JP5869220B2 - 無機ナノ粒子を含有するマウンティングマット並びにその作製方法 - Google Patents
無機ナノ粒子を含有するマウンティングマット並びにその作製方法 Download PDFInfo
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- JP5869220B2 JP5869220B2 JP2010528970A JP2010528970A JP5869220B2 JP 5869220 B2 JP5869220 B2 JP 5869220B2 JP 2010528970 A JP2010528970 A JP 2010528970A JP 2010528970 A JP2010528970 A JP 2010528970A JP 5869220 B2 JP5869220 B2 JP 5869220B2
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- 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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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B30/00—Compositions for artificial stone, not containing binders
- C04B30/02—Compositions for artificial stone, not containing binders containing fibrous materials
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- 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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- D04H1/4209—Inorganic fibres
- D04H1/4218—Glass fibres
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
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- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/52—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by applying or inserting filamentary binding elements
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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
- D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
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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
- D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
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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
- D04H1/645—Impregnation followed by a solidification process
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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
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
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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
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
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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
- F01N3/18—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 methods of operation; Control
- F01N3/20—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 methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
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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
- F01N3/285—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration specially adapted for fibrous supports, e.g. held in place by screens
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- F01N2310/00—Selection of sound absorbing or insulating material
- F01N2310/02—Mineral wool, e.g. glass wool, rock wool, asbestos or the like
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- 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
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- 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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- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
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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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
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- Exhaust Gas After Treatment (AREA)
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- Exhaust Gas Treatment By Means Of Catalyst (AREA)
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Description
(i)成形ワイヤの上に置かれる、開かれた底を有する成形ボックスの入口を通して無機繊維を供給し、成形ワイヤの上に繊維のマットを成形する工程であって、この成形ボックスが、この入口とハウジング底との間のハウジングに少なくとも1列に備えられた、繊維の凝集を解きほぐすための複数の繊維分離ローラーと、エンドレスベルトスクリーンと、を有するものである、工程と、
(ii)繊維分離ローラーの下及び成形ワイヤの上のエンドレスベルトの下位走行部上の繊維の凝集を捉える工程と、
(iii)捉えられた凝集がこのエンドレスベルトから解放され、ローラーに接触してローラーによって解きほぐされ得るように、繊維分離ローラーの上のこのエンドレスベルト上に捉えられた繊維の凝集を搬送する工程と、
(iv)繊維のマットを、成形ワイヤによって成形ボックスから出して移動する工程と、
(v)この繊維のマットを圧縮し、この繊維のマットをその圧縮された状態に拘束し、それにより触媒コンバータのハウジングに汚染防止要素を実装するために好適な望ましい厚さを有するマウンティングマットを得る工程と、を含み、
1nm〜100nmの平均直径を有する無機粒子がこのマウンティングマットに提供される、方法である。
式中、
Rは水素、又は好ましくは1〜20個、より好ましくは1〜12個の炭素原子を有する有機残基であり、
nは、1〜20、好ましくは2〜15、より好ましくは3〜12、そして更により好ましくは4〜12の整数である。好ましくは、繊維ブランケットに含浸させるために使用されるシルセスキオキサンは、室温(23℃±2℃)では固体である。更に、シルセスキオキサンは、以下に示されるように、所望の浸透条件下で、自己架橋することができるヒドロキシ又はアルコキシ基などの官能基を好ましくは末端で含む。それらは、原理上は、例えば三官能性(例えばトリアルコキシ−官能性)シラン類(例えば、R−Si(OR)3)の加水分解重縮合によって得られる。
H2NCH2CH2NHCH2CH(CH3)CH2−、メルカプトプロピル、メルカプトエチル、ヒドロキシプロピル、
サイクル圧縮試験
サイクル圧縮試験の試験装置は以下の要素を含有する。
RCFTの試験装置は以下のものを含む。
比較実施例C1では、下記の組成の膨張性マウンティングマットを調製した。
46.2%繊維(「スーパーウール(SUPERWOOL)607HT」)
11.5%Rガラス短繊維(チョップ)、長さ6mm、700度で1時間熱処理したもの。
3.8%−P1粉末(「ベスタメルト(VESTAMELT)4680」)
比較実施例C1の膨張性マウンティングマットは、310mm幅の不織機(デンマーク所在のフォームファイバー(Formfiber)から入手したもの)を上述の方法に従って動作して作製した。この機械の成形ボックスは、図2に図示した概略図に本質的に相当するものであって、この成形ボックスは、その上位部に互いに対向して配置された3つのスパイクロール2列及びこの成形ボックスの底の近くで互いに対向して配置された3つのスパイクロール2列を有する。図2に図示するように、これら上位及び下位スパイク列の間をエンドレスベルトスクリーンが走る。成形ワイヤを成形ボックスの底の下に配置した。
実施例1Aの膨張性マウンティングマットは、ドイツ、フランクフルト所在のエボニックインダストリーズ社(Evonik Industries AG)の「エアロディスプ(AERODISP)W630」である入手した分散液1.0%(マット組成全体に対して)を搬送ベルト上の繊維に手動ポンプ噴霧器で均等に散布してから未開セクションにそれらの繊維を供給したことを除き、上述の方法と同じように調製された。
実施例1Bの膨張性マウンティングマットは、ドイツ、フランクフルト所在のエボニックインダストリーズ社の「VPディスパージョン(VP DISPERSION)W2650X」である入手した分散液3.0%(マット組成全体に対して)を搬送ベルト上の繊維に手動ポンプ噴霧器で均等に散布してから未開セクションにそれらの繊維を供給したことを除き、上述の方法と同じように調製された。
比較例C2
比較実施例C2では、下記の組成を有するマウンティングマットを作製した。
32.4%繊維(スーパーウール(SUPERWOOL)607HT)
32.4%Rガラス短繊維(チョップド)、長さ36mm、700度で1時間熱処理したもの。
比較実施例C2のマウンティングマットは、比較実施例C1で説明した上述の構造の310mm幅不織機で作製された。
実施例2Aのマウンティングマットは、(マット組成全体に対して)10%のナノ粒子分散液(スウェーデンのエカケミカルス社(Eka Chemicals)の「ビンドジル(BINDZIL)CAT220」(商品名)を入手)を5%固体に希釈し、搬送ベルト上で手動ポンプ噴霧器を用いて均等に散布して繊維に供給してから未開セクションにそれらの繊維を供給したことを除き、上述の比較実施例C2と同じ方法で調製した。
実施例2Bのマウンティングマットは、(マット組成全体に対して)2.8%のナノ粒子(ドイツのエボニックインダストリーズ社(Evonik Industries)の「エアロシル(AEROSIL)200」(商品名)を入手)を搬送ベルト上の繊維上に手動で加えてから未開セクションにそれらの繊維を供給したことを除き、上述の比較実施例C2と同じ方法で調製した。
下記の組成を有する比較実施例C3及び実施例3Aを、実施例C2、2A及び2Bのマウンティングマットの作製で上述したプロセスに従って製造した。成形セクションの後のバインダー繊維の熱接合プロセスに加えて、ニードルタッカー(ドイツ、エベルバッハのディロ(DILO)から入手したもの)を使用して1平方センチメートル当たり24のニードルパンチをした。
31.8%繊維(「イソフラックス(ISOFRAX)」)
31.8%繊維(「サッフィル(SAFFIL)3D+」)
31.8%シリカ繊維(チョップド)、長さ65mm(Steklovoloknoより「シリカヤーン(SILICA YARN)K11C」(商品名)を入手)。繊維は800℃のキルンで1時間熱処理した。
実施例3Aの組成物
比較実施例3のマウンティングマットと同じ組成の試料は、マットを懸濁液中に含浸させてから120℃の炉で50分間乾燥させることにより、水中0.5%ナノ粒子(ラポナイト(LAPONITE)RD)懸濁液に含浸させた。
以下に、本願発明に関連する発明の実施形態について列挙する。
[実施形態1]
触媒コンバータに汚染防止装置を実装するためのマウンティングマットであって、前記マウンティングマットが、1nm〜100nmの平均直径を有する無機粒子が中に分布された無機繊維の不織マットを含み、前記マウンティングマットが、有機結合剤を含まないか、又は前記マウンティングマットの総重量に基づき5重量%以下の有機結合剤を含有するものである、マウンティングマット。
[実施形態2]
少なくとも0.5重量%の前記無機粒子の粉末が前記マットに含有されている、実施形態1に記載のマウンティングマット。
[実施形態3]
前記マウンティングマットが膨張性材料を更に含有する、実施形態1か2のいずれか1項に記載のマウンティングマット。
[実施形態4]
前記無機繊維が、焼きなまし溶融成形セラミック繊維を含む溶融成形セラミック繊維、ゾルゲル成形セラミック繊維、多結晶繊維、熱処理されたガラス繊維を含むガラス繊維、アルミナ−シリカ繊維、生体溶解性繊維、及びこれらの組み合わせから選択されるものである、実施形態1から3のいずれか1項に記載のマウンティングマット。
[実施形態5]
前記マウンティングマットが、ニードルパンチ又はステッチ結合される、実施形態1から4のいずれか1項に記載のマウンティングマット。
[実施形態6]
スクリム及び網目から選択される1層以上の層を更に含む実施形態1から5のいずれか1項に記載のマウンティングマット。
[実施形態7]
前記マットの対向する主要面の片面又は両面が、スクリム又は網目を含む、実施形態1から5のいずれか1項に記載のマウンティングマット。
[実施形態8]
前記スクリム又は網目が、無機繊維を含む、実施形態6又は7に記載のマウンティングマット。
[実施形態9]
前記無機粒子粉末が、シリカ、アルミナ、若しくはジルコニアである酸化物、チタニア、又はケイ酸塩を含有する、実施形態1から8のいずれか1項に記載のマウンティングマット。
[実施形態10]
汚染防止装置であって、ハウジングと、前記ハウジング内に配置された汚染防止要素と、前記汚染防止要素及び前記ハウジングの間に配置されて前記汚染防止要素の位置を定め、並びに機械的衝撃及び熱衝撃を吸収するマウンティングマットとを有し、前記マウンティングマットが実施形態1〜9のいずれか一項に記載のマウンティングマットを含む汚染防止装置。
[実施形態11]
実施形態1に記載のマウンティングマットを作製する方法であって、
(i)成形ワイヤの上に置かれる、開かれた底を有する成形ボックスの入口を通して無機繊維を供給し、前記成形ワイヤの上に繊維のマットを成形する工程であって、前記成形ボックスが、前記入口とハウジング底との間のハウジングに少なくとも1列に備えられた、繊維の凝集を解きほぐすための複数の繊維分離ローラーと、エンドレスベルトスクリーンと、を有するものである、工程と、
(ii)繊維分離ローラーの下であり前記成形ワイヤの上にある前記エンドレスベルトの下位走行部上の繊維の凝集を捉える工程と、
(iii)捉えられた凝集が前記エンドレスベルトから解放され、前記ローラーに接触して解きほぐされることができるように、繊維分離ローラーの上にある前記エンドレスベルト上に捉えられた繊維の凝集を搬送する工程と、
(iv)前記繊維のマットを、前記成形ワイヤによって前記成形ボックスから出して移動する工程と、
(v)前記繊維のマットを圧縮し、前記繊維のマットをその圧縮された状態に拘束し、それにより触媒コンバータのハウジングに汚染防止要素を実装するために好適な望ましい厚さを有する、マウンティングマットを得る工程と、を含み、
前記マウンティングマットに、1nm〜100nmの平均直径を有する無機粒子が提供される、方法。
[実施形態12]
無機粒子の粉末を前記成形ボックスに供給することによって、前記マウンティングマットに前記無機粒子が提供される、実施形態11に記載の方法。
[実施形態13]
前記無機繊維を前記成形ボックスに提供する前に、前記無機粒子の分散液を前記無機繊維に散布することによって、又は前記繊維のマットの圧縮の前又は後に前記繊維のマットに前記分散液を散布することによって、前記マウンティングマットに前記無機粒子が提供される、実施形態11に記載の方法。
Claims (1)
- 触媒コンバータに汚染防止装置を実装するためのマウンティングマットを作製する方法であって、前記マウンティングマットは膨張性材料と無機粒子とを含む無機繊維の不織マットを含み、前記方法は、
(i)成形ワイヤの上に置かれる、開かれた底を有する成形ボックスの入口を通して無機繊維を供給し、前記成形ワイヤの上に繊維の不織マットを成形する工程であって、前記成形ボックスが、前記入口とハウジング底との間のハウジングに少なくとも1列に備えられた、繊維の凝集を解きほぐすための複数の繊維分離ローラーと、エンドレスベルトスクリーンと、を有するものである、工程と、
(ii)繊維分離ローラーの下であり前記成形ワイヤの上にある前記エンドレスベルトの下位走行部上の繊維の凝集を捉える工程と、
(iii)捉えられた凝集が前記エンドレスベルトから解放され、前記ローラーに接触して解きほぐされることができるように、繊維分離ローラーの上にある前記エンドレスベルト上に捉えられた繊維の凝集を搬送する工程と、
(iv)前記繊維の不織マットを、前記成形ワイヤによって前記成形ボックスから出して移動する工程と、
(v)前記繊維の不織マットを圧縮し、前記繊維の不織マットをその圧縮された状態に拘束し、それにより触媒コンバータのハウジングに汚染防止要素を実装するために好適な望ましい厚さを有する、マウンティングマットを得る工程と、を含み、
1nm〜100nmの平均直径を有する無機粒子が、(a)前記無機粒子の分散液を、前記成形ボックスに供給される前の前記無機繊維に散布するか、又は、(b)前記無機粒子の粉末を前記成形ボックスに供給することによって、前記繊維の不織マットの全体に無機繊維とともに均一に分布するようにされ、
前記不織マットは、機械的衝撃及び熱衝撃を吸収し汚染防止要素とハウジングとの熱膨張の差を補うのに適したものであり、
前記マウンティングマットが、有機結合剤を含まないか、又は前記マウンティングマットの総重量に基づき5重量%以下の有機結合剤を含有するものである、方法。
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Publication number | Publication date |
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US20160341094A1 (en) | 2016-11-24 |
PL2752562T3 (pl) | 2019-01-31 |
EP2205838B1 (en) | 2014-05-07 |
CN101883917B (zh) | 2015-01-28 |
JP2011501016A (ja) | 2011-01-06 |
KR20100081343A (ko) | 2010-07-14 |
WO2009048857A1 (en) | 2009-04-16 |
EP2205838A1 (en) | 2010-07-14 |
KR101623217B1 (ko) | 2016-05-20 |
EP2752562B1 (en) | 2018-09-05 |
PL2205838T3 (pl) | 2014-10-31 |
US9416053B2 (en) | 2016-08-16 |
JP2017129149A (ja) | 2017-07-27 |
JP6764812B2 (ja) | 2020-10-07 |
JP2015092037A (ja) | 2015-05-14 |
CN101883917A (zh) | 2010-11-10 |
US9932872B2 (en) | 2018-04-03 |
JP6151728B2 (ja) | 2017-06-21 |
US20100209308A1 (en) | 2010-08-19 |
EP2752562A1 (en) | 2014-07-09 |
DK2205838T3 (da) | 2014-07-28 |
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