US20060178068A1 - Non-woven and woven fabric for use as reforming catalyst - Google Patents
Non-woven and woven fabric for use as reforming catalyst Download PDFInfo
- Publication number
- US20060178068A1 US20060178068A1 US11/325,426 US32542606A US2006178068A1 US 20060178068 A1 US20060178068 A1 US 20060178068A1 US 32542606 A US32542606 A US 32542606A US 2006178068 A1 US2006178068 A1 US 2006178068A1
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- United States
- Prior art keywords
- woven fabric
- reforming catalyst
- carbon core
- precious metal
- woven
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
- D01D5/30—Conjugate filaments; Spinnerette packs therefor
- D01D5/36—Matrix structure; Spinnerette packs therefor
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
- D03D15/25—Metal
- D03D15/258—Noble metal
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
- D03D15/275—Carbon fibres
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/292—Conjugate, i.e. bi- or multicomponent, fibres or filaments
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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
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/002—Inorganic yarns or filaments
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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
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
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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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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2101/00—Inorganic fibres
- D10B2101/10—Inorganic fibres based on non-oxides other than metals
- D10B2101/12—Carbon; Pitch
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2101/00—Inorganic fibres
- D10B2101/20—Metallic fibres
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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
- F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
- F01N2240/30—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a fuel reformer
-
- 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
- F01N2310/00—Selection of sound absorbing or insulating material
- F01N2310/14—Wire mesh fabric, woven glass cloth 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
- 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
- F01N2330/10—Fibrous material, e.g. mineral or metallic wool
-
- 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
- F01N2330/18—Composite material
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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
- F01N2330/20—Plastics, e.g. polymers, polyester, polyurethane
-
- 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
- F01N2370/00—Selection of materials for exhaust purification
- F01N2370/02—Selection of materials for exhaust purification used in catalytic reactors
-
- 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
- F01N2510/00—Surface coverings
- F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
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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.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3065—Including strand which is of specific structural definition
- Y10T442/3089—Cross-sectional configuration of strand material is specified
-
- 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.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
- Y10T442/609—Cross-sectional configuration of strand or fiber material is specified
-
- 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.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
- Y10T442/609—Cross-sectional configuration of strand or fiber material is specified
- Y10T442/611—Cross-sectional configuration of strand or fiber material is other than circular
Definitions
- This invention relates to a non-woven fabric for use as a reforming catalyst used when producing hydrogen as a fuel for a fuel cell.
- Fuel cells are gathering much attention these days as next-generation energy generators. Fuel cells generate electricity by chemically reacting hydrogen as a fuel with oxygen in the atmosphere. Because of their high generating efficiency and low burden on the environment, fuel cells are considered to have limitless applications.
- Hydrogen which is scarcely present in the atmosphere, is typically produced by reacting e.g. methanol contained in utility gas with vapor in the presence of a catalyst in the form of a precious metal such as platinum.
- JP patent publication 2002-121006A proposes a reforming catalyst containing a composite oxide of a predetermined element carrying platinum and zirconium.
- An object of the present invention is to provide a reforming catalyst for producing hydrogen as a fuel for fuel cells from utility gas which contains small amounts of precious metals and thus can produce hydrogen at a lower cost.
- a non-woven fabric for use as a reforming catalyst comprising composite fibers each comprising an elongated carbon core, and a plurality of ribs provided on an outer periphery of the carbon core so as to extend in a longitudinal direction of the carbon core while being circumferentially spaced apart from each other, the ribs containing a precious metal.
- the precious metal is a precious and chemically stable metal suitable for use as a catalyst, such as platinum, palladium, rhodium, iridium or ruthenium.
- a woven fabric for use as a reforming catalyst comprising composite fibers each comprising an elongated carbon core, and a plurality of ribs provided on an outer periphery of the carbon core so as to extend in a longitudinal direction of the carbon core while being circumferentially spaced apart from each other, the ribs containing a precious metal.
- each composite fiber has its almost entire outer surface covered with the precious metal, so that the fabric maintains sufficient catalytic performance with a far smaller amount of precious metal used than is used in conventional reforming catalysts comprising metallic plates.
- the fabric as the reforming catalyst according to the present invention is lightweight because it contains only a small amount of precious metal. Since the fabric as the reforming catalyst according to the invention is mainly made of carbon fibers, it is flexible and easy to work. Thus, the reforming catalyst can be used for many different applications.
- the reforming catalyst in the form of a non-woven fabric according to the present invention has a much greater surface area than conventional reforming catalysts in the form of metallic plates and thus is much higher in the efficiency of catalytic reaction.
- the composite fibers have preferably a diameter in the range of 5 to 100 micrometers.
- FIG. 1 schematically shows how the fabric according to the present invention is formed by melt blowing
- FIG. 2 is an enlarged perspective view of a composite fiber according to the present invention
- FIG. 3A is a vertical sectional view of a die for forming composite fibers according to the present invention.
- FIG. 3B is a sectional view taken along the line B-B of FIG. 3A .
- the embodiment is directed to a method of manufacturing a non-woven fabric 12 for use as a reforming catalyst according to the present invention by melt blowing.
- a polymer 10 a and a polymer 10 b containing precious metal powder are prepared.
- the polymer 10 a may be petroleum pitch, coal pitch, a thermosetting resin such as epoxy resin or phenolic resin, or a melt spinnable resin containing a curing agent.
- the precious metal forming the precious metal powder may be platinum, palladium, rhodium, iridium or ruthenium. If reduced at a later stage, the precious metal may also be a metallic salt such as platinum chloride or platinum oxide.
- the precious metal powder has preferably a particle diameter not exceeding 3 micrometers and its content in the polymer is preferably less than 40 percent by volume.
- a typical melt blow process comprises the steps of feeding the polymers 10 a and 10 b into hoppers 20 a and 20 b , respectively, heat-melting the polymers 10 a and 10 b in extruders 30 a and 30 b , respectively, feeding the polymers 10 a and 10 b into a die 40 , spinning the mixture out of the die 40 in the form of fibers 11 to deposit the fibers 11 onto a collecting net of a conveyor 50 in the form of a sheet, peeling the sheet off the conveyor 50 , optionally feeding the sheet through calender rolls 60 , and winding the sheet onto a winder 70 as a non-woven fabric 12 .
- Each fiber 11 comprises an elongated core 11 a made of the polymer 10 a and formed with four longitudinal recesses having an arcuate section and circumferentially spaced apart from each other at equal intervals, and four elongated ribs 11 b made of the polymer 10 b and each filling one of the recesses so that the fiber 11 has a circular cross-section.
- Such fibers 11 are formed in the die 40 in the manner as shown in FIGS. 3A and 3 B.
- the die 40 has an axial passage 40 d having a cross-section complementary to the core 11 a of each fiber 11 , and four radial passages 40 e .
- Each passage 40 e merges with the axial passage 40 d at a juncture 40 c .
- each passage 40 e has a cross-section complementary to one of the elongated ribs 11 b of each fiber 11 (see FIG. 3B ).
- the polymer 10 a is introduced into the axial passage 40 d through its inlet port 40 a in a molten state.
- the polymer 10 b is introduced into the radial passages 40 e through their inlet ports 40 b in a molten state.
- the polymers 10 a and 10 b thus merge at the juncture 40 c and are formed into fibers 11 .
- the fibers 11 thus formed are discharged through a spinneret 40 f by hot air fed through hot air inlet ports 40 g and hot air blowing slits 40 h ( FIG. 3A ).
- the fibers 11 thus formed have their axial core 11 a , which is made of the polymer 10 a , partially exposed.
- the fibers 11 maintain self-adhesiveness during melt blowing.
- the fibers 11 are bonded together into a non-woven fabric 12 , which is then calcined at a temperature in the range of 1500 to 1600 degrees C. and subjected to graphitization to allow the polymers forming the fibers 11 to turn into carbon.
- a non-woven fabric for use as a reforming catalyst according to the present invention is thus formed.
- the thus formed reforming catalyst according to the invention is, unlike conventional metallic plates, easy to work because it is a soft non-woven fabric comprising carbon fibers. Thus, it can be used for many different applications. If the polymer 10 b contains not a precious metal but a precious metal salt, it has to be reduced to a metallic element.
- the fabric may also be subjected to infusible treatment.
- the non-woven fabric 12 is formed by melt blowing.
- the non-woven fabric 12 according to the present invention may be formed by any other known method such as needle punching, spunlacing or spun-bonding.
- the catalyst according to the present invention may be a woven fabric comprising composite fibers 11 . Such a woven fabric may be formed using a conventional weaving machine or by any known method.
- the fibers forming such a fabric should have as small a diameter as possible. But simultaneously, the fabric has to maintain sufficient strength as an end product. Thus, the fibers forming the fabric have preferably diameters in the range of about 5 to 100 micrometers.
Abstract
A reforming catalyst is proposed which is used when producing hydrogen as a fuel for a fuel cell from e.g. utility gas. The reforming catalyst is a non-woven or woven fabric made up of composite fibers each including an elongated carbon core, and a plurality of ribs attached to the carbon core so as to extend in a longitudinal direction of the carbon core while being circumferentially spaced apart from each other. The ribs contain a precious metal. The fabric contains less precious metal and is thus less expensive.
Description
- This invention relates to a non-woven fabric for use as a reforming catalyst used when producing hydrogen as a fuel for a fuel cell.
- Fuel cells are gathering much attention these days as next-generation energy generators. Fuel cells generate electricity by chemically reacting hydrogen as a fuel with oxygen in the atmosphere. Because of their high generating efficiency and low burden on the environment, fuel cells are considered to have limitless applications.
- Hydrogen, which is scarcely present in the atmosphere, is typically produced by reacting e.g. methanol contained in utility gas with vapor in the presence of a catalyst in the form of a precious metal such as platinum.
- For this purpose, JP patent publication 2002-121006A proposes a reforming catalyst containing a composite oxide of a predetermined element carrying platinum and zirconium.
- But because a large amount of precious metals are used in such a catalyst, the cost for producing hydrogen as a fuel for fuel cells tends to be high.
- An object of the present invention is to provide a reforming catalyst for producing hydrogen as a fuel for fuel cells from utility gas which contains small amounts of precious metals and thus can produce hydrogen at a lower cost.
- According to the present invention, there is provided a non-woven fabric for use as a reforming catalyst, the non-woven fabric comprising composite fibers each comprising an elongated carbon core, and a plurality of ribs provided on an outer periphery of the carbon core so as to extend in a longitudinal direction of the carbon core while being circumferentially spaced apart from each other, the ribs containing a precious metal. The precious metal is a precious and chemically stable metal suitable for use as a catalyst, such as platinum, palladium, rhodium, iridium or ruthenium.
- From another aspect of the invention, there is provided a woven fabric for use as a reforming catalyst, the woven fabric comprising composite fibers each comprising an elongated carbon core, and a plurality of ribs provided on an outer periphery of the carbon core so as to extend in a longitudinal direction of the carbon core while being circumferentially spaced apart from each other, the ribs containing a precious metal.
- With this arrangement, each composite fiber has its almost entire outer surface covered with the precious metal, so that the fabric maintains sufficient catalytic performance with a far smaller amount of precious metal used than is used in conventional reforming catalysts comprising metallic plates. Thus, using the reforming catalyst according to the present invention, it is possible to reduce the cost for producing hydrogen as a fuel for fuel cells. The fabric as the reforming catalyst according to the present invention is lightweight because it contains only a small amount of precious metal. Since the fabric as the reforming catalyst according to the invention is mainly made of carbon fibers, it is flexible and easy to work. Thus, the reforming catalyst can be used for many different applications.
- The reforming catalyst in the form of a non-woven fabric according to the present invention has a much greater surface area than conventional reforming catalysts in the form of metallic plates and thus is much higher in the efficiency of catalytic reaction.
- The composite fibers have preferably a diameter in the range of 5 to 100 micrometers.
- By determining the diameter of the composite fibers in this range, it is possible to maximize the surface area of the fabric and thus the efficiency of catalytic reaction while maintaining sufficient strength to ensure resistance to repeated use as a final product.
- Other features and objects of the present invention will become apparent from the following description made with reference to the accompanying drawings, in which:
-
FIG. 1 schematically shows how the fabric according to the present invention is formed by melt blowing; -
FIG. 2 is an enlarged perspective view of a composite fiber according to the present invention; -
FIG. 3A is a vertical sectional view of a die for forming composite fibers according to the present invention; and -
FIG. 3B is a sectional view taken along the line B-B ofFIG. 3A . - Now with reference to the drawings, the embodiment of the invention is described. The embodiment is directed to a method of manufacturing a
non-woven fabric 12 for use as a reforming catalyst according to the present invention by melt blowing. - First, a
polymer 10 a and apolymer 10 b containing precious metal powder are prepared. Thepolymer 10 a may be petroleum pitch, coal pitch, a thermosetting resin such as epoxy resin or phenolic resin, or a melt spinnable resin containing a curing agent. The precious metal forming the precious metal powder may be platinum, palladium, rhodium, iridium or ruthenium. If reduced at a later stage, the precious metal may also be a metallic salt such as platinum chloride or platinum oxide. The precious metal powder has preferably a particle diameter not exceeding 3 micrometers and its content in the polymer is preferably less than 40 percent by volume. - As shown in
FIG. 1 , a typical melt blow process comprises the steps of feeding thepolymers hoppers polymers extruders polymers die 40, spinning the mixture out of thedie 40 in the form offibers 11 to deposit thefibers 11 onto a collecting net of aconveyor 50 in the form of a sheet, peeling the sheet off theconveyor 50, optionally feeding the sheet throughcalender rolls 60, and winding the sheet onto awinder 70 as a non-wovenfabric 12. - Each
fiber 11 comprises anelongated core 11 a made of thepolymer 10 a and formed with four longitudinal recesses having an arcuate section and circumferentially spaced apart from each other at equal intervals, and fourelongated ribs 11 b made of thepolymer 10 b and each filling one of the recesses so that thefiber 11 has a circular cross-section.Such fibers 11 are formed in the die 40 in the manner as shown inFIGS. 3A and 3B. - As shown in
FIG. 3A , the die 40 has anaxial passage 40 d having a cross-section complementary to thecore 11 a of eachfiber 11, and fourradial passages 40 e. Eachpassage 40 e merges with theaxial passage 40 d at ajuncture 40 c. Near thejuncture 40 c, eachpassage 40 e has a cross-section complementary to one of theelongated ribs 11 b of each fiber 11 (seeFIG. 3B ). Thepolymer 10 a is introduced into theaxial passage 40 d through itsinlet port 40 a in a molten state. Thepolymer 10 b is introduced into theradial passages 40 e through theirinlet ports 40 b in a molten state. Thepolymers juncture 40 c and are formed intofibers 11. Thefibers 11 thus formed are discharged through a spinneret 40 f by hot air fed through hotair inlet ports 40 g and hot air blowingslits 40 h (FIG. 3A ). As shown inFIG. 2 , thefibers 11 thus formed have theiraxial core 11 a, which is made of thepolymer 10 a, partially exposed. Thus, thefibers 11 maintain self-adhesiveness during melt blowing. - The
fibers 11 are bonded together into anon-woven fabric 12, which is then calcined at a temperature in the range of 1500 to 1600 degrees C. and subjected to graphitization to allow the polymers forming thefibers 11 to turn into carbon. A non-woven fabric for use as a reforming catalyst according to the present invention is thus formed. The thus formed reforming catalyst according to the invention is, unlike conventional metallic plates, easy to work because it is a soft non-woven fabric comprising carbon fibers. Thus, it can be used for many different applications. If thepolymer 10 b contains not a precious metal but a precious metal salt, it has to be reduced to a metallic element. The fabric may also be subjected to infusible treatment. - In the embodiment, the
non-woven fabric 12 is formed by melt blowing. But thenon-woven fabric 12 according to the present invention may be formed by any other known method such as needle punching, spunlacing or spun-bonding. Also, the catalyst according to the present invention may be a woven fabric comprisingcomposite fibers 11. Such a woven fabric may be formed using a conventional weaving machine or by any known method. - For higher catalytic efficiency, the fibers forming such a fabric should have as small a diameter as possible. But simultaneously, the fabric has to maintain sufficient strength as an end product. Thus, the fibers forming the fabric have preferably diameters in the range of about 5 to 100 micrometers.
Claims (4)
1. A non-woven fabric for use as a reforming catalyst, said non-woven fabric comprising composite fibers each comprising an elongated carbon core, and a plurality of ribs provided on an outer periphery of said carbon core so as to extend in a longitudinal direction of said carbon core while being circumferentially spaced apart from each other, said ribs containing a precious metal.
2. The non-woven fabric of claim 1 wherein said composite fibers have a diameter in the range of 5 to 100 micrometers.
3. A woven fabric for use as a reforming catalyst, said woven fabric comprising composite fibers each comprising an elongated carbon core, and a plurality of ribs provided on an outer periphery of said carbon core so as to extend in a longitudinal direction of said carbon core while being circumferentially spaced apart from each other, said ribs containing a precious metal.
4. The woven fabric of claim 3 wherein said composite fibers have a diameter in the range of 5 to 100 micrometers.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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JP2005-034712 | 2005-02-10 | ||
JP2005034712A JP4129459B2 (en) | 2005-02-10 | 2005-02-10 | Nonwoven fabric and woven fabric for reforming catalyst |
Publications (1)
Publication Number | Publication Date |
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US20060178068A1 true US20060178068A1 (en) | 2006-08-10 |
Family
ID=36780546
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US11/325,426 Abandoned US20060178068A1 (en) | 2005-02-10 | 2006-01-05 | Non-woven and woven fabric for use as reforming catalyst |
Country Status (2)
Country | Link |
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US (1) | US20060178068A1 (en) |
JP (1) | JP4129459B2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN110461631A (en) * | 2017-01-24 | 2019-11-15 | 蓄积者公司 | Electrification heat-producing machine system |
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US4583299A (en) * | 1984-12-20 | 1986-04-22 | Trw Inc. | Fluidization aid for cohesive materials |
US5037697A (en) * | 1986-01-22 | 1991-08-06 | Nitto Boseki Co., Ltd. | Carbon fiber and process for producing the same |
US5188894A (en) * | 1989-08-31 | 1993-02-23 | Tanaka Kikinzoku Kogyo K.K. | Composite carbon fiber and process for preparing same |
US5326633A (en) * | 1986-03-24 | 1994-07-05 | Ensci, Inc. | Coated substrates |
US6264045B1 (en) * | 1997-06-02 | 2001-07-24 | Hitco Carbon Composites, Inc. | High performance filters comprising an inorganic composite substrate and inorganic fiber whiskers |
US6383972B1 (en) * | 1997-11-24 | 2002-05-07 | Messier-Bugatti | Preparation of a catalyst support in activated carbon fibres |
US20050169820A1 (en) * | 2003-08-26 | 2005-08-04 | Tatarchuk Bruce J. | Microfibrous entrapment of small reactive particulates and fibers for high contacting efficiency removal of contaminants from gaseous or liquid streams |
US20060099134A1 (en) * | 2002-07-17 | 2006-05-11 | Shigeo Maruyama | Method for producing fine carbon fiber |
-
2005
- 2005-02-10 JP JP2005034712A patent/JP4129459B2/en not_active Expired - Fee Related
-
2006
- 2006-01-05 US US11/325,426 patent/US20060178068A1/en not_active Abandoned
Patent Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
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US4583299A (en) * | 1984-12-20 | 1986-04-22 | Trw Inc. | Fluidization aid for cohesive materials |
US5037697A (en) * | 1986-01-22 | 1991-08-06 | Nitto Boseki Co., Ltd. | Carbon fiber and process for producing the same |
US5326633A (en) * | 1986-03-24 | 1994-07-05 | Ensci, Inc. | Coated substrates |
US5188894A (en) * | 1989-08-31 | 1993-02-23 | Tanaka Kikinzoku Kogyo K.K. | Composite carbon fiber and process for preparing same |
US6264045B1 (en) * | 1997-06-02 | 2001-07-24 | Hitco Carbon Composites, Inc. | High performance filters comprising an inorganic composite substrate and inorganic fiber whiskers |
US6383972B1 (en) * | 1997-11-24 | 2002-05-07 | Messier-Bugatti | Preparation of a catalyst support in activated carbon fibres |
US20060099134A1 (en) * | 2002-07-17 | 2006-05-11 | Shigeo Maruyama | Method for producing fine carbon fiber |
US20050169820A1 (en) * | 2003-08-26 | 2005-08-04 | Tatarchuk Bruce J. | Microfibrous entrapment of small reactive particulates and fibers for high contacting efficiency removal of contaminants from gaseous or liquid streams |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN110461631A (en) * | 2017-01-24 | 2019-11-15 | 蓄积者公司 | Electrification heat-producing machine system |
Also Published As
Publication number | Publication date |
---|---|
JP4129459B2 (en) | 2008-08-06 |
JP2006218413A (en) | 2006-08-24 |
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