Holding material for gas treatment device, gas treatment device, and production processes therefor

Patent metadata

Field	Value
Publication number	US-9796634-B2
Application number	US-201214374066-A
Country	US
Kind code	B2
Filing date	Nov 14, 2012
Priority date	Jan 23, 2012
Publication date	Oct 24, 2017
Grant date	Oct 24, 2017

Abstract

Provided are a holding material for a gas treatment device, which is inexpensive, has a simple structure, and exhibits high holding force, a gas treatment device, and a method for manufacturing the same. A holding material for a gas treatment device according to the present invention is a holding material, which is a holding material to be arranged, in a gas treatment device including a treatment structure and a casing for housing the treatment structure, between the treatment structure and the casing, the holding material including silica fibers and an alumina sol in an amount of 3 parts by mass or more in terms of a solid content with respect to 100 parts by mass of the silica fibers.

First claim

The invention claimed is:

1. A holding material for a gas treatment device, which is arranged, in the gas treatment device comprising a treatment structure and a casing for housing the treatment structure, between the treatment structure and the casing,
the holding material comprising silica fibers at a content of 85 mass % or more with respect to the total mass of the holding material and an alumina sol in an amount of 3 parts by mass or more in terms of a solid content with respect to 100 parts by mass of the silica fibers,
wherein a content of alumina in the silica fibers is from 0 to 3 mass % with respect to the total mass of the silica fiber.

2. The holding material for a gas treatment device according to claim 1 , wherein the holding material exhibits a surface pressure 1.2 times or more as high as a surface pressure of a holding material free of the alumina sol, at a time of expansion at 1,000th cycle in an expansion/compression test employing an initial bulk density of from 0.3 to 0.5 g/cm 3 , a temperature of from 700 to 900° C., and a stroke amount of 0.2 mm.

3. A gas treatment device, comprising:
a treatment structure;
a casing for housing the treatment structure; and
a holding material according to claim 2 arranged between the treatment structure and the casing.

4. A method for manufacturing a gas treatment device comprising a treatment structure, a casing for housing the treatment structure, and a holding material arranged between the treatment structure and the casing,
the method comprising arranging the holding material according to claim 2 between the treatment structure and the casing.

5. The holding material for a gas treatment device according to claim 1 , wherein the holding material exhibits a surface pressure 1.5 times or more as high as a surface pressure of a holding material free of the alumina sol, at a time of expansion at 1,000th cycle in an expansion/compression test employing an initial bulk density of from 0.3 to 0.5 g/cm 3 , a temperature of from 240 to 300° C., and a stroke amount of 0.08 mm.

6. A gas treatment device, comprising:
a treatment structure;
a casing for housing the treatment structure; and
a holding material according to claim 5 arranged between the treatment structure and the casing.

7. A method for manufacturing a gas treatment device comprising a treatment structure, a casing for housing the treatment structure, and a holding material arranged between the treatment structure and the casing,
the method comprising arranging the holding material according to claim 5 between the treatment structure and the casing.

8. A gas treatment device, comprising:
a treatment structure;
a casing for housing the treatment structure; and
a holding material according to claim 1 arranged between the treatment structure and the casing.

9. A method for manufacturing a gas treatment device comprising a treatment structure, a casing for housing the treatment structure, and a holding material arranged between the treatment structure and the casing,
the method comprising arranging the holding material according to claim 1 between the treatment structure and the casing.

10. The holding material for a gas treatment device according to claim 1 , wherein the content of alumina in the silica fibers is from 1 to 3 mass % with respect to the total mass of the silica fiber.

11. A method for manufacturing a holding material for a gas treatment device, which is arranged, in the gas treatment device comprising a treatment structure and a casing for housing the treatment structure, between the treatment structure and the casing,
the method comprising manufacturing the holding material by wet molding of a slurry comprising silica fibers at a content of 85 mass % or more with respect to the total mass of the holding material and an alumina sol in an amount of 3 parts by mass or more in terms of a solid content with respect to 100 parts by mass of the silica fibers,
wherein a content of alumina in the silica fibers is from 0 to 3 mass % with respect to the total mass of the silica fiber.

12. The method for manufacturing a holding material for a gas treatment device according to claim 11 , wherein the holding material is manufactured, and exhibits a surface pressure 1.2 times or more as high as a surface pressure of a holding material free of the alumina sol, at a time of expansion at 1,000th cycle in an expansion/compression test employing an initial bulk density of from 0.3 to 0.5 g/cm 3 , a temperature of from 700 to 900° C., and a stroke amount of 0.2 mm.

13. The method for manufacturing a holding material for a gas treatment device according to claim 11 , wherein, the holding material is manufactured, and exhibits a surface pressure 1.5 times or more as high as a surface pressure of a holding material free of the alumina sol, at a time of expansion at 1,000th cycle in an expansion/compression test employing an initial bulk density of from 0.3 to 0.5 g/cm 3 , a temperature of from 240 to 300° C., and a stroke amount of 0.08 mm.

Assignees

• Nichias Corp

Inventors

• Satoh Junya
• Tomosue Nobuya
• Isomura Kazutoshi
• Sato Kiyoshi
• Sakane Tadashi
• Nakamura Hiroki

Classifications

• Y10T29/49345

  Catalytic device making · CPC title

• F01N3/2835

  fibrous · CPC title

• F01N3/2853

  using mats or gaskets between catalyst body and housing · CPC title

• D21H13/38 Primary

  siliceous · CPC title

• F01N2310/02

  Mineral wool, e.g. glass wool, rock wool, asbestos or the like · CPC title