WO2021049274A1 - Matériau de natte, dispositif de purification de gaz d'échappement, tube d'échappement équipé d'un matériau de natte, et système d'échappement - Google Patents

Matériau de natte, dispositif de purification de gaz d'échappement, tube d'échappement équipé d'un matériau de natte, et système d'échappement Download PDF

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Publication number
WO2021049274A1
WO2021049274A1 PCT/JP2020/031607 JP2020031607W WO2021049274A1 WO 2021049274 A1 WO2021049274 A1 WO 2021049274A1 JP 2020031607 W JP2020031607 W JP 2020031607W WO 2021049274 A1 WO2021049274 A1 WO 2021049274A1
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Prior art keywords
mat material
water
exhaust gas
soluble polymer
exhaust
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PCT/JP2020/031607
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English (en)
Japanese (ja)
Inventor
隆彦 岡部
前田　敏幸
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イビデン株式会社
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Priority claimed from JP2019234522A external-priority patent/JP2021046646A/ja
Application filed by イビデン株式会社 filed Critical イビデン株式会社
Publication of WO2021049274A1 publication Critical patent/WO2021049274A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/10—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing oxygen
    • D06M13/184—Carboxylic acids; Anhydrides, halides or salts thereof
    • D06M13/192—Polycarboxylic acids; Anhydrides, halides or salts thereof
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/327—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated alcohols or esters thereof
    • D06M15/333—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated alcohols or esters thereof of vinyl acetate; Polyvinylalcohol
    • 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
    • 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
    • D21H17/03—Non-macromolecular organic compounds
    • D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
    • D21H17/14—Carboxylic acids; Derivatives thereof
    • D21H17/15—Polycarboxylic acids, e.g. maleic acid
    • 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
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/08—Other arrangements or adaptations of exhaust conduits
    • 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
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/14—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having thermal insulation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors

Definitions

  • the present invention relates to a mat material, an exhaust gas purification device, an exhaust pipe with a mat material, and an exhaust system.
  • Exhaust gas emitted from an internal combustion engine such as a diesel engine contains particulate matter (hereinafter, also referred to as PM), and in recent years, it has become a problem that this PM causes harm to the environment and the human body. ..
  • the exhaust gas also contains harmful gas components such as CO, HC, and NOx, there are concerns about the effects of these harmful gas components on the environment and the human body.
  • an exhaust gas purification device that collects PM in the exhaust gas and purifies harmful gas components
  • an exhaust gas treatment body made of porous ceramics such as silicon carbide and cordierite
  • a casing that houses the exhaust gas treatment body.
  • various exhaust gas purification devices composed of a holding seal material (mat material) disposed between the exhaust gas treatment body and the casing have been proposed.
  • This holding seal material (mat material) prevents the exhaust gas treatment body from coming into contact with the casing covering the outer periphery of the exhaust gas treatment body due to vibration or impact generated by the running of an automobile or the like, and prevents the exhaust gas treatment body and the casing from being damaged. It is arranged mainly for the purpose of preventing exhaust gas from leaking from between.
  • the holding seal material (mat material) is a filamentous body and has a light specific gravity
  • the holding seal material (mat material) is assembled to the catalyst carrier and the shell to prepare a catalytic converter
  • the surface of the holding seal material (mat material) is used. Inorganic fibers may be scattered in the air. Therefore, there is a possibility that the working environment of the work place where the above-mentioned assembly work is performed may be deteriorated, and it is necessary for the worker to wear a dust mask or the like to perform the work.
  • Patent Document 1 describes that a mat material is impregnated with an acrylic resin as an organic binder. Further, Patent Document 2 describes that the mat material is impregnated with silicone oil.
  • the mat material placed in the exhaust gas purification device or the like receives heat from the exhaust gas and becomes hot.
  • the matte material is impregnated with an acrylic resin as in Patent Document 1
  • the acrylic resin is decomposed by heat and the generated thermal decomposition gas has a strong odor.
  • the surface pressure of the mat material is lowered, and there is also a problem that the exhaust gas treated body is likely to fall off.
  • the present invention has been made in view of the above problems, and an object of the present invention is to provide a mat material that is easy to handle, can prevent scattering of inorganic fibers, and does not easily reduce the surface pressure during use. is there.
  • the mat material of the present invention is a mat material made of inorganic fibers, and the mat material contains a fiber scattering inhibitor containing a water-soluble polymer, and the weight ratio of the water-soluble polymer to the mat material ( The weight of the water-soluble polymer / the weight of the mat material) is 3.0 wt% or less, and the water-soluble polymer is characterized in that it is solid at room temperature and does not melt at 300 ° C.
  • the weight ratio of the water-soluble polymer to the mat material is 3.0 wt% or less. Therefore, the scattering of inorganic fibers can be sufficiently suppressed. If this ratio exceeds 3.0 wt%, the mat material becomes hard and tends to lose its flexibility. Therefore, the mat material becomes difficult to handle.
  • the weight ratio of the water-soluble polymer to the mat material is preferably 0.01 to 3.0 wt%, more preferably 0.05 to 3.0 wt%.
  • the water-soluble polymer is solid at room temperature. That is, in the mat material of the present invention, the water-soluble polymer adheres to the inorganic fiber in a solid state. Therefore, the surface of the inorganic fibers is roughened, and the friction between the inorganic fibers is large. With such a mat material, the surface pressure becomes large.
  • the water-soluble polymer does not melt at 300 ° C.
  • the water-soluble polymer melts at 300 ° C. when the mat material is heated to 300 ° C., the water-soluble polymer adhering to the surface of the inorganic fibers melts, and the inorganic fibers become slippery. Therefore, the surface pressure of the mat material is reduced.
  • the water-soluble polymer does not melt at 300 ° C. even if the mat material is heated to about 300 ° C., the state of the water-soluble polymer does not change, so that the surface pressure of the mat material is unlikely to decrease.
  • the water-soluble polymer is preferably a water-soluble polycarboxylic acid salt, and more preferably a water-soluble sodium polycarboxylic acid.
  • these compounds are difficult to melt at 300 ° C. Therefore, even if the mat material reaches about 300 ° C., the surface pressure is unlikely to decrease. Further, these compounds are less likely to generate pyrolysis gas and have less strong odor.
  • the odor index measured by the odor sensor for the odor of the decomposition gas generated by placing the mat material on a hot plate at 500 ° C. is 1.0 for acrylic resin as a fiber scattering inhibitor.
  • the odor index of the matte material adhered by weight% is preferably 80 or less as a relative value of 130.
  • the mat material of the present invention is designed so that the odor index by the odor sensor falls within a low range even if the fiber scattering inhibitor is thermally decomposed. Therefore, when the mat material is arranged around the exhaust pipe, it is possible to prevent the odor in the engine room from becoming severe.
  • a mat material is placed on a hot plate at 500 ° C. using a handy odor monitor OMX-SRM (manufactured by Shinei Technology Co., Ltd.), which is a semiconductor type odor sensor, as an odor sensor. It is an index that measures the decomposition gas generated. Further, it is a relative value with the odor index of a mat material to which 1.0% by weight of acrylic resin (Nipol Lx854E, manufactured by Nippon Zeon Corporation) is attached as a fiber scattering inhibitor as 130.
  • OMX-SRM manufactured by Shinei Technology Co., Ltd.
  • the exhaust gas purification device of the present invention comprises an exhaust gas treatment body, a metal casing accommodating the exhaust gas treatment body, and a mat material arranged between the exhaust gas treatment body and the metal casing and holding the exhaust gas treatment body.
  • the mat material of the present invention can sufficiently suppress the scattering of inorganic fibers. Therefore, it is possible to prevent the inorganic fibers from scattering from the mat material during the manufacture of the exhaust gas purification device. Further, the water-soluble polymer in the mat material of the present invention is difficult to be melted by heat and is not easily decomposed by heat. Therefore, even if the exhaust gas flows into the exhaust gas purification device of the present invention and the mat material is heated, the surface pressure of the mat material is unlikely to decrease and the odor is unlikely to become strong.
  • the exhaust pipe with a mat material of the present invention is an exhaust pipe with a mat material including an exhaust pipe, a mat material arranged so as to cover the exhaust pipe, and a metal cover arranged outside the mat material.
  • the mat material is the mat material of the present invention.
  • the mat material of the present invention can sufficiently suppress the scattering of inorganic fibers. Therefore, it is possible to prevent the inorganic fibers from scattering from the mat material during the production of the exhaust pipe with the mat material. Further, the water-soluble polymer in the mat material of the present invention is difficult to be melted by heat and is not easily decomposed by heat. Therefore, even if the exhaust gas flows into the exhaust pipe with the mat material of the present invention and the mat material is heated, when the mat material is arranged around the exhaust pipe, the odor in the engine room is unlikely to become strong.
  • the exhaust system of the present invention is characterized in that the mat material of the present invention is arranged on the inner peripheral side of a heat insulator arranged on the outside of an exhaust manifold in an automobile exhaust system.
  • the mat material of the present invention can sufficiently suppress the scattering of inorganic fibers. Therefore, it is possible to prevent the inorganic fibers from scattering from the mat material during the manufacture of the exhaust system. Further, the water-soluble polymer in the mat material of the present invention is difficult to be melted by heat and is not easily decomposed by heat. Therefore, even if the exhaust gas flows into the exhaust system of the present invention and the mat material is heated, the odor is unlikely to become strong.
  • FIG. 1 is a perspective view schematically showing an example of the mat material of the present invention.
  • FIG. 2 is a cross-sectional view schematically showing an example of an exhaust gas purification device provided with the mat material of the present invention.
  • FIG. 3A is a perspective view schematically showing an example of an exhaust gas treatment body constituting the exhaust gas purification device of the present invention.
  • FIG. 3B is a cross-sectional view taken along the line AA of FIG. 3A.
  • FIG. 4 is a cross-sectional view schematically showing an example of an exhaust pipe with a matte material provided with the matte material of the present invention.
  • FIG. 5 is a perspective view schematically showing another example of the exhaust system of the present invention.
  • FIG. 6 is a cross-sectional view schematically showing a part of the exhaust system of the present invention shown in FIG.
  • FIG. 1 is a perspective view schematically showing an example of the mat material of the present invention.
  • the mat material 10 is made of inorganic fibers and has a rectangular shape in a plan view. Further, when the mat material 10 is wound around an object, a convex portion 11a is provided on one end portion 11 of the mat material 10 so that the end portions are fitted to each other, and the other end portion 12 is provided with a convex portion 11a. A recess 12a is provided. When such a convex portion 11a and a concave portion 12a are provided, the sealing property is improved when the mat material 10 is arranged in the exhaust gas purification device described later.
  • the mat material of the present invention does not have to have a convex portion and a concave portion at the end portion of the mat material.
  • the mat material 10 contains a fiber scattering inhibitor containing a water-soluble polymer.
  • the weight ratio of the water-soluble polymer to the mat material 10 is 3.0 wt% or less. This weight ratio is preferably 0.01 to 3.0 wt%, more preferably 0.05 to 3.0 wt%, further preferably 0.1 to 3.0 wt%, and 0. .2 to 2.5 wt% is particularly preferable, and 0.3 to 2.0 wt% is more particularly preferable. With such a weight ratio, scattering of inorganic fibers can be sufficiently suppressed.
  • this ratio is less than 0.01 wt%, the amount of the water-soluble polymer is small, and it becomes difficult to prevent the inorganic fibers from scattering. If this ratio exceeds 3.0 wt%, the mat material becomes hard and tends to lose its flexibility. Therefore, it is difficult for the mat material to be wrapped around the curved surface of the surface of the exhaust pipe, which makes it difficult to handle.
  • the water-soluble polymer is solid at room temperature.
  • the water-soluble polymer 30 is attached to the inorganic fiber 20 in a solid state. Therefore, the surface of the inorganic fibers 20 is roughened, and the friction between the inorganic fibers 20 is large. With such a mat material 10, the surface pressure becomes large.
  • room temperature means 15 to 30 ° C.
  • the water-soluble polymer does not melt at 300 ° C.
  • the water-soluble polymer melts at 300 ° C. when the mat material is heated to 300 ° C., the water-soluble polymer adhering to the surface of the inorganic fibers melts, and the inorganic fibers become slippery. Therefore, the surface pressure of the mat material is reduced.
  • the water-soluble polymer does not melt at 300 ° C. even if the mat material is heated to about 300 ° C., the state of the water-soluble polymer does not change, so that the surface pressure of the mat material is unlikely to decrease.
  • Examples of such a water-soluble polymer include a water-soluble polycarboxylic acid and a water-soluble polycarboxylic acid salt.
  • a water-soluble polycarboxylic acid salt is preferable, and a water-soluble sodium polycarboxylic acid is more preferable.
  • These compounds are difficult to melt at 300 ° C. Therefore, even if the mat material reaches about 300 ° C., the surface pressure is unlikely to decrease. Further, these compounds are less likely to generate pyrolysis gas and have less strong odor.
  • the inorganic fibers constituting the mat material 10 are not particularly limited, and examples thereof include alumina fibers, alumina-silica fibers, silica fibers, biosoluble fibers, glass wool, and rock wool. Of these, alumina-silica fibers are preferred. These inorganic fibers have high heat resistance, and the mat material formed of such inorganic fibers does not easily change its shape due to temperature changes.
  • Alumina (Al 2 O 3 ): Silica (SiO 2 ) 70: 30 to 74: 26 is more preferable.
  • the average length of the inorganic fibers is preferably 0.1 to 150 mm, more preferably 0.2 to 80 mm. If the average fiber length of the inorganic fibers is less than 0.1 mm, the fiber lengths of the inorganic fibers are too short, so that the inorganic fibers are not sufficiently entangled with each other, it becomes difficult to obtain the strength of the mat material, and the shape of the mat material is maintained. The sex tends to decrease. If the average fiber length of the fibers exceeds 150 mm, the fiber lengths of the fibers are too long, so that the number of fibers constituting the mat material is reduced, and the denseness is lowered.
  • the average fiber diameter of the inorganic fibers is preferably 1 to 20 ⁇ m, more preferably 2 to 15 ⁇ m, and even more preferably 3 to 10 ⁇ m.
  • the breaking load is low and the inorganic fiber is easily broken by an impact or the like.
  • the average fiber diameter of the inorganic fiber exceeds 20 ⁇ m, defects inside the fiber are likely to occur, the strength of the inorganic fiber is lowered, and the surface pressure value as a mat material for holding the exhaust gas treated body is lowered.
  • An inorganic binder may be attached to the mat material 10.
  • the inorganic binder include particles such as alumina, silica, and zirconia. These particles are preferably derived from an inorganic sol dispersion solution (alumina sol, silica sol, zirconia sol, etc.).
  • an inorganic binder is attached to the mat material, the frictional force between the inorganic fibers is improved, so that the warping force of the mat material is improved, and the mat material is misaligned when it is sandwiched between exhaust pipes and arranged as a heat insulating material. Is suppressed.
  • the holding power of the exhaust gas treatment body is improved. Further, even when the mat material is not arranged by being sandwiched between something, the frictional resistance of the mat material increases due to the adhesion of the inorganic binder, so that the misalignment of the mat material is suppressed.
  • the odor index measured by the odor sensor for the odor of the decomposition gas generated by placing the mat material 10 on a hot plate at 500 ° C. is 1.0% by weight of acrylic resin as a fiber scattering inhibitor.
  • the relative value of the attached mat material with the odor index as 130 is preferably 80 or less, more preferably 65 or less, and further preferably 55 or less.
  • the mat material of the present invention is designed so that the odor index by the odor sensor falls within a low range even if the fiber scattering inhibitor is thermally decomposed. Therefore, when the mat material is arranged around the exhaust pipe, it is possible to prevent the odor in the engine room from becoming severe.
  • the mat material of the present invention may be produced by a needle punching method or a papermaking method. Each method will be described below.
  • the inorganic fiber precursor is compressed to prepare a continuous sheet-like product having a predetermined size, which is subjected to needle punching treatment and then calcining treatment to obtain alumina.
  • the density of needle punching is preferably 0.1 to 30 pieces / cm 2 .
  • inorganic particles, an inorganic binder, an organic binder and the like may be added to the fiber scattering inhibitor aqueous solution as needed.
  • the mat material of the present invention can be produced.
  • the raw material sheet is heated and pressurized to prepare a mat material. Further, at the time of heating and pressurizing, a heat treatment may be performed in which hot air is aerated through the raw material sheet to dry the raw material sheet, or a wet state may be obtained without the heat treatment.
  • the heating temperature and hot air temperature are preferably 100 to 250 ° C. in order to prevent deterioration of the organic binder due to heat. In the range of 100 to 250 ° C., moisture can be removed from the mat material while suppressing deterioration of the organic binder.
  • the heating temperature or hot air temperature is less than 100 ° C., the temperature is not transmitted to the central portion of the mat material, and the drying time becomes long. On the other hand, if the temperature exceeds 250 ° C., the organic binder is deteriorated and the binding force between the fibers is reduced, so that the thickness of the mat material cannot be controlled.
  • the mat material of the present invention can be produced through the above steps.
  • the fiber scattering inhibitor was added to the mixed solution in the mixed solution preparation step, but in the method for producing the mat material of the present invention, the fiber scattering inhibitor is suppressed in the "(2-1) mixed solution adjusting step".
  • An aqueous solution of a fiber scattering inhibitor containing a water-soluble polymer is attached to the mat material after the "(2-3) heating and pressurizing step" without using an agent, and then dried to make the inorganic fibers of the mat material water-soluble.
  • a sex polymer may be attached.
  • FIG. 2 is a cross-sectional view schematically showing an example of an exhaust gas purification device provided with the mat material of the present invention.
  • the exhaust gas purification device 100 is arranged between the exhaust gas treatment body 40, the metal casing 50 accommodating the exhaust gas treatment body 40, and the exhaust gas treatment body 40 and the metal casing 50, and is arranged between the exhaust gas treatment body 40 and the metal casing 50. It is provided with a mat material 10 for holding the above. Further, the mat material 10 is the mat material of the present invention.
  • the exhaust gas flows into the exhaust gas purification device 100 (in FIG. 2, the exhaust gas is indicated by a symbol "G” and the gas flow is indicated by an arrow), and the exhaust gas treatment body 40 and the mat material 10 are heated. become.
  • the water-soluble polymer adhering to the surface of the inorganic fiber is difficult to melt. Therefore, it is possible to prevent the inorganic fibers from slipping each other. As a result, it is possible to prevent the surface pressure of the mat material from decreasing.
  • FIG. 3A is a perspective view schematically showing an example of an exhaust gas treatment body constituting the exhaust gas purification device of the present invention.
  • FIG. 3B is a cross-sectional view taken along the line AA of FIG. 3A.
  • the exhaust gas treatment body 40 included in the exhaust gas purification device 100 is a columnar one in which a large number of cells 41 are arranged side by side in the longitudinal direction across the cell wall 42. Further, in the exhaust gas treatment body 40, one of the cells 41 is an exhaust gas filter (honeycomb filter) sealed with a sealing material 43.
  • the exhaust gas discharged from the internal combustion engine and flowing into the exhaust gas treatment body 40 (in FIG. 3B, the exhaust gas is indicated by G and the flow of the exhaust gas is indicated by an arrow) is the exhaust gas inflow side end face of the exhaust gas treatment body 40. It flows into one cell 41 opened in the air and passes through the cell wall 42 separating the cells 41. At this time, PM in the exhaust gas is collected by the cell wall 42, and the exhaust gas is purified. The purified exhaust gas flows out from another cell 41 opened on the exhaust gas outflow side end face and is discharged to the outside.
  • the exhaust gas treatment body 40 shown in FIGS. 3A and 3B is a filter in which one end of the cell 41 is sealed with a sealing material 43, but the exhaust gas constituting the exhaust gas purification device of the present invention.
  • the processed body does not have to be sealed at the end of the cell.
  • Such an exhaust gas treated body can be suitably used as a catalyst carrier.
  • the exhaust gas treatment body 40 may be made of a non-oxidized porous ceramic such as silicon carbide or silicon nitride, or may be made of an oxide porous ceramic such as alumina, cordierite, or mullite. Among these, silicon carbide is preferable.
  • the cell density in the cross section of the exhaust gas treatment body 40 is not particularly limited, but the preferable lower limit is 31.0 pcs / cm 2 (200 pcs / inch 2 ), and the preferable upper limit is 93.0 pcs / cm 2 (600 pcs / inch / inch). inch 2 ).
  • the more preferable lower limit is 38.8 pieces / cm 2 (250 pieces / inch 2 ), and the more preferable upper limit is 77.5 pieces / cm 2 (500 pieces / inch 2 ).
  • the exhaust gas treatment body 40 may be supported with a catalyst for purifying the exhaust gas, and the catalyst to be supported is preferably a noble metal such as platinum, palladium, or rhodium, and among these, platinum is more preferable. Further, as other catalysts, for example, alkali metals such as potassium and sodium and alkaline earth metals such as barium can be used. These catalysts may be used alone or in combination of two or more. When these catalysts are supported, PM can be easily burned and removed, and toxic exhaust gas can be purified.
  • the metal casing 50 has a substantially cylindrical shape.
  • the inner diameter of the metal casing 50 (the inner diameter of the portion accommodating the exhaust gas treatment body) is preferably slightly shorter than the diameter of the exhaust gas treatment body 40 around which the mat material 10 is wound.
  • the metal casing 50 is not particularly limited, but is preferably made of stainless steel.
  • the exhaust pipe with a mat material provided with the mat material of the present invention is also the exhaust pipe with a mat material of the present invention.
  • FIG. 4 is a cross-sectional view schematically showing an example of an exhaust pipe with a matte material provided with the matte material of the present invention.
  • the exhaust pipe 200 with a mat material includes an exhaust pipe 60, a mat material 10 arranged so as to cover the exhaust pipe 60, and a metal cover 70 arranged outside the mat material 10. ..
  • an exhaust system including the mat material of the present invention which is an example of the method of using the mat material of the present invention, will be described.
  • the exhaust system including the mat material of the present invention is also the exhaust system of the present invention.
  • FIG. 5 is a perspective view schematically showing another example of the exhaust system of the present invention.
  • FIG. 6 is a cross-sectional view schematically showing a part of the exhaust system of the present invention shown in FIG.
  • an exhaust manifold 82 is attached to the side surface of the automobile engine 81.
  • a part of the outer peripheral surface of the exhaust manifold 82 is covered with the heat insulator 83.
  • the heat insulator 83 is partially fixed to the exhaust manifold 82 by bolts 84, but there is a space between the heat insulator 83 and the exhaust manifold 82.
  • the mat material 10 of the present invention is arranged on the inner peripheral side of the heat insulator 83, that is, on the exhaust manifold 82 side. In FIG. 6, the mat material 10 is also fixed by the bolt 84.
  • the exhaust manifold 82 has a function of collecting the exhaust gas from each cylinder and further sending the exhaust gas to the exhaust gas purification device. A part of the outer peripheral surface of the exhaust manifold 82 is covered with the heat insulator 83.
  • High-temperature exhaust gas flows through the exhaust manifold 82 in the exhaust system of an automobile, and it is preferable that the exhaust gas flows to the downstream exhaust gas treatment body while the temperature of the exhaust gas remains high because the catalytic efficiency in the exhaust gas treatment body is improved. Therefore, it is preferable to insulate the exhaust manifold 82.
  • the heat insulator 83 is a plate-shaped member made of metal or the like, and a part of the heat insulator 83 is fixed to the exhaust manifold 82 by bolts 84 or the like, but there is a space between the heat insulator 83 and the exhaust manifold 82.
  • the mat material 10 is arranged on the inner peripheral side of the heat insulator 83, that is, on the exhaust manifold 82 side.
  • the mat material 10 is preferably fixed to the inner peripheral surface of the heat insulator 83 by fixing means such as an adhesive, bolts and nuts, rivets, staples, caulking, stud pins, and eyelets. Since the mat material 10 arranged on the inner peripheral side of the heat insulator 83 is not wound around the pipe, it is not necessary to form concave portions or convex portions, and the outer shape is matched to the shape of the inner peripheral surface of the heat insulator 83. It may have a processed shape.
  • the inner peripheral surface of the heat insulator 83 is usually not a simple flat surface, it is also possible to arrange the mat material 10 on the inner peripheral surface of the heat insulator 83 without a gap by combining a plurality of mat materials 10. preferable.
  • the mat material 10 can sufficiently suppress the scattering of inorganic fibers. Therefore, it is possible to prevent the inorganic fibers from scattering from the mat material 10 at the time of manufacturing the exhaust system 300. Further, the water-soluble polymer in the mat material 10 is hard to be melted by heat and is hard to be thermally decomposed. Therefore, even if the exhaust gas flows into the exhaust system 300 and the mat material 10 is heated, the odor is unlikely to become strong.
  • an organic polymer polyvinyl alcohol
  • the alumina fiber precursor was compressed to prepare a continuous sheet having a width of 1254 mm and a thickness of 7.9 mm. Needle punching was performed so that the density was 23 pieces / cm 2. Then, the sheet-like material was calcined at a maximum temperature of 1300 ° C. to convert the alumina fiber precursor into alumina fiber to obtain a sheet of an inorganic fiber aggregate.
  • Comparative Example 1 The mat material according to Comparative Example 1 was produced in the same manner as in Example 1 except that a water-insoluble acrylic resin that softens and fluidizes at 200 ° C. or lower was used instead of the water-soluble sodium polycarboxylic acid. Since the acrylic resin is water-insoluble, it adheres to the inorganic fiber aggregate with the emulsion liquid dispersed in water.
  • Comparative Example 2 instead of the fiber scattering inhibitor aqueous solution, an emulsion liquid in which water-insoluble silicone oil is dispersed in water is used, and the weight ratio of silicone oil to the mat material produced (weight of silicone oil / weight of mat material) is 1 wt.
  • the mat material according to Comparative Example 2 was produced in the same manner as in Example 1 except that the ratio was set to%.
  • the mat material according to Example 1 and Comparative Example 1 was cut into a size of 5 cm ⁇ 5 cm, and a hot surface pressure measuring device equipped with a heater was used in the portion of the plate for compressing the mat as a sample for surface pressure measurement.
  • Each surface pressure measurement sample was placed at 25 ° C. and compressed to a bulk density (GBD) of 0.21 g / cm 3.
  • the surface pressure at that time was defined as the surface pressure at 25 ° C.
  • the mixture was heated at a heating rate of 45 ° C./min, and the surface pressure at 100 ° C. and the surface pressure at 300 ° C. were measured.
  • the ratio of the surface pressure at 300 ° C. to the surface pressure at 100 ° C. was calculated.
  • the surface pressure at 25 ° C. was measured in the same manner. The results are shown in Table 1.
  • Example 1 and Comparative Example 1 The matte material according to Example 1 and Comparative Example 1 was cut into a size of 25 mm ⁇ 25 mm, placed on a hot plate heated to 500 ° C., and handy odor monitor OMX-SRM (manufactured by Shinei Technology Co., Ltd.), which is a semiconductor type odor sensor. ) was placed above the mat by about 10 to 20 cm, and the odor index of the decomposed gas was measured.
  • the odor index of the mat material of each Example and Comparative Example was shown as a relative value with the odor index of the decomposed gas of Comparative Example 1 as 130.
  • the mat material according to Example 1 had a high surface pressure at room temperature, and it was difficult for the surface pressure to decrease due to an increase in temperature. Further, as shown in Table 2, the mat material according to Example 1 had a sufficiently low odor index.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Toxicology (AREA)
  • Biomedical Technology (AREA)
  • Environmental & Geological Engineering (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Exhaust Gas After Treatment (AREA)

Abstract

L'objectif de la présente invention est de fournir un matériau de natte à partir duquel la dispersion de fibres inorganiques peut être empêchée, et dans lequel la pression de surface pendant l'utilisation ne chute pas facilement. Un agent de natte selon la présente invention est un matériau de natte comprenant des fibres inorganiques, caractérisé en ce que le matériau de natte comprend un agent de prévention de dispersion de fibres contenant un polymère soluble dans l'eau, la proportion en poids du polymère soluble dans l'eau par rapport au matériau de natte (poids de polymère soluble dans l'eau/poids de matériau de natte) étant de 3,0 % en poids ou moins, et le polymère soluble dans l'eau étant solide à température ambiante et ne fondant pas à 300 °C.
PCT/JP2020/031607 2019-09-10 2020-08-21 Matériau de natte, dispositif de purification de gaz d'échappement, tube d'échappement équipé d'un matériau de natte, et système d'échappement WO2021049274A1 (fr)

Applications Claiming Priority (4)

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JP2019-164827 2019-09-10
JP2019164827 2019-09-10
JP2019-234522 2019-12-25
JP2019234522A JP2021046646A (ja) 2019-09-10 2019-12-25 マット材、排ガス浄化装置、マット材付き排気管及び排気システム

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008078615A1 (fr) * 2006-12-22 2008-07-03 Asahi Fiber Glass Company, Limited Liant aqueux pour fibres inorganiques et matériau absorbant acoustique thermiquement isolant à fibres inorganiques
JP2016160541A (ja) * 2015-02-27 2016-09-05 イビデン株式会社 アルミナ繊維の製造方法、紡糸液及びアルミナ繊維
JP2017057545A (ja) * 2015-09-15 2017-03-23 旭ファイバーグラス株式会社 無機繊維断熱吸音材用水性バインダー及び無機繊維断熱吸音材
WO2017141724A1 (fr) * 2016-02-16 2017-08-24 イビデン株式会社 Matériau de tapis et système d'échappement
JP2017145524A (ja) * 2016-02-16 2017-08-24 イビデン株式会社 マット材、及び、排気システム

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008078615A1 (fr) * 2006-12-22 2008-07-03 Asahi Fiber Glass Company, Limited Liant aqueux pour fibres inorganiques et matériau absorbant acoustique thermiquement isolant à fibres inorganiques
JP2016160541A (ja) * 2015-02-27 2016-09-05 イビデン株式会社 アルミナ繊維の製造方法、紡糸液及びアルミナ繊維
JP2017057545A (ja) * 2015-09-15 2017-03-23 旭ファイバーグラス株式会社 無機繊維断熱吸音材用水性バインダー及び無機繊維断熱吸音材
WO2017141724A1 (fr) * 2016-02-16 2017-08-24 イビデン株式会社 Matériau de tapis et système d'échappement
JP2017145524A (ja) * 2016-02-16 2017-08-24 イビデン株式会社 マット材、及び、排気システム

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