U.S. patent application number 10/399036 was filed with the patent office on 2004-03-18 for holding seal material for catalytic converter and method of manufacturing the holding and seal material.
Invention is credited to Fukushima, Koji, Nishikawa, Yoshio, Yamada, Keiji.
Application Number | 20040052694 10/399036 |
Document ID | / |
Family ID | 18795696 |
Filed Date | 2004-03-18 |
United States Patent
Application |
20040052694 |
Kind Code |
A1 |
Nishikawa, Yoshio ; et
al. |
March 18, 2004 |
Holding seal material for catalytic converter and method of
manufacturing the holding and seal material
Abstract
A holding and sealing material (1) for a catalytic converter is
disposed between a cylindrical catalyst carrier (3) and a metal
shell (2) covering the outer periphery of the catalyst carrier (3).
The holding and sealing material (1) comprises a fiber aggregate
mainly comprised of alumina-silica based ceramic fibers having a
mullite crystal content of 10 wt % or less, and the fiber aggregate
is subjected to a needle punch treatment. Owing to the improved
holding and sealing material, a catalytic converter having
excellent durability and assemblage and having extremely low
pollution characteristics is provided.
Inventors: |
Nishikawa, Yoshio;
(Ogaki-shi, JP) ; Fukushima, Koji; (Ogaki-shi,
JP) ; Yamada, Keiji; (Ogaki-shi, JP) |
Correspondence
Address: |
OBLON, SPIVAK, MCCLELLAND, MAIER & NEUSTADT, P.C.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Family ID: |
18795696 |
Appl. No.: |
10/399036 |
Filed: |
September 22, 2003 |
PCT Filed: |
October 17, 2001 |
PCT NO: |
PCT/JP01/09103 |
Current U.S.
Class: |
422/177 |
Current CPC
Class: |
C04B 35/63416 20130101;
C04B 2235/80 20130101; D04H 1/4209 20130101; C04B 35/6263 20130101;
C04B 2235/526 20130101; C04B 35/62245 20130101; C04B 2235/763
20130101; C04B 2235/5264 20130101; C04B 2235/5268 20130101; C04B
35/62675 20130101; F01N 3/2853 20130101; C04B 2235/3463 20130101;
D04H 1/46 20130101; C04B 2235/444 20130101 |
Class at
Publication: |
422/177 |
International
Class: |
F01N 003/28; D04H
001/42 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 17, 2000 |
JP |
2000-316798 |
Claims
1. A holding and sealing material (1) disposed between a catalyst
carrier (3) and a metal shell (2) covering the catalyst carrier,
the holding and sealing material (1) comprising a fiber aggregate
mainly comprised of alumina-silica based ceramic fibers having a
mullite crystal content of 10 wt % or less, and the fiber aggregate
having been subjected to a needle punch treatment.
2. A holding and sealing material (1) disposed between a catalyst
carrier (3) and a metal shell (2) covering the catalyst carrier,
the holding and sealing material (1) comprising a fiber aggregate
mainly comprised of alumina-silica based ceramic fibers having a
mullite crystal content of 0.5 to 4 wt %, and the fiber aggregate
having been subjected to a needle punch treatment.
3. The holding and sealing material according to claim 1 or 2,
wherein said alumina-silica based ceramic fibers have a chemical
composition with the alumina content being 68 wt % to 83 wt % and
the silica content being 17 wt % to 32 wt %.
4. The holding and sealing material according to any one of claims
1 to 3, wherein the seal material disposed between the catalyst
carrier (3) and the metal shell (2) generates a contact pressure of
0.02 MPa or more.
5. The holding and sealing material according to any one of claims
1 to 4, wherein the abundance density of said needle punch spots is
from 10 to 500 spots per 100 cm.sup.2.
6. A holding and sealing material (1) disposed between a catalyst
carrier (3) and a metal shell (2) covering the catalyst carrier,
the holding and sealing material comprising a fiber aggregate
mainly comprised of alumina-silica based ceramic fibers having a
mullite crystal content of 10% or less, with some of said ceramic
fibers intertwined in the direction of thickness of said fiber
aggregate.
7. A method for manufacturing a holding and sealing material (1)
for a catalytic converter disposed between a catalyst carrier (3)
and a metal shell (2) covering the catalyst carrier, the method
comprises the steps of: performing fiber spinning using as a raw
material an aqueous solution composed of a mixture of an aluminum
salt, a silica sol and an organic polymer to prepare alumina-silica
based ceramic fibers; stacking the alumina-silica based ceramic
fibers to prepare a fiber aggregate: subjecting said fiber
aggregate to a needle punch treatment; and baking said fiber
aggregate subjected to the needle punch treatment to prepare a
holding and sealing material (1) comprising a fiber aggregate
having a mullite crystal content of 10 wt % or less.
8. The method for manufacturing a holding and sealing material
according to claim 7, wherein the baking temperature in said baking
step is 1100.degree. C. to 1300.degree. C.
9. The method for manufacturing a holding and sealing material
according to claim 8, wherein the baking time in said baking step
is 1 to 60 minutes.
10. A catalytic converter (5) comprising: a catalyst carrier (3); a
metal shell (2) covering said catalyst carrier; and a holding and
sealing material (1) disposed between the catalyst carrier (3) and
the metal shell (2), the holding and sealing material (1) including
a fiber aggregate mainly comprised of alumina-silica based ceramic
fibers having a mullite crystal content of 10 wt % or less, and the
fiber aggregate having been subjected to a needle punch
treatment.
11. A catalytic converter (5) comprising: a catalyst carrier (3); a
metal shell (2) covering said catalyst carrier; and a holding and
sealing material (1) disposed between the catalyst carrier (3) and
the metal shell (2), the holding and sealing material (1) including
a fiber aggregate mainly comprised of alumina-silica based ceramic
fibers having a mullite crystal content of 0.5 to 4 wt %, and the
fiber aggregate having been subjected to a needle punch
treatment.
12. The catalytic converter according to claim 10 or 11, wherein
said alumina-silica based ceramic fibers have a chemical
composition with the alumina content being 68 wt % to 83 wt % and
the silica content being 17 wt % to 32 wt %.
13. The catalytic converter according to any one of claims 10 to
12, wherein contact pressure generated in the seal material
disposed between the catalyst carrier (3) and the metal shell (2)
is 0.02 MPa or more.
14. The catalytic converter according to any one of claims 10 to
13, wherein the abundance density of said needle punch spots is 10
to 500 spots per 100 cm.sup.2.
15. A catalytic converter (5) comprising: a catalyst carrier (3); a
metal shell (2) covering said catalyst carrier; and a holding and
sealing material (1) disposed between the catalyst carrier (3) and
the metal shell (2), said holding and sealing material including a
fiber aggregate mainly comprised of alumina-silica based ceramic
fibers having a mullite crystal content of 10% or less, with some
of said ceramic fibers intertwined in the direction of thickness of
said fiber aggregate.
Description
TECHNICAL FIELD
[0001] The present invention relates to a catalytic converter, and
particularly relates to a holding and sealing material for
catalytic converters and a method for manufacturing the same.
BACKGROUND ART
[0002] Internal combustion engines using gasoline and light oil as
fuels have been used for a hundred years or longer as power sources
for vehicles, particularly automobiles. However, harmful effects on
the health and environment from exhaust became a matter of concern,
and since then, various kinds of exhaust gas cleaning catalytic
converters, which are apparatuses for removing CO, NOx and PM
contained in exhaust gas have been proposed. A usual exhaust gas
cleaning catalytic converter comprises a catalyst carrier, a metal
shell covering the outer periphery of the catalyst carrier, and a
holding and sealing material disposed in a gap between the former
and the latter. A honeycomb-shaped cogierite carrier, for example,
is used for the catalyst carrier, and a catalyst such as platinum
is carried on the cogierite carrier.
[0003] The holding and sealing material of the catalytic converter
serves to prevent damage to the catalyst carrier due to contact
between the catalyst carrier and the metal shell when the car is
traveling, while preventing leakage of gas from the gap between the
metal shell and the catalyst carrier. The holding and sealing
material also serves to establish thermal insulation from the metal
shell in order to make the catalyst undergo efficient reaction from
the initial stage of its use. A suitable material capable of
performing these roles is a mat-like material made of
alumina-silica based ceramic fibers.
[0004] The mat-like material made of alumina-silica based ceramic
fibers is bulky. Therefore, for the holding and sealing material,
assemblage in the catalyst carrier should be improved. In view of
the above described situation, techniques, which reduce the
thickness of the mat-like material by impregnating a mat-like
material made of inorganic fibers with an organic binder, have been
proposed.
[0005] In the case of the holding and sealing material impregnated
with the organic binder, however, when the holding and sealing
material is used while it is arranged in a gap, the organic binder
is decomposed due to the heat from the exhaust gas, and the
decomposition gas is released into the atmosphere. At least several
wt % or more of such organic binder should be used for impregnating
the holding and sealing material in order to improve assemblage.
Therefore, with the conventional technique, it is very difficult to
achieve a low-pollution characteristic surpassing the
conventionally achievable level while maintaining suitable
assemblage.
[0006] In addition, in recent years, the temperature of exhaust gas
has been on a gradual increase as the performance of engines has
been improved. For a high fuel efficiency lean-burn engine, for
example, exhaust gas temperature reaches nearly 1000.degree. C.,
and thus the contact pressure generated by the holding and sealing
material exposed to high temperature drops in a relatively short
time. Therefore, sealing performance and carrier holding
performance in the gap portion is deteriorated at an early stage,
and thus the durability of the catalytic converter is reduced.
DISCLOSURE OF THE INVENTION
[0007] A first object of the present invention is to provide a
catalytic converter having an extremely low-pollution
characteristic while being excellent in durability and
assemblage.
[0008] The second object of the present invention is to provide a
holding and sealing material for catalytic converters suitable for
achieving the above described excellent catalytic converter, and a
method for manufacturing the same.
[0009] In a first aspect of the present invention, a holding and
sealing material disposed between a catalyst carrier and a metal
shell covering the catalyst carrier is provided. The holding and
sealing material includes a fiber aggregate mainly comprised of
alumina-silica based ceramic fibers having a mullite crystal
content of 10 wt % or less, and the fiber aggregate having been
subjected to a needle punch treatment.
[0010] In a second aspect of the present invention, a holding and
sealing material disposed between a catalyst carrier and a metal
shell covering the catalyst carrier is provided. The holding and
sealing material includes a fiber aggregate mainly comprised of
alumina-silica based ceramic fibers having a mullite crystal
content of 0.5 to 4 wt %, and the fiber aggregate having been
subjected to a needle punch treatment.
[0011] In a third aspect of the present invention, a holding and
sealing material disposed between a catalyst carrier and a metal
shell covering the catalyst carrier is provided. The holding and
sealing material includes a fiber aggregate mainly comprised of
alumina-silica based ceramic fibers having a mullite crystal
content of 10% or less, with some of the ceramic fibers intertwined
in the direction of thickness of the fiber aggregate.
[0012] In a fourth aspect of the present invention, a method is
provided for manufacturing a holding and sealing material for a
catalytic converter, disposed between a catalyst carrier and a
metal shell covering the catalyst carrier . The manufacturing
method includes the steps of performing fiber spinning using as a
raw material an aqueous solution composed of a mixture of an
aluminum salt, a silica sol and an organic polymer to prepare
alumina-silica based ceramic fibers, stacking the alumina-silica
based ceramic fibers to prepare a fiber aggregate, subjecting the
fiber aggregate to a needle punch treatment, and baking the fiber
aggregate, having been subjected to a needle punch treatment, to
prepare a holding and sealing material comprising a fiber aggregate
having a mullite crystal content of 10wt % or less.
[0013] In a fifth aspect of the present invention, a catalytic
converter is provided. The catalytic converter includes a catalyst
carrier, a metal shell covering the catalyst carrier, and a holding
and sealing material disposed between the catalyst carrier and the
metal shell. The holding and sealing material includes a fiber
aggregate mainly comprised of alumina-silica based ceramic fibers
having a mullite crystal content of 10 wt % or less, and the fiber
aggregate having been subjected to a needle punch treatment.
[0014] In a sixth aspect of the present invention, a catalytic
converter is provided. The catalytic converter includes a catalyst
carrier, a metal shell covering the catalyst carrier, and a holding
and sealing material disposed between the catalyst carrier and the
metal shell. The holding and sealing material includes a fiber
aggregate mainly comprised of alumina-silica based ceramic fibers
having a mullite crystal content of 0.5 to 4 wt %, with the fiber
aggregate having been subjected to a needle punch treatment.
[0015] In the seventh aspect of the present invention, a catalytic
converter is provided. The catalytic converter includes a catalyst
carrier, a metal shell covering the catalyst carrier, and a holding
and sealing material disposed between the catalyst carrier and the
metal shell. The holding and sealing material includes a fiber
aggregate mainly comprised of alumina-silica based ceramic fibers
having a mullite crystal content of 10% or less, with some of the
ceramic fibers intertwined in the direction of thickness of the
fiber aggregate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is an explanatory view of a state of use of a
catalytic converter of one embodiment according to the present
invention;
[0017] FIG. 2 is a schematic sectional view of the catalytic
converter of one embodiment according to the present invention;
[0018] FIG. 3(a) is a plan view of a holding and sealing material
for use in the catalytic converter of FIG. 2;
[0019] FIG. 3(b) is a schematic perspective view illustrating a
method of assembly for the catalytic converter of FIG. 2.
[0020] FIG. 3(c) is a schematic perspective view of the catalytic
converter in which assembly is completed; and
[0021] FIG. 4 is a graph showing a relationship between the mullite
content in the holding and sealing material for use in the
catalytic converter and the contact pressure.
BEST MODE FOR CARRYING OUT THE INVENTION
[0022] A catalytic converter 5 for an automobile exhaust gas
cleaning apparatus 6fone embodiment according to the present
invention will be described in detail below based on FIGS. 1 to
4.
[0023] As shown in FIG. 1, the catalytic converter 5 is provided at
some position along an exhaust pipe 91 of an engine 9 along a body
92 of a vehicle. Furthermore, since the distance between the engine
9 and the catalytic converter 5 is relatively small, a high
temperature exhaust gas of about 700.degree. C. to 900.degree. C.
is supplied to the catalytic converter 5. In the case where the
engine is a lean burn engine, an exhaust gas of higher temperature
of about 900.degree. C. to 1000.degree. C. is supplied to the
catalytic converter 5.
[0024] As shown in FIG. 2, the catalytic converter 5 comprises a
cylindrical catalyst carrier 3, a metal shell 2 covering the outer
periphery of the catalyst carrier 3, and a holding and sealing
material 1 disposed in a gap between the catalyst carrier 3 and the
metal shell 2.
[0025] The catalyst carrier 3 is prepared using a ceramic material
represented by cogierite or the like. Also, the catalyst carrier 3
is preferably a honeycomb structure having a large number of cells
31, 32 extending along the axis line.
[0026] Furthermore, a catalyst such as platinum or rhodium capable
of cleaning exhaust gas components is carried on the wall of
cells.
[0027] The metal shell 2 is preferably a cylindrical metal member
having an O-shaped section, for example, if a press fitting method
is employed for mounting. Furthermore, for the metal material for
forming the cylindrical member, a metal having excellent heat
resistance and impact resistance is preferably selected. If a
so-called canning method is employed instead of the press fitting
method, a metal shell (i.e., clam shell), which is formed by
dividing the cylindrical metal member having an O-shaped section
into a plurality of sections along the axis line, is used.
[0028] In addition, for example, if a rolling method is employed
for mounting, a cylindrical metal member is used, which has a
C-shaped or U-shaped section (i.e., a cylindrical metal member is
formed with one slit (opening) extending along the axis). In this
case, for assembling the catalyst carrier 3, the catalyst carrier 3
with the holding and sealing material 1 fixed on the surface is
disposed in the metal shell 2, the metal shell 2 is rolled up in
this state, and thereafter the end of the slit opening is sealed
(welded, bonded, bolted or the like) . Sealing such as welding,
bonding or bolting is also performed when the canning method is
employed.
[0029] As shown in FIG. 3(a), the holding and sealing material 1 is
an elongated mat-like material, with a concave mating portion 11
provided at one end thereof, while a convex mating portion 12 is
provided at the other end. When the holding and sealing material 1
is wound around the catalyst carrier 3, the convex mating portion
12 is engaged with the concave mating portion 11.
[0030] The holding and sealing material 1 comprises a fiber
aggregate mainly comprised of alumina-silica based ceramic fibers
having a mullite crystal content of 0 to 10 wt %. In other words,
the holding and sealing material 1 comprises a fiber aggregate
mainly comprised of ceramic fibers made of an aluminum-silicon
spinel compound containing no mullite crystal or containing 10 wt %
or less of mullite crystal. With such a chemical composition, the
holding and sealing material 1 has excellent heat resistance and
high resiliency against an applied compression load. Thus, the
contact pressure hardly drops even when the holding and sealing
material 1 is exposed to high temperature while it is situated in
the gap. In this case, the mullite crystal content is more
preferably in the range of from 0.5 to 4 wt %. Also, the
aluminum-silicon spinel compound is, for example, .gamma.-alumina,
.delta.-alumina, or .chi.-alumina.
[0031] The alumina-silica based ceramic fibers have preferably a
chemical composition with the alumina content of 68 wt % to 83 wt %
and the silica content of 17 wt % to 32 wt %, and specifically more
preferably have a composition of
A1.sub.2O.sub.3:SiO.sub.2=72:28.
[0032] If the content of alumina is less than 68 wt % or the
content of silica exceeds 32 wt %, it may be impossible to achieve
sufficient improvement in heat resistance and in resiliency against
an applied compression load. Similarly, if the content of alumina
exceeds 83 wt % or the content of silica is less than 17 wt %, it
may be impossible to achieve sufficiently improvement in heat
resistance and in resiliency against an applied compression
load.
[0033] The fiber aggregate is prepared by a needle punch treatment
that is one type of a fiber intertwinement treatment. Consequently,
some of the ceramic fibers are intertwined at needle punch spots in
the direction of thickness of the fiber aggregate. Furthermore, in
the needle punch treatment, for example, a tabular jig (needle
board) with a large number of needles erected thereon is used.
[0034] The abundance density of needle punch spots is preferably 10
to 500 spots, more preferably 20 to 250 spots per 100 cm.sup.2.
[0035] If the abundance density of needle punch spots is less than
10 spots per 100 cm.sup.2, the holding and sealing material 1
cannot reliably be compressed in the direction of thickness, and
thus it may be impossible to reduce the thickness of the holding
and sealing material I sufficiently to a level allowing achievement
of suitable assemblage. If the abundance density of needle punch
spots exceeds 500 spots per 100 cm.sup.2, on the other hand, the
thickness of the holding and sealing material 1 can be reduced
sufficiently, but it may be impossible to enhance resiliency
against an applied compression load due to the existence of the
large number of needle punch spots.
[0036] Before assembly and after the needle punch treatment is
applied, it is preferably that the bulk density (GBD) of the
holding and sealing material 1 is 0.1 g/cm.sup.3 to 0.6 g/cm.sup.3,
further preferably 0.2 g/cm.sup.3 to 0.4 g/cm.sup.3. Also, the pack
density with the holding and sealing material 1 assembled is
preferably set to a level the same as described above. If the bulk
density and the pack density are too small, it may be impossible to
reliably hold the catalyst carrier 3 due to a reduction in
generated contact pressure. If the bulk density and the pack
density are too large, on the other hand, rigidity is improved, but
it may be difficult to carry out assembly due to a reduction in
deformability.
[0037] The content of the organic component (organic binder)
contained in ceramic fibers constituting the holding and sealing
material 1 is preferably 1 wt % or less, further preferably 0.1 wt
% or less, particularly preferably 0.01 wt % or less. If the
content of organic binder is increased to several wt % or more, the
organic binder is decomposed by the heat from exhaust gas, thereby
increasing the amount of gas released into the atmosphere.
Therefore, it is very difficult to achieve low-pollution
characteristics surpassing the conventionally achievable level.
[0038] The thickness of the holding and sealing material 1 before
being assembled is equivalent to preferably about 1.1 to 4.0 times,
further preferably about 1.5 to 3.0 times as large as the size of
the gap between the catalyst carrier 3 and the metal shell 2. If
the thickness is smaller than 1.1 times the size of the gap, it may
be impossible to obtain a high level of carrier holding
performance, thus raising the possibility that the catalyst carrier
3 is shifted relative to the metal shell 2 and worn. In this case,
it is also impossible to obtain a high level of sealing
performance, and therefore the exhaust gas is more easily leaked
through the gap portion, thus making it impossible to achieve a
high level low-pollution characteristic. Also, if the thickness of
the holding and sealing material 1 is larger than 4.0 times the
size of the gap, it is difficult to place the catalyst carrier 3 in
the metal shell 2, especially if a press fitting method is
employed. Thus, it may be impossible to achieve an improvement in
assemblage.
[0039] In addition, the average diameter of alumina-silica based
ceramic fibers constituting the holding and sealing material 1 is
preferably about 5 to 20 .mu.m, more preferably about 7 to 13
.mu.m. The average length of the ceramic fibers is preferably about
0.1 to 100 mm, more preferably about 2 to 50 mm. The tensile
strength of the ceramic fiber itself is preferably 0.1 GPa or more,
particularly preferably 0.5 GPa or more.
[0040] The procedure for manufacturing the holding and sealing
material 1 will now be described.
[0041] First, an aluminum salt, a silica sol and an organic polymer
are mixed with water as a solvent to prepare a spinning solution.
In this case, an anti-foam agent and the like may be added to the
spinning solution. Furthermore, by changing the ratio between the
aluminum salt and the silica sol, the chemical composition of
alumina-silica based ceramic fibers can be controlled to some
extent.
[0042] Then, the obtained spinning solution is concentrated under
reduced pressure, thereby preparing a spinning solution of which
concentration, temperature, viscosity and the like are suitable for
spinning. Here, the spinning solution with the concentration of
about 20 wt % is preferably concentrated to about 30 to 40 wt
%.
[0043] In addition, the prepared spinning solution is made to
continuously issue into the atmosphere from the nozzle of a
spinning apparatus, and formed alumina-silica based ceramic fibers
are drawn and wound up. In this case, for example, a dry pressure
spinning method may be employed.
[0044] Long fibers of the alumina-silica based ceramic fibers
obtained through the above described spinning step are chopped into
a predetermined length to form relatively short fibers, and
thereafter the fibers are dispersed in water. The obtained fiber
dispersion is caused to flow into a molding jig to pressurize and
dry the fiber dispersant, thereby obtaining a mat-like material
with fibers stacked thereon.
[0045] The mat-like material (fiber aggregate) obtained through the
above described stacking step is subjected to a needle punch
treatment using the above described needle punch. By this
processing, uncured and flexible fibers are reliably and uniformly
intertwined.
[0046] Then, the fiber aggregate subjected to a needle punch
treatment is baked, whereby the uncured and flexible fibers are
dried and baked, and are thereby cured. In this case, baking
conditions should be set so that the content of mullite crystal in
the fiber aggregate obtained by baking is 10 wt % or less.
[0047] For example, the baking temperature in the baking step is
set to preferably 1100.degree. C. to 1300.degree. C. If the baking
temperature is lower than 1100.degree. C., the alumina-silica based
fibers may not be sufficiently dried and baked, and it may thus be
impossible to reliably achieve excellent heat-resistance and a high
level of resiliency against an applied compression load to the
holding and sealing material 1. Conversely, if the. baking
temperature is higher than 1300.degree. C., formation of the
mullite crystal easily proceeds in the alumina-silica based ceramic
fibers. Consequently, the content of mullite crystal can hardly be
kept at 10 wt % or less, and it may thus be impossible to reliably
achieve excellent heat-resistance and a high level of resiliency
against an applied compression load to the holding and sealing
material 1.
[0048] In addition, the baking time is set to preferably 1 to 60
minutes. If the baking time is shorter than 1 minute, the
alumina-silica based fibers may not be sufficiently dried and
baked, and it may thus be impossible to reliably achieve excellent
heat-resistance and a high level of resiliency against an applied
compression load to the holding and sealing material 1. Conversely,
if the baking time exceeds 60 minutes, formation of the mullite
crystal easily proceeds in the alumina-silica based ceramic fibers.
Consequently, the content of mullite crystal can hardly be kept at
10 wt % or less, and it may thus be impossible to reliably Achieve
excellent heat-resistance and a high level of resiliency against an
applied compression load to the holding and sealing material 1.
[0049] In addition, for baking the fiber aggregate at a high
temperature of 1100.degree. C. to 1300.degree. C., it is preferably
heated at 200.degree. C. to 400.degree. C. for about 10 to 60
minutes as a pretreatment.
[0050] Furthermore, after the above described baking step, the
holding and sealing material 1 may be impregnated with the organic
binder, and thereafter compressed in the direction of thickness as
necessary. The organic binder in this case is polyvinyl alcohol,
acryl resin as well as latex such as acryl rubber or nitrile rubber
or the like. For the impregnation method, a well known method such
as a dipping, spray, or roll-coater method may be employed.
[0051] Then, the holding and sealing material 1 prepared through
the above described steps is wound around the outer periphery of
the catalyst carrier 3 and thereby fixed, followed by carrying out
press fitting, canning or rolling-up to complete the catalytic
converter 5.
[Example 1]
[0052] (Preparation in Example 1)
[0053] In Example 1, a cogierite monolith having an outer diameter
of 130 mm and a length of 100 mm was used as the catalyst carrier
3. Also, a cylindrical shell made of SUS 304 and having a thickness
of 1.5 mm and an inner diameter of 140 mm was used as the metal
shell 2. The mat-like holding and sealing material 1 was prepared
in the following way.
[0054] First, 23.5 wt % of basic aluminum chloride, 20 wt % of
colloid silica, 10 wt % of polyvinyl alcohol and a small amount of
anti-foam agent (n-octanol) were mixed with water and sufficiently
stirred to prepare a spinning solution.
[0055] The obtained spinning solution was concentrated under
reduced pressure using an evaporator, whereby the concentration,
temperature and viscosity of the spinning solution was adjusted. In
this Example, the concentration of the spinning solution was set to
38 wt %, the temperature was set to 50.degree. C., and the
viscosity was set to 1000 poise, and the spinning solution was left
standing for one day.
[0056] The prepared spinning solution after being left standing for
one day or longer was made to continuously issue into the
atmosphere (20.degree. C., humidity of 50%) from the nozzle of a
dry pressure spinning apparatus and stacked.
[0057] Then, the fiber aggregate obtained through the above
described stacking step was subjected to a needle punch treatment
using the above described jig. Here, the abundance density of
needle punch spots was set to 100 spots per 100 cm.sup.2.
[0058] In addition, the fiber aggregate subjected to the needle
punch treatment was heated at 25.degree. C. for 30 minutes as a
pretreatment, and was thereafter baked at 1250.degree. C. for 10
minutes under a normal oxidizing atmosphere in a box type electric
furnace. As a result, alumina-silica based ceramic fibers with the
mullite crystal content of 2 wt % were obtained.
[0059] In this connection, the average diameter of alumina silica
based ceramic fibers obtained by baking was 9.1 .mu.m, and the
average length was 5 mm, and the fiber had an almost circular
section and a linear structure. Also, the density of the ceramic
fiber itself was 3.0 g/cm.sup.3, and the tensile strength thereof
was 0.65 GPa. The ceramic fiber had a composition of
Al.sub.2O.sub.3:SiO.sub.2=72:28, and had .gamma.-alumina and
.chi.-alumina as a main component.
[0060] After the above described baking step, the holding and
sealing material 1 was impregnated with the organic binder by the
dipping method, followed by compressing the holding and sealing
material 1 in the direction of thickness. Here, latex was selected
as the organic binder, and the concentration of latex was set to 1
wt % or less at this point.
[0061] The obtained bulk density of the holding and sealing
material 1 was about 0.15 g/cm.sup.3 at this time.
[0062] The holding and sealing material 1 prepared through the
above described steps was then wound around the outer periphery of
the catalyst carrier 3 and thereby fixed, and was thereafter
press-fitted in the metal shell 2 to complete the catalytic
converter 5.
[0063] (Preparation in Examples 2 to 5)
[0064] In Examples 2 to 5, fundamentally, the holding and sealing
material 1 was prepared in accordance with the procedure and
conditions in Example 1, and was mounted in the same manner as
Example 1 to complete the catalytic converter 5. In Examples 2 and
3, the temperature during baking was set to a temperature higher
than that of Example 1 so that the mullite crystal content was 3 wt
% and 9.8 wt %, respectively. Conversely, in Examples 4 and 5, the
temperature during baking was set to a temperature lower than that
of Example 1 so that the mullite crystal content was 0 wt % and 1
wt %, respectively. However, the baking temperature and the baking
time were set within the range of from 1100.degree. C. to
1300.degree. C. and from 1 to 60 minutes, respectively.
[0065] (Preparation in Comparative Examples 1 and 2)
[0066] In Comparative Examples 1 and 2, fundamentally, the holding
and sealing material 1 was prepared in accordance with the
procedure and conditions in Example 1, and was assembled in the
same manner as Example 1 to complete the catalytic converter 5.
However, in Comparative Examples 1 and 2, the temperature for
baking was set to a temperature higher than 1300.degree. C. As a
result, the mullite crystal contents were 15 wt % and 20 wt %,
respectively, both of which exceeded the mullite crystal contents
of Examples.
[0067] (Preparation in Comparative Example 3)
[0068] In Comparative Example 3, fundamentally, the holding and
sealing material 1 was prepared in accordance with the procedure
and conditions in Example 1, and was mounted in the same manner as
Example 1 to complete the catalytic converter 5. In Comparative
Example 3, however, a needle punch treatment was not carried out
and instead, the content of organic binder was increased to 15 wt %
to prepare the holding and sealing material 1. Furthermore, the
mullite crystal content was set to 15 wt %.
[0069] (Method of Comparison Test and Result)
[0070] The catalytic converters 5 of Examples 1 to 5 and
Comparative Examples 1 to 3 described above were set in a testing
apparatus, and an exhaust gas of 100.degree. C. was caused o flow
therethrough for 30 minutes, followed by measuring generated
contact pressure (MPa) of the holding and sealing material 1. The
results are shown in the graph of FIG. 4.
[0071] From this graph, it can be understood that highest contact
pressure was generated in Examples 1, 2 and 5, and high contact
pressure is generated in Examples 3 and 4. On the other hand, it
can be understood that in Comparative Examples 1, 2 and 3, the
values of generated contact pressure were smaller than those in the
Examples, resulting in apparently poor performance compared to the
Examples. Furthermore, the exhaust gas was caused to flow through
the testing apparatus for a prolonged time period, followed by
measuring the generated contact pressure, and it was found that the
generated contact pressure hardly dropped at least for the
Examples.
[0072] The assemblage of the holding and sealing material 1 is
satisfactory in any case.
[0073] In addition, when operating tests were conducted with the
catalytic converter 5 installed in a vehicle, and thereafter
observations were made, neither shifts in position and cracks in
the catalyst carrier 3 nor leakage of exhaust gas were not found at
all for the Examples. For Comparative Examples in which the
generated contact pressure was relatively low, shifts in position
and cracks easily occurred in the catalyst carrier 3. In addition,
in some Comparative Examples, exhaust gas was leaked.
[0074] Gas released to the environment through a muffler from the
catalytic converter 5 during the operating test was sampled, and
its components analyzed. As a result, the contents of CO, HC, NOx
and the like causing air pollution were extremely small for the
Examples, while for the Comparative Examples, the content of the
above described compounds were somewhat larger compared to the
Examples.
[0075] The holding and sealing material 1 of this embodiment
achieves the following advantages.
[0076] (1) The holding and sealing material 1 of this embodiment
comprises a fiber aggregate mainly comprised of alumina-silica
based ceramic fibers having a mullite crystal content of 10 wt % or
less. Consequently, it has excellent heat resistance and a high
level of resiliency against an applied compression load. Therefore,
even when the holding and sealing material 1 disposed in the gap is
exposed to high temperature, the generated contact pressure hardly
drops. Thus, if the catalytic converter 5 is fabricated using the
holding and sealing material 1, the catalytic converter 5 capable
of maintaining a high level of sealing performance and carrier
holding performance for a long period and having excellent
durability can be obtained.
[0077] (2) The fiber aggregate of the holding and sealing material
1 is subjected to a needle punch treatment. Consequently, some
ceramic fibers are intertwined at needle punch spots in the
direction of thickness of the fiber aggregate, and thus the
thickness of the fiber aggregate is reduced such that it is
compressed in the direction of thickness. Therefore, bulkiness of
the fiber aggregate is alleviated, thus bringing about excellent
assemblage. In addition, the amount of organic binder required for
reducing the thickness of the fiber aggregate can be reduced as it
is subjected to a needle punch treatment. Therefore, extremely
low-pollution characteristics can be achieved while maintaining
satisfactory assemblage.
[0078] (3) According to the method for manufacturing the holding
and sealing material in this embodiment, fibers can be intertwined
reliably and uniformly, thus making it possible to set the
abundance density of needle punch spots to a lower level. From the
fact described above and so on, according to this manufacturing
method, the above described holding and sealing material 1 for
catalytic converters can be obtained easily and reliably.
[0079] Furthermore, the embodiment of the present invention may be
changed as follows.
[0080] Fibers may be intertwined by a mechanical fiber
intertwinement processing method other than the needle punch
treatment. In addition, a non-mechanical fiber intertwinement
processing method utilizing water power, air power or the like may
be employed.
[0081] The form of the holding and sealing material 1 may freely be
changed. For example, concave and convex positional mating portions
11 and 12 may be eliminated to provide a simpler form.
[0082] The sectional form of the catalyst carrier 3 is not limited
to a circle, and for example, an elliptical or oblong form is
acceptable. In this case, the sectional form of the metal shell 2
may be changed to an elliptical or oblong form in accordance
therewith.
[0083] A material other than precious metals may be carried on the
catalyst carrier 3 as a catalyst.
[0084] For the catalyst carrier 3, a cogierite carrier formed into
a honeycomb shape is used, but a honeycomb porous sintered body
such as silicon carbide or silicon nitride, for example, may also
be used.
[0085] The holding and sealing material 1 of the present invention
may be used not only in the catalytic converter 5 for an exhaust
gas cleaning apparatus, but also in, for example, a diesel
particulate filter (DPF) and a catalytic converter for a fuel cell
reforming apparatus.
* * * * *