CN102686302A - 用于污染控制装置的低剪切安装垫 - Google Patents

用于污染控制装置的低剪切安装垫 Download PDF

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CN102686302A
CN102686302A CN2010800438035A CN201080043803A CN102686302A CN 102686302 A CN102686302 A CN 102686302A CN 2010800438035 A CN2010800438035 A CN 2010800438035A CN 201080043803 A CN201080043803 A CN 201080043803A CN 102686302 A CN102686302 A CN 102686302A
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weight
fiber
pad
yue
installation pad
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CN102686302B (zh
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M·博哈诺瓦
A·库马
M·D·斯塔尔曼
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Unifrax 1 LLC
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Unifrax Corp
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Abstract

本发明涉及用于废气处理装置(10)的安装垫(20)，所述安装垫(20)包含含有氧化铝的耐高温陶瓷纤维和/或耐高温生物可溶性无机纤维、在粘合剂烧尽之前在高温下至少部分地液化的有机粘合剂、胶体无机氧化物和任选的膨胀性材料。所述废气处理装置(10)包括外壳(12)、弹性安装在外壳(12)内的脆性催化剂承载结构(18)和布置在外壳(12)与脆性催化剂承载结构(18)之间的间隙中的安装垫(20)。

Description

用于污染控制装置的低剪切安装垫
处理废气的装置，诸如催化式排气净化器或柴油机颗粒捕集器。所述装置包括通过安装垫安装在外壳内的脆性结构，所述安装垫布置在外壳和脆性结构之间的间隙中。
废气处理装置用于汽车上以降低发动机排放物的大气污染。广泛使用的废气处理装置的实例包括催化式排气净化器、柴油机颗粒捕集器及其他污染控制装置。
用于处理汽车发动机的废气的催化式排气净化器包括外壳、用于保持用以进行一氧化碳和烃的氧化和氮氧化物的还原的催化剂的脆性催化剂承载结构和布置在脆性催化剂承载结构的外表面与外壳的内表面之间以将脆性催化剂承载结构弹性保持在外壳内的安装垫。
用于控制由柴油发动机产生的污染的柴油机颗粒捕集器通常包括外壳、用于收集来自柴油发动机排放物的颗粒的脆性颗粒过滤器或捕集器、和布置在过滤器或捕集器的外表面与外壳的内表面之间以将脆性过滤器或捕集器结构弹性保持在外壳内的安装垫。
脆性结构通常包含由金属易碎材料或脆性陶瓷材料诸如氧化铝、二氧化硅、氧化镁、氧化锆、堇青石、碳化硅等制成的单片结构。这些材料提供具有多个气体流动通道的骨架型结构。这些单片结构可以是如此脆弱，以至于即使小的冲击载荷或应力也经常足以破裂或压碎它们。为了保护脆性结构免受热和机械冲击和其他上述的应力，以及为了提供热绝缘和气密性，使安装垫位于脆性结构与外壳之间的间隙中。
所用的安装垫材料应当能够满足由脆性结构制造者或废气处理装置制造者所提出的许多设计或物理要求中的任何一个。例如，该安装垫材料应当能够在脆性结构上产生有效的残留保持压力，即使当废气处理装置经历大范围的温度波动时也应当如此，该大范围的温度波动引起了金属外壳相对于该脆性结构而言明显的膨胀和收缩，这依次引起了安装垫在一定的时期内明显的压缩和释放循环。
在废气处理装置中所用的陶瓷和金属基底大部分时候安装在具有基于无机纤维的安装垫的金属外壳内。该安装垫材料可仅含有无机纤维。然而，该安装垫材料还可含有其他类型的纤维、有机粘合剂、无机填料和/或膨胀性材料。
安装垫必须在宽范围操作温度内起作用以有效地将基底保持在适当的位置。基底由于振动而经受作用在基底上的轴向力。安装垫还对金属外壳比基底本身更大或更小地膨胀的事实进行补偿。各种废气处理装置在约20℃的环境条件至约1200℃的整个温度范围内操作。因此，安装垫必须在该宽温度范围内提供稳固的保持压力性能。
从更有效的发动机设计或柴油驱动车辆数量的增加而言，由于低温应用变得越来越普遍，因此对于安装垫能够在低温和高温二者中都表现出色的要求增加。
在诸如涡轮增压直喷式(TDI)柴油驱动车辆的低温应用中，废气温度通常为约150℃且可能不会超过300℃。已经在本领域中观察到，在这类车辆中使用的用典型膨胀垫组装的废气处理装置以出乎意料的高频率失效。
虽然不希望受理论限制，但造成这些失效的一个原因可能是废气的温度太低而不能迅速烧尽有机粘合剂，所述有机粘合剂在周围温度至约350℃的温度范围内可至少部分地液化。“至少部分地液化”是指有机粘合剂变软，以粘度降低为特征，使得有机粘合剂可至少部分地流动。随着有机粘合剂开始液化，安装垫内的纤维可开始彼此滑动，使得安装垫致密，这导致负膨胀和安装垫的剪切强度和保持力损失。从室温至约200℃，保持力逐渐损失。然而，保持力从约200℃至约250℃迅速损失。当随后用于低温应用时，垫可能不能对脆性结构提供足够的压力，且使用该安装垫的废气处理装置会失效。
在高于350℃的温度下，通常存在于安装垫中的膨胀粒子膨胀并增加垫对脆性结构的保持力。然而，在诸如安装垫不会经历高于350℃的温度的上述那些应用的应用中，膨胀性材料不暴露于足以导致其膨胀的温度，且安装垫不会受益于由该膨胀引起的保持力增加。
先前已经进行了改善废气处理装置的安装垫材料的低温性能的尝试。一种这样的尝试涉及将膨胀性粒子包括在安装垫中，其在有机粘合剂具有不利的影响的整个温度范围内发生膨胀(即，体积增加)。不幸的是，这样的膨胀粒子在如下温度下连续膨胀，该温度远高于有机粘合剂对垫性能表现出它们的不利影响的温度；且因此在较高温度下提供不合需要的膨胀。
在工业中所需的是用于废气处理装置的柔性安装垫，其能够容易地安装，并且其能够在宽范围的入口气体温度内起作用，而没有垫厚度和相应的剪切强度和保持压力性能的明显损失。
图1显示包括本发明的安装垫的说明性废气处理装置的片断图。
图2为与现有技术的安装垫相比，用以测试本发明的安装垫的设备的简化示意图。
图3为比较本发明的安装垫和现有技术安装垫的作为热面温度(℃)的函数的剪切强度损失％的图表。
图4为比较本发明的安装垫与现有技术安装垫的作为热面温度(℃)的函数的剪切强度损失％的图表。
提供用于废气处理装置应用的安装垫。所述安装垫包括至少一种板层或薄片，其由耐热无机纤维、有机粘合剂和胶体无机氧化物构成。根据某些实施方案，所述安装垫可以任选包含膨胀性材料。已经出乎意料地发现将诸如胶体氧化铝、胶体氧化硅或胶体氧化锆的胶体无机氧化物包含在所述安装垫中降低了垫在350℃和更低温度下经历的剪切应变。所述安装垫提供了以相对低的成本在宽温度范围内改善的保持性能。
还提供了用于处理废气的装置。所述装置包括外金属外壳、通过布置在外壳内表面与脆性结构外表面之间的安装垫安装在外壳内的至少一种脆性结构。术语“脆性结构”意欲表示并且包括例如金属或陶瓷单片等的结构，所述结构可为脆性或本质上易碎的，并且其将受益于诸如本文所述的安装垫。
催化式排气净化器催化剂结构通常包括通过耐热材料安装在外壳内的一种或多种多孔管状或蜂窝状结构。各结构在每平方英寸上可包括约200-约900个或更多个通道或小室，这取决于废气处理装置的类型。柴油机颗粒捕集器不同于催化式排气净化器的结构之处在于在颗粒捕集器内的各通道或小室在一端封闭。将颗粒从废气中收集到所述多孔结构中，直到通过高温烧尽方法进行再生。安装垫的非汽车应用可包括用于化工排放(废气)烟道的催化式排气净化器。
用于处理废气的装置的一种说明性形式在图1中用数字10来表示。应当理解该安装垫并非意欲限制于用于图1中所示的装置中，并且因此该形状仅作为一种说明性实施方案来显示。实际上，安装垫可用于安装或承载适于处理废气的任何脆性结构，例如柴油机催化剂结构，柴油机颗粒捕集器等。
催化式排气净化器10可包括通常呈管状的外壳12，该外壳12由两片通过凸缘16保持在一起的例如耐高温钢的金属形成。供选地，该外壳可包括预成形的罐，其中插入安装垫包裹的脆性结构。外壳12包括在一端的入口14和在其相对端的出口(未示出)。入口14和出口合适地在其外端形成，由此它们可紧固到内燃机的废气系统中的管路上。装置10含有脆性结构，诸如易碎的陶瓷单片18，其通过安装垫20承载并限制在外壳12内。单片18包括多个气体能够通过的通路，所述通路从其一端的入口轴向延伸到在其相对端的其出口。单片18可用任何合适的难熔金属或陶瓷材料以任何已知方式和构型来构造。单片的横截面构型通常为椭圆形或圆形，但其他形状也是可能的。
该单片通过一定的距离或间隙与外壳的内表面间隔开，这将根据所用装置的类型和设计而变化，该装置例如为催化式排气净化器、柴油机催化剂结构或柴油机颗粒捕集器。该间隙用安装垫20填充以对陶瓷单片18提供弹性支撑。弹性安装垫20提供与外部环境的热绝缘和对于脆性结构的机械支撑二者，由此保护该脆性结构在宽范围的废气处理装置操作温度内免受机械冲击影响。
通常，安装垫包含含有氧化铝的耐高温陶瓷纤维和/或耐高温生物可溶性无机纤维、在粘合剂烧尽之前在高温下至少部分地液化的有机粘合剂、胶体无机氧化物和任选至少一种类型的膨胀性材料。安装垫20能够提供足以在整个宽温度范围内将脆性催化剂承载结构18弹性保持在废气处理装置10的外壳12内的保持压力。
在本发明的安装垫中使用的耐高温无机纤维可经受住安装垫形成工艺，可经受住废气处理装置的操作温度，并在该操作温度下可提供最小保持压力性能以将脆性结构保持在废气处理装置外壳内。在不受限制的情况下，可用以制备安装垫和废气处理装置的合适无机纤维包括高氧化铝多晶纤维；莫来石纤维；难熔陶瓷纤维，诸如硅铝酸盐纤维或高岭土纤维；氧化铝-氧化锆-氧化硅纤维；氧化铝-氧化镁-氧化硅纤维，诸如S-玻璃纤维或S2-玻璃纤维；E-玻璃纤维；生物可溶性碱土金属硅酸盐纤维，诸如氧化钙-氧化镁-氧化硅纤维或氧化镁-氧化硅纤维；或其组合。
根据某些实施方案，用以制备所述安装垫的耐高温无机纤维包括陶瓷纤维，所述陶瓷纤维包含氧化铝。在不受限制的情况下，合适的陶瓷纤维包括氧化铝纤维、莫来石纤维、硅铝酸盐纤维、氧化铝-氧化锆-氧化硅纤维和类似纤维。高氧化铝多晶纤维可包含约72％重量-约100％重量的氧化铝和约0％重量-约28％重量的氧化硅的纤维化产物。合适的硅铝酸盐陶瓷纤维以注册商标FIBERFRAX自Unifrax ILLC(Niagara Falls，New York)购得。FIBERFRAX
Figure BPA00001530647300051
陶瓷纤维包含含有约45％重量-约75％重量的氧化铝和约25％重量-约55％重量的氧化硅的熔体的纤维化产物。FIBERFRAX
Figure BPA00001530647300061
纤维表现出高达约1540℃的操作温度和高达约1870℃的熔点。FIBERFRAX
Figure BPA00001530647300062
纤维可容易地形成耐高温的薄片和纸张。
在某些实施方案中，硅铝酸盐纤维可包含约40％重量-约60％重量的Al2O3和约60％重量-约40％重量的SiO2。氧化铝/氧化硅/氧化镁玻璃纤维通常包含约64％重量-约66％重量的SiO2、约24％重量-约25％重量的Al2O3和约9％重量-约11％重量的MgO。
E-玻璃纤维通常包含约52％重量-约56％重量的SiO2、约16％重量-约25％重量的CaO、约12％重量-约16％重量的Al2O3、约5％重量-约10％重量的B2O3、高达约5％重量的MgO、高达约2％重量的氧化钠和氧化钾及痕量的氧化铁和氟化物，其中典型的组成为约55％重量的SiO2、约15％重量的Al2O3、约7％重量的B2O3、约3％重量的MgO、约19％重量的CaO及痕量的高达约0.3％重量的其他上述材料。
在不受限制的情况下，可用以制备用于废气处理装置的安装垫的生物可溶性碱土金属硅酸盐纤维的合适实例包括在美国专利6,953,757、6,030,910、6,025,288、5,874,375、5,585,312、5,332,699、5,714,421、7,259,118、7,153,796、6,861,381、5,955,389、5,928,075、5,821,183和5,811,360号中公开的那些纤维，这些专利通过引用的方式结合在本文中。
根据某些实施方案，生物可溶性碱土金属硅酸盐纤维可包含氧化镁和氧化硅的混合物的纤维化产物。这些纤维通称为硅镁酸盐纤维。所述硅镁酸盐纤维通常包含约60％重量-约90％重量的氧化硅、大于0％重量-约35％重量的氧化镁和约5％重量或更少的杂质的纤维化产物。根据某些实施方案，所述碱土金属硅酸盐纤维包含约65％重量-约86％重量的氧化硅、约14％重量-约35％重量的氧化镁和约5％重量或更少的杂质的纤维化产物。根据其他实施方案，所述碱土金属硅酸盐纤维包含约70％重量-约86％重量的氧化硅、约14％重量-约30％重量的氧化镁和约5％重量或更少的杂质的纤维化产物。合适的硅镁酸盐纤维以注册商标ISOFRAX自Unifrax I LLC(Niagara Falls，NewYork)购得。市售ISOFRAX
Figure BPA00001530647300071
纤维通常包含约70％重量-约80％重量的氧化硅、约18％重量-约27％重量的氧化镁和约4％重量或更少的杂质的纤维化产物。
根据某些实施方案，生物可溶性碱土金属硅酸盐纤维可包含氧化钙、氧化镁和氧化硅的混合物的纤维化产物。这些纤维通称为氧化钙-氧化镁-氧化硅纤维。根据某些实施方案，所述氧化钙-氧化镁-硅酸盐纤维包含约45％重量-约90％重量的氧化硅、大于0％重量-约45％重量的氧化钙、大于0％重量-约35％重量的氧化镁和约10％重量或更少的杂质的纤维化产物。有用的氧化钙-氧化镁-硅酸盐纤维以注册商标INSULFRAX自Unifrax I LLC(Niagara Falls，New York)购得。INSULFRAX
Figure BPA00001530647300072
纤维通常包含约61％重量-约67％重量的氧化硅、约27％重量-约33％重量的氧化钙和约2％重量-约7％重量的氧化镁的纤维化产物。其他合适的氧化钙-氧化镁-硅酸盐纤维以商标SUPERWOOL 607、SUPERWOOL 607 MAX和SUPERWOOL HT自Thermal Ceramics(Augusta，Georgia)购得。SUPERWOOL
Figure BPA00001530647300073
607纤维包含约60％重量-约70％重量的氧化硅、约25％重量-约35％重量的氧化钙和约4％重量-约7％重量的氧化镁及痕量的氧化铝。SUPERWOOL
Figure BPA00001530647300074
607 MAX纤维包含约60％重量-约70％重量的氧化硅、约16％重量-约22％重量的氧化钙和约12％重量-约19％重量的氧化镁及痕量的氧化铝。SUPERWOOL
Figure BPA00001530647300075
HT纤维包含约74％重量的氧化硅、约24％重量的氧化钙及痕量的氧化镁、氧化铝和氧化铁。
任选可并入安装垫中的膨胀性材料包括而不限于未膨胀的蛭石、离子交换的蛭石、热处理的蛭石、可膨胀的石墨、水黑云母、水溶胀性四硅氟云母、碱金属硅酸盐或其混合物。所述安装垫可包含大于一种类型的膨胀性材料的混合物。所述膨胀性材料可包含相对量为约9∶1-约1∶2蛭石∶石墨的未膨胀蛭石与可膨胀石墨的混合物，如在美国专利5,384,188号中所述。
安装垫还包含一种或多种有机粘合剂。所述有机粘合剂可以固体、液体、溶液、分散体、胶乳、乳液或类似形式提供。所述有机粘合剂可包括热塑性或热固性粘合剂，其在固化后为一种柔性材料，该材料可在安装垫安装时烧尽。合适有机粘合剂的实例包括但不限于丙烯酸胶乳、(甲基)丙烯酸胶乳、苯乙烯和丁二烯的共聚物、乙烯基吡啶、丙烯腈、丙烯腈和苯乙烯的共聚物、氯乙烯、聚氨酯、乙酸乙烯酯和乙烯的共聚物、聚酰胺等。其他树脂包括低温柔性热固性树脂，诸如不饱和聚酯、环氧树脂和聚乙烯基酯。
有机粘合剂可以以如下量包含在安装垫中：基于安装垫的总重量计算，大于0％重量-约20％重量，在某些实施方案中，约0.5％重量-约15％重量，在其他实施方案中，约1％重量-约10％重量，和在一些实施方案中，约2％重量-约8％重量。
安装垫可包含聚合物粘合纤维以代替树脂质或液体粘合剂，或除了树脂质或液体粘合剂之外还包含聚合物粘合纤维。这些聚合物粘合纤维可以以如下量使用以帮助将耐热无机纤维粘合到一起：基于安装垫的总重量计算，大于0％重量-约20％重量，在某些实施方案中，约1％重量-约15％重量，和在其他实施方案中，约2％重量-约10％重量。粘合纤维的合适实例包括聚乙烯醇纤维、聚烯烃纤维如聚乙烯和聚丙烯、丙烯酸纤维、聚酯纤维、乙基乙烯基乙酸酯纤维(ethyl vinyl acetatefiber)、尼龙纤维及其组合。
典型地，有机粘合剂为用以将纤维初始粘合在一起的牺牲粘合剂。“牺牲”意谓有机粘合剂最后将从安装垫中烧尽，基本仅留下无机纤维、以下论述的无机氧化物和任选的膨胀性材料作为安装垫的组分以将脆性结构承载在金属外壳内。推理该有机粘合剂烧尽方法在安装垫暴露的高温的较低范围如低于约350℃下引起安装垫的剪切破坏。据信所述有机粘合剂在安装垫烧尽之前和/或代替安装垫烧尽而至少部分地液化，容许纤维彼此滑过，因此降低剪切强度。
为了克服该问题，所述安装垫还包含胶体无机氧化物，诸如胶体氧化铝、胶体氧化硅、胶体氧化锆或其混合物。已经发现这种胶体无机氧化物的加入增加在这些较低温度下安装垫对剪切破坏的抵抗。基于安装垫的总重量计算，所述胶体无机氧化物可以以约0.1％重量-约10％重量的量加到安装垫中。
虽然不希望受理论限制，但存在胶体无机氧化物可在低温下在安装垫内增加对剪切破坏的抵抗的两种机制：(1)胶体无机氧化物可赋予耐摩擦性，该耐摩擦性抗击在安装垫内的纤维中由于在低于约350。的温度下至少部分地液化的有机粘合剂的存在而引起的剪切或内部滑动；和/或(2)胶体无机氧化物的高表面积可用以吸附有机粘合剂形成的任何液化的有机粘合剂，防止液化的有机粘合剂导致在安装垫内的纤维之中的剪切或内部滑动。这些机制中的一种或两种可在本文所述的本发明安装垫中起作用。
安装垫可通过本领域已知的形成片状材料的任何方式来生产。例如，常规的造纸方法，无论是手工铺设还是机器铺设都可用来制备所述片材。手抄纸模、长网抄纸机或真空圆网抄纸机可用来制造所述片材。
例如，使用造纸方法可以将无机纤维、有机粘合剂、胶体无机氧化物和任选的膨胀性材料混合在一起以形成混合物或浆料。组分的浆料可通过将絮凝剂加到该浆料中来进行絮凝。将絮凝的混合物或浆料放置在造纸机上以形成含纤维纸张的板层或薄片。该薄片通过空气干燥或烘箱干燥来进行干燥。对于所使用的标准造纸技术的更详细的说明，参见美国专利3458329号，其公开内容通过引用结合到本文中。
供选地，该板层或薄片可通过真空流延浆料来形成。根据该方法，将组分的浆料湿铺到能通过的网上。施加真空到该网上以从浆料中提取大部分水分，由此形成湿的薄片。随后，通常在烘箱中干燥该湿的板层或薄片。在干燥之前，可使该薄片穿过一组辊来压缩该薄片。
在其他实施方案中，纤维可通过诸如干燥空气成网(dry air laying)的常规手段加工成安装垫。在该阶段，垫具有非常小的结构整体性且相对于常规催化式排气净化器和柴油机颗粒捕集器安装垫来说非常厚。所产生的垫因此可以针式干燥(如本领域通常已知)来使该垫致密化并增加其强度。
在使用干燥空气层化技术的情况下，垫可供选地通过浸渍将粘合剂添加到垫中来进行加工以形成不连续的纤维复合材料。在该技术中，粘合剂是在垫形成后加入，而非如上文关于常规造纸技术所提到的形成垫预浸料坯。该制备垫的方法通过减少破裂而有助于保持纤维的长度。
用粘合剂浸渍垫的方法包括将垫完全浸没在液体粘合剂体系中，或供选地喷涂该垫。在一种连续的方法中，纤维垫(其可以辊形式传输)是未卷绕的，且诸如在传送带或纱幕(scrim)上移动，穿过喷嘴，该喷嘴将粘合剂施用到垫上。供选地，该垫可在重力作用下穿过喷嘴。该垫/粘合剂预浸料坯随后在压辊之间穿过，其除去了多余的液体，且使该预浸料坯致密化到其大致期望的厚度。该致密化预浸料坯随后可穿过烘箱来除去任何剩余的溶剂，且如果需要，则部分地固化粘合剂以形成复合材料。干燥和固化温度主要取决于所用的粘合剂和溶剂(如果存在的话)。随后可将该复合材料切割或辊压以便储存或运输。
安装垫还可以如下批次模式制造：将垫的一部分浸入液体粘合剂中，移除预浸料坯，且加压以除去多余的液体，此后干燥以形成复合材料，并储存或切割到一定的尺寸。
应当注意的是安装垫的密度对于在某些应用中容易使用而言太低。因此，它们可通过本领域已知的任何方式进行进一步的致密化以提供更高的密度。一种这样的致密化方式是针刺纤维以使得它们缠绕和卷绕。另外或供选地，可使用水绕方法。另外供选项为通过将纤维卷送穿过压辊来将其压成垫形状。这些垫致密化方法中的任一种或这些方法的组合可以容易地用来获得具有恰当和期望形式的安装垫。
无论使用上述技术中的哪一种技术，该复合材料都可诸如通过模冲压来切割以形成具有可再现公差的精确形状和尺寸的安装垫。安装垫20表现出在例如通过针刺等的致密化时合适的处理性质，这意味着它可容易地进行处理，并且不像许多其他纤维毯子或垫那样脆，以至于在人手里会粉碎。它可容易且柔性地安装或包裹在脆性结构18或类似脆性结构周围，而不会破裂，并随后布置在催化式排气净化器外壳12内。通常，所述安装垫包裹的脆性结构可插入外壳内，或所述外壳可构建或以其它方式制作在安装垫包裹的脆性结构周围。
以下实施例仅用于进一步说明安装垫和废气处理装置。这些说明性实施例不应当被解释为对安装垫、并入安装垫的废气处理装置或以任何方式制造安装垫或废气处理装置的方法的限制。
安装垫由硅铝酸盐难熔陶瓷纤维、聚烯烃有机粘合剂和基于安装垫的总重量计的0％重量-5％重量的胶体氧化铝(自Nyacol
Figure BPA00001530647300111
NanoTechnologies，Inc.，Ashland，MA购得的Nyacol)制成。所述垫通过以下方式制造：向装备有混合器且含有约7.7L水的20L烧杯中加入8.5g粘合纤维和123.5g FIBERFRAX纤维，在1750rpm下搅拌1分钟且随后加入65g 0.5％固形物(solids)的絮凝剂溶液，引起浆料絮凝。体积由此增加到13.6L。随后将浆料转移到具有12英寸×12英寸的筛网面积的手抄纸模且通过真空基本除去水由此形成垫结构。使垫热固化，产生最终垫样品。从纤维垫上切下两个2英寸×2英寸的试样并将其用于如下所述的剪切测试。实施例1的安装垫含有1％的胶体氧化铝，实施例2的安装垫含有3％的胶体氧化铝，实施例3的安装垫含有5％的胶体氧化铝且比较实施例4的安装垫不含胶体氧化铝。除了代替聚烯烃有机粘合剂加入8.5g丙烯酸胶乳有机粘合剂以外，实施例5和比较实施例6类似于实施例1-4来制造。实施例5含有5％的胶体氧化铝，且比较实施例6不含胶体氧化铝。测试各实施例的3个垫以提供如下所述并示于图3和图4中的数据。在图3和图4的图例中与各实施例相关的数字为各实施例在500℃的冷面温度下的剪切应变％。
剪切测试
参考图2，将实施例1-4的安装垫102依次放置在测试设备100中。为了模拟在单片周围包裹安装垫102，将安装垫102放置在石英加热器部件104的任一侧。在安装垫102的与加热器部件104相对的一侧放置冷却部件106。在冷却部件106之一的一侧放置可移动夹片108。压板110、径向力负载单元112和固定夹片114放置在另一冷却部件106的另一侧。
约500kPa的径向力经径向力负载单元112和压板110施加到测试设备110。对石英加热器部件104施加法向力60N历时5分钟。在5分钟的保持期之后，使加热器部件中的温度在10分钟内从室温增加到约500℃，同时保持60N法向力。记录保持60N的法向力所必需的石英部件104的位移。将安装垫的剪切应变计算为垫挠度(matdeflection)(石英部件位移)除以间隙除以2(因为在该系统中存在两个垫样品)。该测试的结果绘于图3和图4中，这显示包含胶体无机氧化物的本发明安装垫比缺乏胶体无机氧化物的现有技术安装垫表现好。
具体地讲，在图3中，含有1％胶体氧化铝的实施例1(30)具有1.95％的剪切应变，含有3％的胶体氧化铝的实施例2(32)具有1.71％的剪切应变，且含有5％的胶体氧化铝的实施例3(34)具有1.66％的剪切应变，与此相比，不含胶体氧化铝的实施例4(36)具有6.46％的剪切应变。并且，在图4中，含有5％的氧化铝的实施例5(40)具有1.07％的剪切应变，而不含胶体氧化铝的实施例6(42)具有15.7％的剪切应变。
这些垫对于催化式排气净化器和柴油机颗粒捕集器工业来说是有利的。所述安装垫可以冲切，且可用作薄型弹性载体，提供处理容易性，和呈柔性形式，以便能够提供催化剂承载结构的全面包裹(如果需要的话)，而无破裂。供选地，所述安装垫可整体包裹在至少一部分的催化剂承载结构的整个圆周或周长。如果需要，所述安装垫还可部分地包裹且包括目前用于一些常规转化器装置中的端部密封以防止气体旁流(gas by-pass)。
上述安装垫也可用于多种应用中，诸如用于例如摩托车和其他小型发动机车辆的常规汽车催化式排气净化器和汽车预净化器以及高温隔离器、垫圈和甚至未来一代汽车底盘催化式排气净化器系统。通常，它们可用于需要垫或垫圈以在室温下施加保持压力且更重要地提供高温(包括在热循环期间)维持该保持压力的能力的任何应用中。
本发明的安装垫材料可用作废气处理装置中的端锥体(end cone)绝缘体。根据某些实施方案，提供用于废气处理装置的端锥体。所述端锥体通常包括外金属锥体、内金属锥体和布置在该外金属端锥体与该内金属端锥体之间的间隙或空间中的端锥体绝缘体。
根据其他实施方案，端锥体可包括外金属锥体和至少一层锥体绝缘体，所述锥体绝缘体毗邻于外金属锥体的内表面安置。根据这些实施方案，端锥体组件没有装备内金属锥体。相反，所述锥体绝缘体以某一方式刚性化来提供自支持式锥体结构，该结构能够耐受流过装置的高温气体。
提供包括至少一个端锥体的废气处理装置。所述废气处理装置包括外壳；安置在外壳内的脆性结构；用于将废气管道附接到外壳上的入口和出口端锥体组件，每个端锥体组件包括内端锥体外壳和外端锥体外壳；和布置在内锥体外壳与外锥体外壳之间的端锥体绝缘体，所述端锥体绝缘体包含含有氧化铝的耐高温陶瓷纤维和/或耐高温生物可溶性无机纤维、在粘合剂烧尽之前在高温下至少部分地液化的有机粘合剂、胶体无机氧化物和任选的膨胀性材料。
还提供了用于废气处理装置的端锥体，其包括：外金属锥体；和包括上述安装垫中的任一种的锥体绝缘体；其中存在至少一项：(i)所述端锥体包括内金属锥体且所述锥体绝缘体布置在所述外金属锥体与所述内金属锥体之间；或(ii)所述锥体绝缘体为自支持式的且毗邻于所述外金属锥体的内表面布置。
上述安装垫还可用于化学工业中所用的催化式排气净化器中，该催化式排气净化器位于废气或排放烟道中，包括含有需要保护性安装的脆性蜂窝型结构的这些。
还提供了降低在最初使用安装垫期间经历的低温剪切破坏的方法，所述安装垫包含含有氧化铝的耐高温陶瓷纤维和/或耐高温生物可溶性无机纤维；在粘合剂烧尽之前在高温下至少部分地液化的有机粘合剂；胶体无机氧化物；和任选的膨胀性材料；所述方法包括在所述安装垫的制造期间向所述安装垫中加入有效降低低温剪切破坏的量的至少一种胶体无机氧化物。
在第一说明性实施方案中，提供用于废气处理装置的安装垫，其包含：含有氧化铝的耐高温陶瓷纤维和/或耐高温生物可溶性无机纤维；在粘合剂烧尽之前在高温下至少部分地液化的有机粘合剂；胶体无机氧化物；和任选的膨胀性材料。
在第二说明性实施方案中，提供第一说明性实施方案的安装垫，其中所述陶瓷纤维包括高氧化铝多晶纤维、难熔陶瓷纤维、莫来石纤维、氧化铝-氧化锆-氧化硅纤维、氧化铝-氧化镁-氧化硅纤维或其组合中的至少一种。
第二说明性实施方案的安装垫可进一步包含高氧化铝多晶纤维，所述高氧化铝多晶纤维包含约72％重量-约100％重量的氧化铝和约0％重量-约28％重量的氧化硅的纤维化产物。
第二说明性实施方案的安装垫还可包含难熔陶瓷纤维，所述难熔陶瓷纤维包括硅酸铝盐纤维，所述硅酸铝盐纤维包含约45％重量-约75％重量的氧化铝和约25％重量-约55％重量的氧化硅的纤维化产品。
以上说明性实施方案中任一个的安装垫还可包含耐高温生物可溶性无机纤维，所述耐高温生物可溶性纤维包括氧化镁-硅酸盐纤维，所述氧化镁-硅酸盐纤维包含约65％重量-约86％重量的氧化硅和约14％重量-约35％重量的氧化镁的纤维化产物。
以上说明性实施方案中任一个的安装垫还可包含耐高温生物可溶性无机纤维，所述耐高温生物可溶性纤维包括氧化钙-氧化镁-硅酸盐纤维，所述氧化钙-氧化镁-硅酸盐纤维包含约45％重量-约90％重量的氧化硅、大于0％重量-约45％重量的氧化钙和大于0％重量-约35％重量的氧化镁的纤维化产物。
以上说明性实施方案中任一个的安装垫还可包含有机粘合剂，所述有机粘合剂包括丙烯酸胶乳、(甲基)丙烯酸胶乳、苯乙烯和丁二烯的共聚物、乙烯基吡啶、丙烯腈、丙烯腈和苯乙烯的共聚物、氯乙烯、聚氨酯、乙酸乙烯酯和乙烯的共聚物、聚酰胺、聚硅氧烷、不饱和聚酯、环氧树脂和聚乙烯酯或其混合物中的至少一种。
以上说明性实施方案中任一个的安装垫还可包含有机粘合剂，所述有机粘合剂包括聚乙烯醇纤维、聚烯烃纤维、聚乙烯纤维、聚丙烯纤维、丙烯酸纤维、聚酯纤维、乙基乙烯基乙酸酯纤维、尼龙纤维或其组合的至少一种。
以上说明性实施方案中任一个的安装垫还可包含膨胀性材料，所述膨胀性材料为：未膨胀的蛭石、离子交换的蛭石、热处理的蛭石、可膨胀的石墨、水黑云母、水溶胀的四硅氟云母、碱金属硅酸盐或其混合物中的至少一种。
以上说明性实施方案中任一个的安装垫还可包含胶体无机氧化物，所述胶体无机氧化物包括胶体氧化硅、胶体氧化铝、胶体氧化锆或其组合中的至少一种。
以上说明性实施方案中任一个的安装垫还可包含陶瓷纤维，所述陶瓷纤维包括硅铝酸盐纤维，且其中所述胶体无机氧化硅包括胶体氧化铝。
以上说明性实施方案中任一个的安装垫还可包括如下安装垫，所述安装垫包含约0.1％重量-约10％重量的至少一种胶体无机氧化物。
在第三说明性实施方案中，提供废气处理装置，其包括：外壳；弹性安装在所述外壳内的脆性结构；和布置在所述外壳和所述脆性结构之间的间隙中的以上实施方案中任一个的安装垫。
在第四说明性实施方案中，提供降低在初始使用以上实施方案中任一个的安装垫期间经历的低温剪切破坏的方法，所述方法包括在所述安装垫的制造期间向所述安装垫中加入有效降低低温剪切破坏的量的至少一种胶体无机氧化物。
在第五说明性实施方案中，提供用于废气处理装置的端锥体，其包括：外金属锥体；和包括以上实施方案中任一个的安装垫的锥体绝缘体，其中以下的至少一种：(i)所述端锥体包括内金属锥体且所述锥体绝缘体布置在所述外金属锥体与所述内金属锥体之间；或(ii)所述锥体绝缘体为自支持式的且毗邻于所述外金属锥体的内表面布置。
虽然已经关于各种说明性实施方案描述了安装垫和废气处理装置，但是应当理解的是，可使用其他类似的实施方案或可对所述实施方案进行改进和添加以执行与此处所述相同的功能，而不偏离该方案。在供选方面上述实施方案并非必需的，因为可对各种实施方案进行组合以提供所需特性。因此，安装垫和废气处理装置不应当限于任何单一的实施方案，而是在附加权利要求所述的宽度和范围内进行解释。

Claims (15)

1.用于废气处理装置的安装垫，其包含：
含有氧化铝的耐高温陶瓷纤维和/或耐高温生物可溶性无机纤维；在粘合剂烧尽之前在高温下至少部分地液化的有机粘合剂；胶体无机氧化物；和任选的膨胀性材料。
2.权利要求1的安装垫，其中所述陶瓷纤维包括高氧化铝多晶纤维、难熔陶瓷纤维、莫来石纤维、氧化铝-氧化锆-氧化硅纤维、氧化铝-氧化镁-氧化硅纤维或其组合中的至少一种。
3.权利要求2的安装垫，其中所述高氧化铝多晶纤维包含约72％重量-约100％重量的氧化铝和约0％重量-约28％重量的氧化硅的纤维化产物。
4.权利要求2的安装垫，其中所述难熔陶瓷纤维包括硅酸铝盐纤维，所述硅酸铝盐纤维包含约45％重量-约75％重量的氧化铝和约25％重量-约55％重量的氧化硅的纤维化产物。
5.权利要求1的安装垫，其中所述耐高温生物可溶性无机纤维包括氧化镁-硅酸盐纤维，所述氧化镁-硅酸盐纤维包含约65％重量-约86％重量的氧化硅和约14％重量-约35％重量的氧化镁的纤维化产物。
6.权利要求1的安装垫，其中所述耐高温生物可溶性无机纤维包括氧化钙-氧化镁-硅酸盐纤维，所述氧化钙-氧化镁-硅酸盐纤维包含约45％重量-约90％重量的氧化硅、大于0％重量-约45％重量的氧化钙和大于0％重量-约35％重量的氧化镁的纤维化产物。
7.权利要求1的安装垫，其中所述有机粘合剂包括丙烯酸胶乳、(甲基)丙烯酸胶乳、苯乙烯和丁二烯的共聚物、乙烯基吡啶、丙烯腈、丙烯腈和苯乙烯的共聚物、氯乙烯、聚氨酯、乙酸乙烯酯和乙烯的共聚物、聚酰胺、聚硅氧烷、不饱和聚酯、环氧树脂和聚乙烯酯或其混合物中的至少一种。
8.权利要求1的安装垫，其中所述有机粘合剂包括聚乙烯醇纤维、聚烯烃纤维、聚乙烯纤维、聚丙烯纤维、丙烯酸系纤维、聚酯纤维、乙基乙烯基乙酸酯纤维、尼龙纤维或其组合中的至少一种。
9.权利要求1的安装垫，其中所述膨胀性材料为未膨胀的蛭石、离子交换的蛭石、热处理的蛭石、可膨胀的石墨、水黑云母、水溶胀的四硅氟云母、碱金属硅酸盐或其混合物中的至少一种。
10.权利要求1的安装垫，其中所述胶体无机氧化物包括胶体氧化硅、胶体氧化铝、胶体氧化锆或其组合中的至少一种。
11.权利要求1的安装垫，其中所述陶瓷纤维包括硅铝酸盐纤维，且其中所述胶体无机氧化物包括胶体氧化铝。
12.权利要求1的安装垫，其中所述安装垫包含约0.1％重量-约10％重量的至少一种胶体无机氧化物。
13.废气处理装置，其包括：
外壳；
弹性安装在所述外壳内的脆性结构；和
布置在所述外壳与所述脆性结构之间的间隙中的权利要求1-12中任一项的安装垫。
14.降低在初始使用权利要求1-12中任一项的安装垫期间经历的低温剪切破坏的方法，所述方法包括在所述安装垫的制造期间向所述安装垫中加入有效降低低温剪切破坏的量的至少一种胶体无机氧化物。
15.用于废气处理装置的端锥体，其包括：
外金属锥体；和
锥体绝缘体，其包括权利要求1-12中任一项的安装垫；
其中以下的至少一种：
(i)所述端锥体还包括内金属锥体且所述锥体绝缘体布置在所述外金属锥体与所述内金属锥体之间；或
(ii)所述锥体绝缘体为自支持式的且毗邻于所述外金属锥体的内表面布置。
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