WO2016136258A1 - 保持材、その製造方法及びそれを用いた気体処理装置 - Google Patents
保持材、その製造方法及びそれを用いた気体処理装置 Download PDFInfo
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- WO2016136258A1 WO2016136258A1 PCT/JP2016/001009 JP2016001009W WO2016136258A1 WO 2016136258 A1 WO2016136258 A1 WO 2016136258A1 JP 2016001009 W JP2016001009 W JP 2016001009W WO 2016136258 A1 WO2016136258 A1 WO 2016136258A1
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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
- D04H1/587—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 characterised by the bonding agents used
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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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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/36—Inorganic fibres or flakes
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/20—Macromolecular organic compounds
- D21H17/33—Synthetic macromolecular compounds
- D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H17/37—Polymers of unsaturated acids or derivatives thereof, e.g. polyacrylates
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/0211—Arrangements for mounting filtering elements in housing, e.g. with means for compensating thermal expansion or vibration
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- 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
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
- F01N3/2825—Ceramics
- F01N3/2828—Ceramic multi-channel monoliths, e.g. honeycombs
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
- F01N3/2835—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support fibrous
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
- F01N3/2842—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration specially adapted for monolithic supports, e.g. of honeycomb type
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
- F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
- F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
- F01N3/2871—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing the mats or gaskets having an additional, e.g. non-insulating or non-cushioning layer, a metal foil or an adhesive layer
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/06—Ceramic, e.g. monoliths
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- 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
- F01N2350/00—Arrangements for fitting catalyst support or particle filter element in the housing
- F01N2350/02—Fitting ceramic monoliths in a metallic housing
- F01N2350/04—Fitting ceramic monoliths in a metallic housing with means compensating thermal expansion
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- 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
- F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
- F01N2450/02—Fitting monolithic blocks into the housing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Definitions
- the present invention relates to a holding member for a processing structure used in an exhaust gas purifying gas processing apparatus such as an automobile.
- Such a gas processing apparatus generally includes a processing structure such as a catalyst carrier formed in a cylindrical shape, a metal casing that accommodates the processing structure, and a processing structure and a casing that are attached to the processing structure. And a holding material interposed in the gap.
- the holding material interposed in the gap between the processing structure and the casing has a function of safely holding the processing structure so that the processing structure does not collide with the casing due to vibration or the like during driving of the automobile and is damaged. It is required to have a function of sealing so that unpurified exhaust gas does not leak from the gap between the processing structure and the casing.
- Patent Document 1 discloses a holding material having a high surface pressure in which silica fibers and alumina sol are combined.
- An object of the present invention is to provide a holding material that has a high surface pressure and can be manufactured with high productivity, and a gas processing apparatus using the holding material.
- the following holding material, gas processing apparatus, and the like are provided.
- the holding material according to 1 or 2 wherein among the intersections of the inorganic fibers, the intersection where the alumina sol adheres in a lump having a minor axis of 500 nm or more is 15% or more. 4).
- the present invention it is possible to provide a holding material that has a high surface pressure and can be manufactured with high productivity, and a gas processing apparatus using the holding material.
- FIG. 1 It is sectional drawing which shows the gas processing apparatus equipped with the holding material of one Embodiment which concerns on this invention. It is a figure which shows the result of having measured the surface pressure about the holding material obtained in Example 3.
- FIG. 1 shows the gas processing apparatus equipped with the holding material of one Embodiment which concerns on this invention. It is a figure which shows the result of having measured the surface pressure about the holding material obtained in Example 3.
- FIG. 1 is a cross-sectional view schematically showing an embodiment of a gas processing apparatus equipped with the holding material of the present invention.
- the illustrated gas processing apparatus 10 includes a processing structure 1 formed in a cylindrical shape, a casing 2 that houses the processing structure 1, and a gap between the processing structure 1 and the casing 2 that is attached to the processing structure 1. It is comprised from the holding
- the holding material 3 is usually in the form of a sheet and is wound around the processing structure 1, but it can also be a cylinder.
- the gas treatment device 10 is used to remove harmful substances and / or particles contained in the gas.
- the gas processing apparatus 10 is an exhaust gas processing apparatus that removes harmful substances and / or particles contained in exhaust gas discharged from an internal combustion engine (gasoline engine, diesel engine, etc.) in a vehicle such as an automobile.
- the gas processing apparatus 10 is used to remove, for example, a catalytic converter used to remove harmful substances contained in exhaust gas of a gasoline engine or particles contained in exhaust gas of a deal engine.
- DPF Diesel Particulate Filter
- the processing structure 1 is a structure having a function of processing a gas.
- the processing structure 1 is a catalyst carrier having a catalyst for purifying gas and a carrier for supporting the catalyst.
- the processing structure 1 is a structure having a filter that captures the particles in the gas.
- the processing structure 1 may include a catalyst.
- the casing 2 is made of metal such as stainless steel, iron, and aluminum.
- the casing 2 may be divided into a plurality of parts.
- the holding material 3 is used for holding the processing structure 1 in the casing 2. That is, the holding member 3 is stably held in the casing 2 by being disposed in a compressed state in the gap between the processing structure 1 and the casing 2.
- the holding material of the present invention comprises an inorganic fiber containing 70% by weight or more of an alumina component, an organic binder other than polyacrylamide whose surface is negatively charged, an alumina sol, and a polysiloxane having a weight average molecular weight of 3 to 6 million. Contains acrylamide.
- the inorganic fiber used in the present invention usually contains 70 to 100% by weight of the alumina component and 0 to 30% by weight of the silica component.
- the alumina component is 72 to 98% by weight and the silica component is 2 to 28% by weight.
- inorganic fibers containing 90 to 98% by weight of the alumina component and 2 to 10% by weight of the silica component can be used. Further, it preferably contains 98% by weight or 100% by weight (including inevitable impurities) of an alumina component and a silica component.
- the amount of alumina sol is 2 to 8 parts by weight when the inorganic fiber is 100 parts by weight.
- the amount is preferably 2.5 to 7 parts by weight, more preferably 3 to 6 parts by weight. If it is less than 2 parts by weight, the surface pressure value after durability will not be improved. If it exceeds 8 parts by weight, the mat may break during winding. Further, increasing the amount of alumina sol improves wind erosion resistance.
- Known organic binders other than polyacrylamide whose surface is negatively charged can be used, and rubbers, water-soluble organic polymer compounds, thermoplastic resins, thermosetting resins, and the like can be used.
- Acrylic resin is preferable.
- acrylic resins include homopolymers and copolymers such as acrylic acid, acrylic ester, acrylonitrile, methacrylic acid, methacrylic ester, acrylonitrile / styrene copolymer, acrylonitrile / butadiene / styrene copolymer, etc. It is done.
- the amount of the organic binder is usually 0.01 to 20 parts by weight when the inorganic fiber is 100 parts by weight.
- the amount is preferably 0.1 to 15 parts by weight, more preferably 2 to 12 parts by weight, and particularly preferably 5 to 11 parts by weight.
- the weight average molecular weight of the polyacrylamide used in the present invention is 3 million to 6 million, for example, 4 million to 5 million. If it is less than 3 million, there is a possibility that the binder cannot be applied. If it exceeds 6 million, there is a risk that productivity will deteriorate.
- the amount of polyacrylamide is 0.01 to 1.0 part by weight when the inorganic fiber is 100 parts by weight. The amount is preferably 0.05 to 0.8 part by weight, more preferably 0.1 to 0.5 part by weight. If it is less than 0.01 part by weight, the coagulation effect may be lowered and the binder cannot be applied. If it exceeds 1.0 part by weight, the balance of charges is lost, so that the agglomeration effect is lowered and the binder cannot be applied.
- the holding material of the present invention can contain organic fibers such as pulp, an expanding material such as vermiculite, etc. in addition to inorganic fibers, alumina sol, polyacrylamide, and organic binder.
- the holding material of the present invention does not need to contain starch.
- the holding material of the present invention can contain 90% by weight, 95% by weight, 98% by weight or 100% by weight (including inevitable impurities) of inorganic fiber, alumina sol, polyacrylamide, and organic binder.
- the holding material of the present invention may be burned off, for example, by firing.
- the thickness of the holding material is not limited, but is usually 6 mm to 20 mm.
- the density is not limited, but is usually 0.10 g / cm 3 to 0.25 g / cm 3 .
- the holding material of the present invention preferably has a surface pressure residual ratio of 24% or more from the initial opening surface pressure as a result of repeated tests 2500 times at a packing density of 0.5 g / cm 3 and a Gap opening rate of 12%. . More preferably, it is 26% or more.
- the inorganic fibers are intertwined, and the alumina sol is attached around the fiber and at the intersection.
- the intersection where the alumina sol adheres in a lump having a minor axis of 500 nm or more is 15% or more.
- the intersection ratio is large, the surface pressure residual ratio tends to increase. More preferably, it is 20% or more.
- An aqueous slurry is prepared by mixing water with the above-described inorganic fiber, organic binder, alumina sol and polyacrylamide. This aqueous slurry is dehydrated to produce a wet molded body. Thereafter, the wet molded body is dried to obtain a holding material.
- the amount of alumina sol is 2 to 8 parts by weight and the amount of polyacrylamide is 0.01 to 1.0 parts by weight when the inorganic fiber is 100 parts by weight.
- Examples 1 and 2 (1) Manufacture of support Alumina fiber (96.0% by weight of Al 2 O 3 component and 4.0% by weight of SiO 2 component), acrylic resin (copolymer of acrylate ester and methacrylate ester) (organic Binder), alumina sol, and polyacrylamide A (weight average molecular weight (molecular weight) 4.5 million) were dispersed in water to prepare an aqueous slurry.
- Table 1 shows the amount of each component. The compounding amount shown in the table is a part by weight when the alumina fiber is 100 parts by weight.
- the aqueous slurry was poured into a dehydrating mold having a wire net and dehydrated to obtain an alumina fiber wet molded body.
- the wet molded body was dried at 100 ° C. while compressing to obtain a holding body.
- the density was 0.165 g / cm 3 .
- the weight average molecular weight was measured by GPC method using HLC-8120 as a column at a flow rate of 1 ml / Min.
- (I) Aggregation state The aggregation state was observed visually. It is preferable that the aggregation state is a flocculent aggregation because the physical properties are stable.
- the surface pressure residual ratio was measured by the following method. The surface pressure was measured using a universal testing machine autograph manufactured by Shimadzu Corporation. A compression jig disk (diameter: 100 mm, thickness: 25 mm) was attached up and down, and the position where the gap between the upper and lower platens was 10 mm was defined as the zero point. Next, the mat produced as described above was placed on the lower platen, and from the zero point position, the mat was compressed at a compression speed of 10 mm / min to a packing density of 0.5 g / cm 3 , and then 12% (packing density 0 The operation of opening up to an opening rate of .446 g / cm 3 ) was repeated 2500 cycles. At this time, the surface pressure ratio at the time of opening at the 2500th cycle was determined from the surface pressure at the time of initial opening.
- Comparative Examples 1-5 A holding body was produced and evaluated in the same manner as in Example 1 with the components and amounts shown in Table 1. The results are shown in Table 1. In Comparative Example 4, polyacrylamide B having a weight average molecular weight of 9 million was used as the flocculant.
- Example 3 The amount of alumina sol was changed from 0.5 parts by weight to 6.5 parts by weight with respect to 100 parts by weight of alumina fibers, 10 parts by weight of acrylic resin, and 0.3 parts by weight of polyacrylamide A used in Example 1.
- a holding material was produced in the same manner as in Example 1.
- the surface pressure at release after 2500 times was measured. The results are shown in FIG.
- the holding material of the present invention can be used for an exhaust gas purifying gas processing apparatus for automobiles and the like.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Mechanical Engineering (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Textile Engineering (AREA)
- Ceramic Engineering (AREA)
- Inorganic Chemistry (AREA)
- Dispersion Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Exhaust Gas After Treatment (AREA)
- Catalysts (AREA)
- Solid-Sorbent Or Filter-Aiding Compositions (AREA)
- Nonwoven Fabrics (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (AREA)
Abstract
Description
1.アルミナ成分を70重量%以上含む無機繊維と、
表面が負に荷電している、ポリアクリルアミド以外の有機バインダーと、
アルミナゾルと、
重量平均分子量が300万~600万のポリアクリルアミドを含み、
前記アルミナゾルの量が、前記無機繊維を100重量部としたとき、2~8重量部であって、
前記ポリアクリルアミドの量が、前記無機繊維を100重量部としたとき、0.01~1.0重量部である、保持材。
2.充填密度0.5g/cm3、Gap開放率12%で2500回繰り返し試験の結果、初期開放時面圧からの面圧残存率が、24%以上である、1記載の保持材。
3.前記無機繊維の交点のうち、短径500nm以上の塊でアルミナゾルが付着する交点が、15%以上である、1又は2記載の保持材。
4.アルミナ成分を70重量%以上含む無機繊維と、
表面が負に荷電している、ポリアクリルアミド以外の有機バインダーと、
アルミナゾルと、
重量平均分子量が300万~600万のポリアクリルアミドを含み、
前記アルミナゾルの量が、前記無機繊維を100重量部としたとき、2~8重量部であって、
前記ポリアクリルアミドの量が、前記無機繊維を100重量部としたとき、0.01~1.0重量部となるように、混合して水性スラリーを調製し、
前記水性スラリーを脱水成形して、湿潤成形体を作製し、
前記湿潤成形体を乾燥させる、
保持材の製造方法。
5.筒状に形成された処理構造体と、
前記処理構造体を収容するケーシングと、
前記処理構造体と前記ケーシングとの間隙に介装される1~3のいずれか記載の保持材とを具備する
気体処理装置。
6.前記処理構造体が、触媒担持体又は排ガスフィルタである5記載の気体処理装置。
図1は、本発明の保持材を装着した気体処理装置の一実施形態を模式的に示す断面図である。図示される気体処理装置10は、筒状に形成された処理構造体1と、処理構造体1を収容するケーシング2と、処理構造体1に装着されて処理構造体1とケーシング2との間隙に介装された保持材3とから構成されている。保持材3は通常シート状であり、処理構造体1に巻き付けるが、筒状とすることもできる。
また、好ましくは、アルミナ成分とシリカ成分を98重量%以上又は100重量%(但し不可避不純物を含む)含む。
有機バインダーの量は、無機繊維を100重量部としたとき、通常、0.01~20重量部である。好ましくは0.1~15重量部、より好ましくは2~12重量部であり、特に好ましくは5~11重量部である。有機バインダーを多く含むと、触媒担体への巻き付け性は向上するものの、有機バインダ分解時に有機バインダが炭化して面圧低下を引き起こしやすい。
ポリアクリルアミドの量は、無機繊維を100重量部としたとき、0.01~1.0重量部である。好ましくは0.05~0.8重量部であり、より好ましくは0.1~0.5重量部である。0.01重量部未満であると、凝集効果が低下してバインダーを付与できなくなる恐れがある。1.0重量部を超えると、電荷のバランスが崩れることで、かえって凝集効果が低下してバインダーを付与できなくなる恐れがある。
本発明の保持材は、好ましくは、充填密度0.5g/cm3、Gap開放率12%で2500回繰り返し試験の結果、初期開放時面圧からの面圧残存率が、24%以上である。より好ましくは26%以上である。
水と、上記の無機繊維、有機バインダー、アルミナゾル及びポリアクリルアミドを混合して水性スラリーを調製する。この水性スラリーを脱水成形して、湿潤成形体を作製する。その後、湿潤成形体を乾燥させて、保持材を得る。
水性スラリーの調製の際は、無機繊維を100重量部としたとき、アルミナゾルの量が2~8重量部、ポリアクリルアミドの量が0.01~1.0重量部となるようにする。
(1)保持体の製造
アルミナ繊維(96.0重量%のAl2O3成分及び4.0重量%のSiO2成分)、アクリル樹脂(アクリル酸エステルとメタクリル酸エステルの共重合体)(有機バインダー)、アルミナゾル及びポリアクリルアミドA(重量平均分子量(分子量)450万)を水に分散させることにより、水性スラリーを調製した。各成分の配合量を表1に示す。表に示す配合量は、アルミナ繊維を100重量部としたときの重量部である。
次いで、金網を有する脱水成形型に水性スラリーを流し込み、脱水成形して、アルミナ繊維製湿潤成形体を得た。さらに、湿潤成形体を圧縮しながら、100℃で乾燥し、保持体を得た。密度は0.165g/cm3であった。
尚、重量平均分子量は、カラムとしてHLC‐8120を用い流速1ml/MinでGPC法で測定した。
以下の方法で、保持体の特性を評価した。
目視において、凝集状態を観察した。凝集状態がふっくらした凝集である方が、物性が安定するため好ましい。
目視において、表面平滑性を観察した。表面が平滑である方が、巻き付け時に表面の凹凸を基点としてマットに割れ、ヒビが発生しにくいため好ましい。巻き付け時にマットに割れ、ヒビが無いときを良好(○)とし、巻き付け時に表面凹凸部を起点としてマットに割れ、ヒビが発生したとき悪い(×)とした。
凝集剤を300rpmで攪拌する10℃の水に、0.5%濃度になるように投入し、完全に溶解するまでの時間を計測した。1時間以内に溶解したものを良好(○)とし、溶解に1時間以上かかるとき悪い(×)とした。
面圧残存率を、以下の方法で測定した。
面圧の測定は、島津(株)製万能試験機オートグラフを使用して行った。圧縮治具の円盤(直径100mm、厚さ25mm)を上下に取り付け、上下圧盤の隙間が10mmとなる位置をゼロ点とした。次いで、上記で作製したマットを下圧盤に配置し、ゼロ点位置から、圧縮速度10mm/minでマットを0.5g/cm3の充填密度となるように圧縮した後、12%(充填密度0.446g/cm3)の開放率まで開放する操作を2500サイクル繰返して測定した。このときの、初期開放時面圧から2500サイクル目の開放時面圧の残存面圧率とした。
直径70mmの触媒担体へ保持材を巻き付け、巻き付け性を観察した。マットに割れ、ヒビが無い時を良好(○)とし、マットに割れ、ヒビが発生したとき悪い(×)とした。
顕微鏡で観察して、無機繊維の交点のうち、短径500nm以上の塊でアルミナゾル無機バインダーが付着する交点の交点割合を測定した。
表1に示す成分と配合量で、実施例1と同様にして保持体を製造し、評価した。結果を表1に示す。
尚、比較例4では、凝集剤として、重量平均分子量が900万のポリアクリルアミドBを用いた。
実施例1で用いたアルミナ繊維100重量部、アクリル樹脂10重量部、ポリアクリルアミドA0.3重量部に対し、アルミナゾルの量を、0.5重量部から6.5重量部に変えて、実施例1と同様に保持材を製造した。実施例1と同様に、2500回後の解放時面圧を測定した。結果を図2に示す。
この明細書に記載の文献及び本願のパリ優先の基礎となる日本出願明細書の内容を全てここに援用する。
Claims (6)
- アルミナ成分を70重量%以上含む無機繊維と、
表面が負に荷電している、ポリアクリルアミド以外の有機バインダーと、
アルミナゾルと、
重量平均分子量が300万~600万のポリアクリルアミドを含み、
前記アルミナゾルの量が、前記無機繊維を100重量部としたとき、2~8重量部であって、
前記ポリアクリルアミドの量が、前記無機繊維を100重量部としたとき、0.01~1.0重量部である、保持材。 - 充填密度0.5g/cm3、Gap開放率12%で2500回繰り返し試験の結果、初期開放時面圧からの面圧残存率が、24%以上である、請求項1記載の保持材。
- 前記無機繊維の交点のうち、短径500nm以上の塊でアルミナゾルが付着する交点が、15%以上である、請求項1又は2記載の保持材。
- アルミナ成分を70重量%以上含む無機繊維と、
表面が負に荷電している、ポリアクリルアミド以外の有機バインダーと、
アルミナゾルと、
重量平均分子量が300万~600万のポリアクリルアミドを含み、
前記アルミナゾルの量が、前記無機繊維を100重量部としたとき、2~8重量部であって、
前記ポリアクリルアミドの量が、前記無機繊維を100重量部としたとき、0.01~1.0重量部となるように、混合して水性スラリーを調製し、
前記水性スラリーを脱水成形して、湿潤成形体を作製し、
前記湿潤成形体を乾燥させる、
保持材の製造方法。 - 筒状に形成された処理構造体と、
前記処理構造体を収容するケーシングと、
前記処理構造体と前記ケーシングとの間隙に介装される請求項1~3のいずれか記載の保持材とを具備する
気体処理装置。 - 前記処理構造体が、触媒担持体又は排ガスフィルタである請求項5記載の気体処理装置。
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