing inorganic fiber molded body was prepared and evaluated in the same manner as in Example 1 except that the liquid coating step was not performed. The results are shown in Table 1.
- Example 5 A binder-containing inorganic fiber molded body was prepared and evaluated in the same manner as in Example 3 except that the liquid coating step was not performed. The results are shown in Table 1.
- Example 6 A binder-containing inorganic fiber molded body was prepared and evaluated in the same manner as in Example 5 except that the liquid coating step was not performed. The results are shown in Table 1.
- Comparative Example 7 In the binder liquid coating step, an acrylate-based latex having a concentration of 5.2% is used, and the latex is sprayed so that the binder solid content is 2.5% (target value) with respect to the mass per inorganic fiber in the inorganic fiber molded body. ) And a binder-containing inorganic fiber molded body was prepared and evaluated in the same manner as in Example 6 except that the liquid application step was not performed. That is, Comparative Example 7 is an embodiment in which the amount of water relative to the mass per inorganic fiber in the inorganic fiber molded body is the same as Example 6, but the liquid application step is not performed. The results are shown in Table 1.
- the present example has less dust generation, is less likely to cause delamination (high shear coefficient), and has little friction with the metal casing during press-fitting (low friction coefficient).
- Example 6 and Comparative Example 7 it is not necessary to include a large amount of water when the binder liquid is applied, and it is understood that the effect can be obtained for the first time by additionally applying a liquid in the liquid application process. It was.
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Abstract
Description
例えば、特許文献1には、無機質繊維マットに有機バインダー液を含浸させた後、無機質繊維マットを厚み方向に圧縮し、無機質繊維マットの厚みを拘束した状態で有機バインダー液の媒体液を除去するという、無機繊維成形体の製造方法が開示されている。また、特許文献2には、無機質繊維マットに樹脂溶液を含浸させた後、無機質繊維マットに厚み方向に熱風を通過させて乾燥するという、樹脂含浸無機質繊維マットの製造方法が開示されている。特許文献3には、繊維材料のマットにラテックス(有機バインダー液)を含浸させる保持材の製造方法であって、マットの内周側の有機バインダー含有量が、マットの外周側の有機バインダー含有量よりも大きく、かつ15~50g/m2の範囲にあるという、保持材の製造方法が開示されている。
また、バインダーを含有する無機繊維成形体の製造においては、無機質繊維マットにバインダー液を含浸させた後、乾燥させる際に、バインダー液の溶媒や分散媒が表面に移行すると同時にバインダーも表面に移行し、乾燥後は無機質繊維マットの表面にバインダーが局在する、いわゆるマイグレーションが起こることが知られている。
ケーシング内において無機繊維成形体および触媒担体または粒子フィルタが所定の位置に収容されていないと、良好な性能を発揮することができない。
本発明のバインダー含有無機繊維成形体の製造方法は、無機繊維成形体にバインダー液を塗布するバインダー液塗布工程と、上記バインダー液が塗布された上記無機繊維成形体に、沸点が120℃未満である液体を塗布する液体塗布工程とを有することを特徴とする方法である。
図1(a)~(e)は本発明のバインダー含有無機繊維成形体の製造方法の一例を示す工程図である。まず、図1(a)に示すようにシート状の無機繊維成形体1を準備し、図1(b)に示すように無機繊維成形体1の片面にバインダー液2を塗布する。次に、図1(c)に示すように無機繊維成形体1のバインダー液2の塗布面に所定の液体3を噴霧し、無機繊維成形体1に液体3を含浸させる。この際、無機繊維成形体1のバインダー液2の塗布面4aとその反対側の面4bとでバインダーの濃度勾配が生じるため、バインダーがバインダー液2の塗布面4aからその反対側の面4bに移動する。その後、図1(d)に示すようにバインダー液2および液体3が塗布された無機繊維成形体1を乾燥する。これにより、図1(e)に示すように無機繊維成形体1にバインダー5が含有されたバインダー含有無機繊維成形体6が得られる。
本発明において、無機繊維成形体は無機繊維の不織布状の集合体であり、例えばマット、ブランケットまたはブロック等と称されるものである。
本発明においては、無機繊維成形体にバインダー液を塗布するバインダー液塗布工程を行う。
無機酸化物の粒径は、例えば1μm以下とすることができる。
また、無機バインダーの場合、バインダー液としては、上記無機バインダーを含むゾル、コロイド、スラリー、溶液を用いることができる。無機バインダー液には、有機バインダーが含有されていてもよい。また、無機バインダー液には、無機バインダーの安定性を高めるために分散安定剤が添加されていてもよい。分散安定剤としては、例えば酢酸、乳酸、塩酸、硝酸等が挙げられる。
接触塗布方式は、例えばバインダー液が供給された塗布ロール等の塗布部材が無機繊維成形体の表面に接触することでバインダー液を塗布する方法である。接触塗布方式では、バインダー液の粘度が低いと塗布ムラが生じる場合があるため、ある程度の粘度を有するバインダー液が用いられる。そのため、バインダー液が無機繊維成形体に浸透しにくい場合がある。
また、非接触塗布方式は、例えばノズル等の塗布部材を無機繊維成形体に接触させない方法である。スプレー法等の非接触塗布方式では、バインダー液を無機繊維成形体の内部にまで浸透させることは、接触塗布方式と比較してもより困難である。
これに対し本発明においては、後述の液体塗布工程にて無機繊維成形体に液体を塗布して含浸させることで、バインダーを無機繊維成形体のバインダー液の塗布面から反対側の面または内部へ移動させることができる。したがって、接触塗布方式および非接触塗布方式を適用する場合に本発明は有用である。
また、非接触塗布方式としては、例えばスプレー法、ダイコート法、カーテンコート法等が挙げられる。中でも、スプレー法が好ましい。ロールツーロール方式で無機繊維成形体にバインダー液を塗布する際に、無機繊維成形体の搬送速度や張力を制御しなくとも、バインダー液の塗布量を制御することができるからである。
本発明においては、上記バインダー液が塗布された上記無機繊維成形体に、沸点が120℃未満である液体を塗布する液体塗布工程を行う。
また、液体の室温(25℃)での蒸気圧は低いことが好ましく、具体的には5kPa以下であることが好ましい。蒸気圧が高すぎると、液体の蒸発速度が速くなり、液体を無機繊維成形体に十分に浸透させることが困難になり、その結果、バインダーを無機繊維成形体の内部に含有させるのが困難になるおそれがある。
ここで、粘度は、20℃における粘度を指し、JIS Z8803(液体の粘度測定方法)に準拠して、回転粘度計を用いて測定された値である。
ここで、液体が不純物を含まないとは、液体に含まれる不純物濃度が0.1質量%以下であることをいう。
特に、バインダー含有無機繊維成形体中のバインダー固形分量が無機繊維成形体中の無機繊維100質量部に対して5質量部以下の場合には、液体の塗布量は、無機繊維成形体中の無機繊維当たりの質量に対して、7.5%~80%の範囲内であることが好ましく、より好ましくは10%~60%の範囲内、さらに好ましくは12%~40%の範囲内である。液体の塗布量が無機繊維成形体中の無機繊維当たりの質量に対して上記範囲内にあることにより、製造されるバインダー含有無機繊維成形体の発塵量が低減し、剪断係数が増加し、摩擦係数が低下し、かつ乾燥条件が過大な負荷とならないため、好ましい。
本発明においては、上記液体塗布工程後、後述の乾燥工程前に、バインダー液および液体が塗布された無機繊維成形体から液体を除去する脱液工程を行うことが好ましい。後述の乾燥工程にてバインダー液の溶媒や分散媒および液体を除去しやすくなり、乾燥時間を短縮することができるからである。
中でも、吸引脱液が好ましく、バインダー液および液体をそれぞれ無機繊維成形体の同じ片面に塗布し、無機繊維成形体のバインダー液および液体の塗布面とは反対側の面から液体を吸引することが好ましい。液体が無機繊維成形体のバインダー液および液体の塗布面から反対側の面に移動するのに伴って、バインダー液も移動させることができ、バインダーの均一化を図ることができるからである。
吸引脱液の方法としては、液体を吸引できる方法であれば特に限定されるものではなく、例えば無機繊維成形体の液体の塗布面とは反対側の面を減圧する方法が挙げられる。
また、加圧脱液の場合には、無機繊維成形体の液体の塗布面を加圧してもよい。液体が無機繊維成形体の液体の塗布面から反対側の面に移動するのに伴って、バインダー液も移動させることができるからである。
本発明においては、通常、上記液体塗布工程後に、バインダー液および液体が塗布された無機繊維成形体を乾燥する乾燥工程が行われる。
通気部材の材質は、例えば金属、樹脂等が挙げられる。中でも、金属の通気部材を用いることが好ましい。熱伝導性が高いため、効率的に乾燥させることができるからである。
また、通気部材は、多数の貫通孔を有することが好ましい。乾燥時間を短縮することができる。
本発明においては、無機繊維成形体と、上記無機繊維成形体に含有されるバインダーとを有するバインダー含有無機繊維成形体を得ることができる。
バインダー含有無機繊維成形体中のバインダーの含有量としては、特に限定されるものではなく、無機繊維やバインダーの種類、バインダー含有無機繊維成形体の厚み、用途等に応じて適宜選択される。例えばバインダー含有無機繊維成形体中のバインダー固形分量は、無機繊維成形体中の無機繊維100質量部に対して、0.5質量部~10.0質量部の範囲内であることが好ましい。上記バインダー固形分量が少なすぎるとバインダー含有無機繊維成形体の所望の厚みが得られないおそれがあり、多すぎるとコスト高になる。また、有機バインダーの場合、上記の有機バインダー固形分量が多いと、有機バインダーが分解されにくくなったり、有機バインダーの分解によって生じるガスにより作業環境が悪化したりするおそれがある。また、無機バインダーの場合、上記の無機バインダー固形分量が多いとクッション性が損なわれるおそれがある。
排ガス浄化装置の構成は特に限定されるものではなく、本発明におけるバインダー含有無機繊維成形体は、上記の構成を備える一般的な排ガス浄化装置に適用することが可能である。
(発塵量)
まず、作製したバインダー含有無機繊維成形体から75mm×75mmの試験片を型抜きし、発塵量測定用サンプルを作製した。次に、アクリル板(厚さ5mm)と接合されたステンレス鋼板(厚さ3mm、測定用サンプルが接する面に導電性シート(1mm)を接着)を用いて、発塵量測定用サンプルを、一定の強さで、1.5秒間隔で各面100回ずつ(合計200回)叩いた。叩く前後の該測定用サンプルの質量差を発塵量(mg/75mm□)とした。
図3は、摩擦係数の測定装置を模式的に示す側面図である。
まず、作製したバインダー含有無機繊維成形体から40mm×40mmの試験片を型抜きし、摩擦係数測定用サンプル(31)2つを作製した。次に、一対のステンレス鋼板(32)にそれぞれ、摩擦係数測定用サンプル(31)を粘着テープ(33)(ニチバン社製、ナイスタックNW-40(普通))により接着させた。その後、引張試験用ステンレスシート(34)(EN 1.4509 表面処理2B仕上げ)を摩擦係数測定用サンプル(31)同士で挟みこむように、ステンレス鋼板(32)を設置した。摩擦係数測定用サンプル(31)の無機繊維の嵩密度が0.375g/cm3となるように適宜ステンレス鋼板の幅を幅調整留め具(35)により調節した。
その後、室温(25℃)にて引張試験用ステンレスシート(34)を測定装置(Technograph社、TG)に接続し、1000mm/minの速度で引っ張り、そのピーク荷重Fを測定した。得られたピーク荷重F(N)と、引張試験用ステンレスシート(34)および摩擦係数測定用サンプル(31)の接触面で働く垂直方向の力N(N)(本測定において、無機繊維の嵩密度を0.375g/cm3に固定した5分後の面圧H(N)とする。)とから、検出されるピーク荷重は摩擦係数測定用サンプル2つ分の摩擦力が検出されることになるため、下記式により摩擦係数μを算出した。
μ=F/2N
図3に示す摩擦係数の測定装置において、さらに摩擦係数測定用サンプル(31)と引張試験用ステンレスシート(34)とを粘着テープ(33)により接着した以外は、摩擦係数の測定方法と同様に測定した。その際に、得られたピーク荷重S(N)と、無機繊維の嵩密度を0.375g/cm3に固定した5分後の面圧H(N)とを元に、下記式により剪断係数αを算出した。
α=S/2H
無機繊維成形体中における無機繊維当たりのバインダー固形分添着量について、バインダー含有無機繊維成形体を800℃で1時間焼成してバインダーを焼失させ、焼成後の質量と焼成前の質量とを比較してバインダー含有量を求めた。該バインダー固形分添着量は、「(焼成前のバインダー含有無機繊維成形体の質量-焼成後のバインダー焼失無機繊維成形体の質量)/焼成後のバインダー焼失無機繊維成形体の質量×100」により算出した。
上記バインダー固形分添着量は、バインダー含有無機繊維成形体を製造する際の、無機繊維成形体のバインダー液の当該無機繊維成形体におけるバインダー固形分量に相当する。
アルミナ繊維成形体原反ロール(商品名:マフテック(登録商標)、三菱樹脂株式会社製、坪量1200g/m2)を用いて、図2に示す製造方法により、バインダー液塗布工程において、アクリレート系ラテックス(商品名:Nipol(登録商標)、日本ゼオン製、濃度10%)をスプレーにより、バインダー固形分添着量が無機繊維成形体中の無機繊維当たりの質量に対して1.0%(目標値)となるように噴霧した。
次に、液体塗布工程において、ラテックスの塗工面からイオン交換水をスプレーにより、イオン交換水の塗布量が無機繊維成形体中の無機繊維当たりの質量に対して15.0%となるように噴霧した。
その後、脱液工程(吸引速度 4.5m/秒)、および通気乾燥による乾燥工程(160℃、30秒間、速度0.95m/秒)を行い、バインダー含有無機繊維成形体を作製した。作製後に回収し、所定の大きさに切断し、上記評価を行った。結果を表1に示す。
液体塗布工程において、ラテックスの塗工面から水をスプレーにより、水の塗布量が無機繊維成形体中の無機繊維当たりの質量に対して30.0%となるように噴霧したこと以外は、実施例1と同様にバインダー含有無機繊維成形体を作製し、評価した。結果を表1に示す。
バインダー液塗布工程において、ラテックスをスプレーにより、バインダー固形分添着量が無機繊維成形体中の無機繊維当たりの質量に対して2.0%(目標値)となるように噴霧したこと以外は、実施例2と同様にバインダー含有無機繊維成形体を作製し、評価した。結果を表1に示す。
液体塗布工程において、ラテックスの塗工面から水をスプレーにより、水の塗布量が無機繊維成形体中の無機繊維当たりの質量に対して60.0%となるように噴霧したこと以外は、実施例3と同様にバインダー含有無機繊維成形体を作製し、評価した。結果を表1に示す。
バインダー液塗布工程において、ラテックスをスプレーにより、バインダー固形分添着量が無機繊維成形体中の無機繊維当たりの質量に対して4.0%(目標値)となるように噴霧し、および液体塗布工程において、ラテックスの塗工面から水をスプレーにより、水の塗布量が無機繊維成形体中の無機繊維当たりの質量に対して22.7%となるように噴霧したこと以外は、実施例1と同様にバインダー含有無機繊維成形体を作製し、評価した。結果を表1に示す。
バインダー液塗布工程において、ラテックスをスプレーにより、バインダー固形分添着量が無機繊維成形体中の無機繊維当たりの質量に対して2.5%(目標値)となるように噴霧したこと以外は、実施例5と同様にバインダー含有無機繊維成形体を作製し、評価した。結果を表1に示す。
液体塗布工程を行わず、また乾燥工程を静置乾燥(160℃、30秒間)にて行ったこと以外は、実施例1と同様にバインダー含有無機繊維成形体を作製し、評価した。結果を表1に示す。
液体塗布工程を行わず、また乾燥工程を静置乾燥(160℃、30秒間)にて行ったこと以外は、実施例3と同様にバインダー含有無機繊維成形体を作製し、評価した。結果を表1に示す。
液体塗布工程を行わず、また乾燥工程を静置乾燥(160℃、30秒間)にて行ったこと以外は、実施例5と同様にバインダー含有無機繊維成形体を作製し、評価した。結果を表1に示す。
液体塗布工程を行わなかったこと以外は、実施例1と同様にバインダー含有無機繊維成形体を作製し、評価した。結果を表1に示す。
液体塗布工程を行わなかったこと以外は、実施例3と同様にバインダー含有無機繊維成形体を作製し、評価した。結果を表1に示す。
液体塗布工程を行わなかったこと以外は、実施例5と同様にバインダー含有無機繊維成形体を作製し、評価した。結果を表1に示す。
バインダー液塗布工程において、濃度5.2%のアクリレート系ラテックスを用い、ラテックスをスプレーにより、バインダー固形分添着量が無機繊維成形体中の無機繊維当たりの質量に対して2.5%(目標値)となるように噴霧し、液体塗布工程を行わなかったこと以外は、実施例6と同様にバインダー含有無機繊維成形体を作製し、評価した。つまり、比較例7は実施例6とは無機繊維成形体中の無機繊維当たりの質量に対する水の量は同じであるが、液体塗布工程を行わない態様である。結果を表1に示す。
以上の結果から、本実施例は、比較例と比べると、発塵が少なく、層間剥離が生じにくく(剪断係数が高い)、かつ圧入時に金属製のケーシングとの摩擦が少ない(摩擦係数が低い)バインダー含有無機繊維成形体であることが判り、触媒担体用途の把持材に適していることが判った。
特に、実施例6と比較例7を比較すると、バインダー液塗布時に水を多く含ませればよいというわけではなく、液体塗布工程により液体を追加で塗布することにより、初めて効果が得られることが判った。
2 … バインダー液
3 … 液体
4a … バインダー液の塗布面
4b … バインダー液の塗布面とは反対側の面
5 … バインダー
6 … バインダー含有無機繊維成形体
Claims (7)
- 無機繊維成形体にバインダー液を塗布するバインダー液塗布工程と、
前記バインダー液が塗布された前記無機繊維成形体に、沸点が120℃未満である液体を塗布する液体塗布工程と
を有することを特徴とするバインダー含有無機繊維成形体の製造方法。 - 前記液体塗布工程では、前記無機繊維成形体の前記バインダー液の塗布面に前記液体を塗布することを特徴とする請求項1に記載のバインダー含有無機繊維成形体の製造方法。
- 前記液体塗布工程後、前記無機繊維成形体を乾燥する乾燥工程を有し、前記乾燥工程では、前記無機繊維成形体を通気乾燥することを特徴とする請求項1または請求項2に記載のバインダー含有無機繊維成形体の製造方法。
- 前記バインダー液塗布工程では、前記無機繊維成形体の片面に前記バインダー液を塗布し、前記液体塗布工程では、前記無機繊維成形体の前記バインダー液の塗布面に前記液体を塗布し、
前記液体塗布工程後、前記無機繊維成形体から前記液体を除去する脱液工程を有し、前記脱液工程では、前記無機繊維成形体の前記バインダー液および前記液体の塗布面とは反対側の面から前記液体を吸引することを特徴とする請求項1から請求項3までのいずれかに記載のバインダー含有無機繊維成形体の製造方法。 - 前記バインダー液の塗布方法が、前記無機繊維成形体に前記バインダー液を非接触塗布する非接触塗布方式であることを特徴とする請求項1から請求項4までのいずれかに記載のバインダー含有無機繊維成形体の製造方法。
- 前記液体の塗布量が、前記無機繊維成形体の前記バインダー液の塗布面における前記バインダー固形分量に対して、3.0~50の範囲内であることを特徴とする請求項1から請求項5までのいずれかに記載のバインダー含有無機繊維成形体の製造方法。
- 前記液体の塗布量が、前記無機繊維成形体中の無機繊維当たりの質量に対して、7.5%~80%の範囲内であることを特徴とする請求項1から請求項6までのいずれかに記載のバインダー含有無機繊維成形体の製造方法。
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