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Pollution control device and mat for mounting a pollution control element

a technology of pollution control and mounting mat, which is applied in the direction of machines/engines, separation processes, manufacturing tools, etc., can solve the problems of reducing the holding strength of the catalyst support, under a significant decrease in strength, etc., and achieve the effect of maintaining the holding strength of the support and not impairing elasticity

Inactive Publication Date: 2007-06-21
3M INNOVATIVE PROPERTIES CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0007] According to the present invention, a mat for mounting a pollution control element, like a catalyst support, can be provided that maintains support holding strength without impairing elasticity even when exposed to temperatures in excess of 800° C. for long periods of time.

Problems solved by technology

However, expanding materials such as the vermiculite, expanding graphite or expanding sodium silicate and so forth used in Japanese Unexamined Patent Publication No. 2002-514283 deteriorate when exposed to temperatures of 800-1000° C., and under a significant decrease in strength.
In addition to the thermal deterioration, a mechanical shock such as decreases the holding strength of the catalyst support.

Method used

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  • Pollution control device and mat for mounting a pollution control element
  • Pollution control device and mat for mounting a pollution control element
  • Pollution control device and mat for mounting a pollution control element

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0026] 92 wt % of alumina fibers, composed of 72 wt % of alumina and 28 wt % of silica, were mixed with 8 wt % of binder (acrylic latex, Nippon Zeon: Nippore LX-816) followed by the addition of water to prepare a first slurry. In addition, 92 wt % of silica fibers (Shinnikka Thermal Ceramics: SC-1260D1), formed by melting and composed of 46 wt % of alumina and 53 wt % of silica, were mixed with 8 wt % of the above binder followed by the addition of water to prepare a second slurry. Samples 1 through 5 of mats for mounting a catalyst support having the weighing capacity ratios between the alumina fiber layer and ceramic fiber layer shown in Table 1 were obtained by the above ordinary rolling method using these slurries.

example 2

[0027] With the exception of using ceramic fibers that were annealed for 60 minutes at a temperature of 1000° C., samples 6 through 8 of mats for mounting a catalyst support shown in Table 2 were obtained in the same manner as Example 1.

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Abstract

A mat for mounting a pollution control element (e.g., a catalytic converter and diesel particulate filter, etc.) that maintains support holding strength without impairing elasticity even when exposed to high temperatures in excess of 800° C. for long periods of time, and a pollution control device that includes such a mat. The mat comprises at least two layers, an alumina fiber layer and a ceramic fiber layer, that are formed into a single sheet without the use of an auxiliary bonding means.

Description

FIELD OF THE INVENTION [0001] The present invention relates to pollution control devices (e.g., catalytic converters, diesel particulate filters, etc.), to mats for mounting pollution control elements in such devices and, in particular, to catalytic converters used in exhaust gas purification devices and, more particularly, to a mat for mounting a catalyst support in a catalytic converter housing. BACKGROUND [0002] Catalytic converters used in the exhaust gas purification devices of automobile and diesel engines normally contain a catalyst support composed of a monolith having a so-called “honeycomb structure” in which through holes are arranged in the shape of honeycombs, in a metal housing. This monolith is loaded with a catalyst such as a precious metal, and purifies exhaust gas by oxidizing carbon monoxide and hydrocarbons and reducing nitrogen oxides. This monolith catalyst support is formed from a metal or ceramic material. In order to receive the catalyst support in a metal h...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): F01N3/28B01D53/88B01D53/94B28B1/00B28B1/52C04B30/02D04H13/00F01N3/021
CPCB01D53/88B01D53/9454B01D2265/06B01D2279/30B28B1/008B28B1/527C04B30/02C04B2111/00612C04B2111/00793D04H13/002F01N3/0211F01N3/2853F01N3/2864F01N2330/02F01N2330/06C04B14/46C04B14/4625C04B40/00C04B40/006C04B40/0259C04B40/0263Y02T10/22D04H1/4209D04H1/4374D04H1/732Y02A50/20Y02T10/12F01N3/20F01N3/28
Inventor WATANABE, TOSHIYUKIMIYASAKA, MUNEKI
Owner 3M INNOVATIVE PROPERTIES CO
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