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.

1 . 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: 
 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    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,    wherein the organic binder has a glass transition point Tg (° C.) of less than or equal to approximately 5° C.    
   
   
       2 . A manufacturing method of a holding and sealing material as claimed in  claim 1 , wherein the organic binder is a rubber on which is not conducted a crosslinking process.  
   
   
       3 . A manufacturing method of a holding and sealing material as claimed in  claim 1 , wherein the organic binder is an acrylate based rubber or a methacrylate based rubber.  
   
   
       4 . A manufacturing method of a holding and sealing material as claimed in  claim 1 , wherein the emulsion has a surface tension of less than or equal to approximately 60 mN/M at the room temperature.  
   
   
       5 . A manufacturing method of a holding and sealing material as claimed in  claim 1 , wherein the emulsion has an emulsion particle diameter of less than or equal to approximately 300 nm.  
   
   
       6 . 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: 
 a mat-like material formed by arranging inorganic fibers in a mat shape; and    an organic binder with a glass transition point Tg (° C.) of less than or equal to approximately 5° C. which is attached to the mat-like material.    
   
   
       7 . A holding and sealing material as claimed in  claim 6 , wherein the organic binder is an acrylate based rubber or a methacrylate based rubber.  
   
   
       8 . A holding and sealing material as claimed in  claim 6 , wherein a flying ratio of the inorganic fibers is less than or equal to approximately 0.15 wt %.