| Holding and sealing material and manufacturing method thereof -> Monitor Keywords |
|
|
  Holding and sealing material and manufacturing method thereofUSPTO Application #: 20060278323Title: Holding and sealing material and manufacturing method thereof Abstract: The present invention relates to a holding and sealing material 2 set between a catalyst carrier 1 and a shell 95 which covering the outside of the catalyst carrier 1 in a catalytic converter for purifying an exhaust gas and manufacturing method thereof. An organic binder 22 on the holding and sealing material 2 has the glass transition point Tg (° C.) of less than or equal to approximately 5° C. In addition, an infiltrating step and a drying step are conducted during the manufacturing. In the infiltrating step, the mat-like material is infiltrated with emulsion containing the organic binder. In the drying step, the mat-like material containing the emulsion is dried. (end of abstract) Agent: C. Irvin Mcclelland Oblon, Spivak, Mcclelland, Maier & Neustadt, P.C. - Alexandria, VA, US Inventor: Masayuki Eguchi USPTO Applicaton #: 20060278323 - Class: 156062600 (USPTO) Related Patent Categories: Adhesive Bonding And Miscellaneous Chemical Manufacture, Methods, Surface Bonding And/or Assembly Therefor, With Formation Of Lamina By Bulk Deposition Of Discrete Particles To Form Self-supporting Article, By Joining Portions Of Batt To Itself The Patent Description & Claims data below is from USPTO Patent Application 20060278323. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCES TO RELATED APPLICATIONS [0001] The present application claims priority under 35 U.S.C. .sctn.119 to Japanese Patent Application No. 2005-171221, filed Jun. 10, 2005, entitled "HOLDING AND SEALING MATERIAL AND MANUFACTURING METHOD THEREOF". The contents of this application are incorporated herein by reference in their entirety. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a holding and sealing material of a catalytic converter for purifying an exhaust gas discharged from an internal combustion engine or the like. [0004] 2. Discussion of the Background [0005] As shown in FIG. 5, conventionally, a catalytic converter 90 for purifying an exhaust gas has been used for purifying an exhaust gas discharged from an internal combustion engine 92 or the like. The catalytic converter 90 has a catalyst carrier 1, a shell 95 made of metal and covering the outside of the catalyst carrier, and a holding and sealing material 91 which is set between the both. The holding and sealing material 91 can prevent the exhaust gas from leaking out from between the catalyst carrier 1 and the shell 95, and also, it can prevent the catalyst carrier 1 from damage in contact with the shell 95. [0006] At a time of manufacturing the catalytic converter 90, the holding and sealing material 91 is wound around the catalyst carrier 1, and the wound unit is set within the shell 95. Then, an inlet connection 97 and an outlet connection 98 are respectively connected to both ends of the shell 95 by welding. The catalytic converter 90 manufactured in the manner mentioned above is set in the middle of a pipe 99 for an exhaust gas discharged from the engine 92. [0007] As the holding and sealing material 91, the material made by infiltrating a mat-like material 911 made of alumina-silica based ceramic fibers (inorganic fibers) or the like with an organic binder 912 has been used. Because the holding and sealing material 91 is an aggregate of filaments and its specific gravity is small, there is a risk that a part of the inorganic fibers flies in all directions in the air from a surface of the holding and sealing material 91 at a time of manufacturing the catalytic converter 90 by mounting the holding and sealing material 91 in the catalyst carrier 1 and the shell 95,. Therefore, there is a risk of deteriorating a working environment of a working area for the mounting work, and it is necessary for a worker to work with wearing an antidust mask or the like. [0008] For the prevention of the inorganic fibers flying, alumina fibers aggregate whose average fiber diameter and minimum fiber diameter are controlled to specific range has been developed so far (refer to Patent document 1). When the alumina fibers aggregate is assembled to the catalyst carrier 1 and the shell 95 as the holding and sealing material 91, it is possible to reduce a flying amount of inorganic fibers (alumina). [0009] However, it was impossible to adequately reduce a flying amount of inorganic fibers even by a conventional holding and sealing material 91 whose fiber diameter is controlled. Therefore, there is a risk that a part of the inorganic fibers flies in all directions in the air while at work and a working environment is deteriorated. [0010] [Patent document 1] JP 2003-105658 Unexamined Patent Publication (Kokai) SUMMARY OF THE INVENTION [0011] According to a preferred embodiment first aspect of the present invention, there is provided a manufacturing method of a holding and sealing material which is configured to be set between a catalyst carrier and a shell covering the outside of the catalyst carrier in a catalytic converter for purifying an exhaust gas comprising: [0012] a infiltrating step for infiltrating a mat-like material formed by arranging inorganic fibers in a mat shape with emulsion made by dispersing a organic binder into water; and [0013] a drying step for attaching the organic binder to the mat-like material by means of drying the mat-like material containing the emulsion and obtaining the holding and sealing material, [0014] wherein the organic binder has a glass transition point Tg (.degree. C.) of less than or equal to approximately 5.degree. C. [0015] In the manufacturing method of the holding and sealing material of the preferred embodiment of the present invention, the infiltrating step and the drying step are conducted as described above. [0016] In the infiltrating step, the mat-like material formed by arranging inorganic fibers in a mat shape is infiltrated with emulsion made by dispersing the organic binder into water. Moreover, in the drying step, by drying the mat-like material containing the emulsion, liquid ingredient in the emulsion is evaporated. As a result, the organic binder is attached to a surface and inside and the like of the mat-like material, and the holding and sealing material is obtained. [0017] Furthermore, in the manufacturing method of the holding and sealing material of the preferred embodiment of the present invention, an organic binder with a low glass transition point Tg (.degree. C.) of less than or equal to 5.degree. C. is used as the organic fiber. Therefore, the organic binder attached to the holding and sealing material can exhibit high motility rubbery state at room temperature (e.g. temperature which is equal to or more than glass transition point of the organic binder). Accordingly, at a time of mounting the holding and sealing material in the catalyst carrier and the shell, the organic binder can combine the inorganic fibers each other of the mat-like material and also can exhibit excellent extensity, and it is possible to absorb damage such as a shock or the like given to the holding and sealing material. Thus, it is possible to suppress a break of the inorganic fibers of the holding and sealing material, and to prevent the inorganic fibers from flying in all directions from the holding and sealing material. Therefore, the workers can comfortably work without wearing the antidust mask or the like and it is possible to keep the working environment of the working area for the mounting work good. [0018] As described above, in the holding and sealing material obtained by the manufacturing method of the preferred embodiment of the present invention, the organic binder can suppress a break of the inorganic fibers of the mat-like material and can hold the inorganic fibers. Therefore, the holding and sealing material can prevent the inorganic fibers from flying in all directions without increasing an amount of an inorganic binder. [0019] According to the preferred embodiment of the present invention, there is provided a holding and sealing material which is configured to be set between a catalyst carrier and a shell covering the outside of the catalyst carrier in a catalytic converter for purifying an exhaust gas comprising: [0020] a mat-like material formed by arranging inorganic fibers in a mat shape; and [0021] an organic binder with a glass transition point Tg (.degree. C.) of less than or equal to approximately 5.degree. C. which is attached to the mat-like material. Continue reading... Full patent description for Holding and sealing material and manufacturing method thereof Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Holding and sealing material and manufacturing method thereof patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Holding and sealing material and manufacturing method thereof or other areas of interest. ### Previous Patent Application: Shaping of air permeable structural members with thermoplastic binders Next Patent Application: Mounting device and method thereof Industry Class: Adhesive bonding and miscellaneous chemical manufacture ### FreshPatents.com Support Thank you for viewing the Holding and sealing material and manufacturing method thereof patent info. IP-related news and info Results in 0.9686 seconds Other interesting Feshpatents.com categories: Software: Finance , AI , Databases , Development , Document , Navigation , Error |
||
