Holding material for catalytic converter and method for producing the same

a technology of catalytic converter and holding material, which is applied in the direction of machines/engines, mechanical equipment, separation processes, etc., can solve the problems of alumina fiber mat, surface pressure is slightly reduced in comparison with other fiber mats in equal density, and the temperature of not less than 600.degree. c of ceramic fiber ma

Inactive Publication Date: 2003-10-02
NICHIAS CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

The ceramic fiber mat however has a problem that the ceramic fiber mat cannot be used at a temperature of not lower than 600.degree. C.
On the other hand, the alumina fiber mat has a disadvantage in that surface pressure is slightly reduced in comparison with other fiber mats in equal density.
Accordingly, the cost increases because it is necessary to increase the density in order to increase the surfac

Method used

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  • Holding material for catalytic converter and method for producing the same
  • Holding material for catalytic converter and method for producing the same

Examples

Experimental program
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Effect test

example 1

[0036] Into water, 97 parts by weight of alumina fiber of low crystallinity containing 96% by weight of Al.sub.2O.sub.3 (and SiO.sub.2 as a residual component) and having a fiber size of about 4 .mu.m and a fiber length of about 3 mm, and 5 parts by weight of an organic binder (acrylic emulsion) were dispersed to prepare an alumina fiber-containing aqueous slurry. On the other hand, 97 parts by weight of mullite fiber of low crystallinity containing 80% by weight of Al.sub.2O.sub.3 (and SiO.sub.2 as a residual component) and having a fiber size of about 4 .mu.m and a fiber length of about 3 mm, and 3 parts by weight of an organic binder (acrylic emulsion) were dispersed into water to prepare a mullite fiber-containing aqueous slurry.

[0037] First, the alumina fiber-containing aqueous slurry was molded by suction dehydration and dried to produce an alumina fiber mat having grammage (areal density) of 400 g / m.sup.2. Then, the mullite fiber-containing aqueous slurry was applied on one s...

second embodiment

[0045] Second Embodiment

[0046] FIG. 2 is a sectional view schematically showing a catalytic converter provided with a holding material according to a second embodiment of the invention. The configuration of the catalytic converter is the same as that of a related-art catalytic converter except that the holding material 3 according to the invention is constituted by a mixture of alumina fiber and mullite fiber.

[0047] The holding material 3 can be shaped like a flat mat. When the holding material 3 is molded into a shape according to the contour shape (e.g., cylindrical shape in FIG. 2) of a catalyst carrier 1, the holding material 3 can be directly mounted on the catalyst carrier 1 to facilitate production of the catalytic converter.

[0048] Materials suitably selected from known materials heretofore used in a holding material can be used as the alumina fiber and the mullite fiber. The material preferably used as the alumina fiber is fiber containing 90% by weight or more of Al.sub.2O....

example of second embodiment

[0061] The invention will be described below more specifically in connection with the following Examples and Comparative Examples but the invention is not limited thereto at all.

[0062] Alumina fiber of low crystallinity containing 96% by weight of Al.sub.2O.sub.3 (and SiO.sub.2 as a residual component) and having a mean fiber size of about 3 .mu.m and a wet volume of 800 cc / 5 g was mixed with mullite fiber of low crystallinity containing 80% by weight of Al.sub.2O.sub.3 (and SiO.sub.2 as a residual component) and having a mean fiber size of about 4 .mu.m and a wet volume of 800 cc / 5 g while the mixture ratio (weight ratio) of alumina fiber to mullite fiber was changed variously to (1) 100% of alumina fiber, (2) 75% of alumina fiber and 25% of mullite fiber, (3) 50% of alumina fiber and 50% of mullite fiber, (4) 25% of alumina fiber and 75% of mullite fiber, and (5) 100% of mullite fiber. With respect to 100 parts by weight of each of the thus obtained mixtures, 8 parts, by weight of...

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Abstract

A holding material for a catalytic converter is interposed in a gap between a catalyst carrier and a metal casing receiving the catalyst carrier. The holding material includes a mat including alumina fiber and mullite fiber, wherein the alumina fiber and the mullite fiber are unitarily collected to form the holding material having a predetermined thickness.

Description

[0001] 1. Field of the Invention[0002] The present invention relates to a holding material for a catalytic converter, for example, for purging exhaust gas emitted from an automobile, and a method for producing the holding material for the catalytic converter.[0003] 2. Description of the Related Art[0004] As known commonly, a catalytic converter for purging exhaust gas is mounted in a vehicle such as an automobile in order to remove detrimental components such as carbon monoxide, hydrocarbon, and nitrogen oxides from exhaust gas emitted from an engine of the vehicle. Generally, as shown in FIG. 2 which is a sectional view, the catalytic converter has a catalyst carrier 1 shaped like a cylinder, a metal casing 2 for receiving the catalyst carrier 1, and a holding material 3 interposed in a gap between the catalyst carrier 1 and the casing 2 while mounted on the catalyst carrier 1.[0005] Generally, the catalyst carrier 1 has a cylindrical honey-comb molded material, for example, made o...

Claims

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Application Information

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IPC IPC(8): F01N3/28
CPCB32B18/00C04B2237/76C04B2235/5224C04B2235/5228C04B2235/526C04B2235/5264C04B2237/38F01N3/2853F01N3/2864C04B35/632C04B35/63424C04B2235/656C04B2237/341C04B2237/343C04B2237/50C04B2237/704C04B35/80C04B35/82C04B2235/5232
Inventor ANJI, TOSHIYUKITANAKA, MASAFUMISAKANE, TADASHIMOCHIDA, TAKAHITO
Owner NICHIAS CORP
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