Inorganic staple fiber accumulation for holding material, process for producing the same and holding material

• US 7,182,999 B2
• Filed: 06/26/2003
• Issued: 02/27/2007
• Est. Priority Date: 06/28/2002
• Status: Active Grant

• Current Assignee: Denki Kagaku Kogyo Kabushiki Kaisha (TDK Corporation)
• Original Assignee: Denki Kagaku Kogyo Kabushiki Kaisha (TDK Corporation)
• Inventors: Ohashi, Hiroyuki, Saito, Tomoo, Fuji, Koichi
• Primary Examiner(s): EDWARDS, NEWTON O
• Application Number:
  US10/517,618
• Publication Number:
  US 20050227058A1
• Time in Patent Office: 1,342 Days
• Field of Search: 428/292.1, 428/116, 501/95.2, 264/628, 555/24
• US Class Current: 428/292.1
• CPC Class Codes: B01J 21/12 Silica and alumina
• CPC Class Codes: B01J 35/40 characterised by dimensions, e.g. grain size in a colloidal state B01J35/23; crystallite size B01J35/77
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 35/58 Fabrics or filaments
• CPC Class Codes: B01J 35/612 less than 10 m2/g
• CPC Class Codes: C04B 2235/3218 Aluminium (oxy)hydroxides, e.g. boehmite, gibbsite, alumina sol
• CPC Class Codes: C04B 2235/3463 Alumino-silicates other than clay, e.g. mullite
• CPC Class Codes: C04B 2235/5264 characterised by the diameter of the fibers
• CPC Class Codes: C04B 2235/5409 expressed by specific surface values
• CPC Class Codes: C04B 2235/656 characterised by specific heating conditions during heat treatment
• CPC Class Codes: C04B 2235/6562 Heating rate
• CPC Class Codes: C04B 2235/6567 Treatment time
• CPC Class Codes: C04B 2235/661 Multi-step sintering
• CPC Class Codes: C04B 2235/80 Phases present in the sintered or melt-cast ceramic products other than the main phase
• CPC Class Codes: C04B 2235/96 Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• CPC Class Codes: C04B 35/62236 Fibres based on aluminium oxide
• CPC Class Codes: C04B 35/62245 rich in aluminium oxide
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: D01F 9/08 of inorganic material working or processing of metal wire B21F; from softened glass, minerals or slags C03B37/00
• CPC Class Codes: D04H 1/4209 Inorganic fibres
• CPC Class Codes: D04H 1/43838 : Ultrafine fibres, e.g. microfibres
• CPC Class Codes: D04H 1/72 : the fibres being randomly arranged
• CPC Class Codes: F01N 2450/02 : Fitting monolithic blocks into the housing
• CPC Class Codes: F01N 3/0222 : the structure being monolithic, e.g. honeycombs
• CPC Class Codes: F01N 3/2828 : Ceramic multi-channel monoliths, e.g. honeycombs
• CPC Class Codes: F01N 3/2853 : using mats or gaskets between catalyst body and housing
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like
• CPC Class Codes: Y10T 428/249924 : Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity

Abstract

An aggregate with small fiber deterioration even after being held under compression under heating at about 1,000° C. for a long term, and a holding material of e.g. a catalyst carrier of a catalyst converter or a honeycomb body of DPE employing it, are provided. An inorganic short fiber aggregate for a holding material, which is an aggregate of inorganic short fibers having a chemical composition of from 74 to 86 mass % of an alumina component and from 26 to 14 mass % of a silica component and having a mineral composition of from 15 to 60 mass % of mullite, wherein the average fiber diameter of the aggregate is from 2 to 8 μm, at least 99% (including 100%) of the number of the inorganic short fibers consists of fibers having fiber diameters of from 1.5 to 15 μm, and the specific surface area is at most 10 m²/g. Its production process, and a holding material consisting of a sheet-shape formed product comprising the aggregate and an organic binder contained in the aggregate, wherein inorganic short fibers are employed.

Claims

1. An inorganic short fiber aggregate for a holding material, which is an aggregate of inorganic short fibers, characterized in that the specific surface area is at most 10 m²/g, at least 99% (including 100%) of the number of the inorganic short fibers consists of inorganic short fibers having fiber diameters of from 1.5 to 15 μ

m, and the inorganic short fibers have a chemical composition of from 74 to 86 mass % of an alumina component and from 26 to 14 mass % of a silica component and a mineral composition of from 15 to 60 mass % of mullite, and have an average fiber diameter of from 2 to 8 μ

m.

2. The inorganic short fiber aggregate for a holding material according to claim 1, wherein when 50 g of the aggregate is put in a stainless steel cylindrical container having a diameter of 80 mm and a depth of 150 mm, a pressure is applied thereto from the upper side, the pressure is released when it reaches 20 MPa, and elutriation classification of the crushed inorganic short fiber aggregate is carried out, the recovered solid material such as fibers is at most 10 mass % when the flow rate of water is 0.50 l/min, at most 5 mass % when the flow rate is 1.38 l/min, and at most 1 mass % when the flow rate is 5.54 l/min.

3. The inorganic short fiber aggregate for a holding material according to claim 1 or 2, wherein the bulk specific gravity in water as an index of the fiber strength is from 0.012 to 0.025, as obtained from the sediment volume obtained in such a manner that 5 g of the aggregate is stirred in 400 ml of water at 1,000 rpm for 10 minutes and then put in a measuring cylinder of 500 ml, water is added so that the total volume becomes 500 ml, and the liquid is left to stand for 30 minutes.

4. A process for producing the inorganic short fiber aggregate for a holding material as defined in claim 1, 2 or 3, which comprises mixing an aluminum oxychloride aqueous solution having a transmittance of at least 80%, a silica sol having a transmittance of at least 75% and a spinning aid to prepare a spinning stock solution having an alumina/silica mass ratio of from 74 to 86%/26 to 14% (total amount of both:

100%) and a viscosity of from 1,000 to 8,000 mPa·

s, supplying the spinning stock solution to a hollow disk having a plurality of pores having a diameter of from 0.10 to 30 mm formed on the circumferential surface and discharging the spinning stock solution from the hollow disk, at from 8 to 20 ml/hr per one pore, while rotating the hollow disk at a circumferential speed of from 30 to 80 m/sec, to form the spinning stock solution into fibers, followed by drying, aggregation and firing.

5. The process for producing the inorganic short fiber aggregate for a holding material according to claim 4, wherein the firing is carried out by using a continuous furnace in such a manner that at the first half stage, the fibers are heated from room temperature to 800 to 1,000°

C. at from 10 to 20°

C./min at a wind speed in the furnace of from 1 to 5 m/sec, and subsequently at the second half stage of the continuous furnace, the fibers are heated to the maximum temperature of from 1,200 to 1,300°

C. at from 20 to 30°

C./min and held at the maximum temperature for from 15 to 30 minutes.

6. A holding material consisting of a sheet-shape formed product comprising the inorganic short fiber aggregate for a holding material as defined in claim 1, 2 or 3, and an organic binder contained in the gap of the aggregate.

7. The holding material according to claim 6, which is a holding material for fixing a catalyst carrier of an automotive exhaust gas clarifying catalyst converter, or a holding material for fixing a honeycomb body for a diesel particulate filter.