KR100739885B1 - Holding seal member for exhaust gas purifier, exhaust gas purification apparatus employing the same, jig for chamfering holding seal member, and method for manufacturing holding seal member - Google Patents

Abstract

The chamfered holding seal member 14 has an end portion 14m including an inclined surface 14f. When the holding seal member for wrapping around the exhaust gas purifying body 21 is inserted into the tubular shell 23, the holding sealing material is elastically deformed and the inclined surface becomes substantially coplanar with the inlet end face of the exhaust gas purifying body. .

Exhaust gas purifying body, holding sealing material, chamfering, inclined surface

Description

Holding sealing material for exhaust gas treating body, exhaust gas purifying device using the same, chamfering jig of holding sealing material, and manufacturing method of holding sealing material , AND METHOD FOR MANUFACTURING HOLDING SEAL MEMBER}

1 is a perspective view showing a holding sealing material of the prior art,

2 is a cross-sectional view showing an exhaust gas purifying apparatus using the holding sealer of the prior art;

3 is a partially enlarged cross-sectional view showing an exhaust gas purification device shown in FIG. 2;

4A, 4B and 4C are a plan view, a rear view and a side view showing a holding sealing material according to a preferred embodiment of the present invention;

FIG. 5A is a partially enlarged view showing the holding sealing material of FIG. 4C; FIG.

5B is a modification of the holding sealer shown in FIG. 5A,

6A and 6B are partial enlarged cross-sectional views showing an exhaust gas purification device using the holding sealer according to the preferred embodiment;

7 is a perspective view showing a chamfering jig to be used for manufacturing the holding sealer according to the preferred embodiment;

8 is a plan view showing a chamfer jig of FIG.

9A is a perspective view showing a holding sealing material before cutting away from an inorganic fiber mat and chamfering;

9B is a cross sectional view taken along line 9B-9B in FIG. 8;

9C is an enlarged view of a portion of FIG. 9B;

10 is a perspective view illustrating the chamfering jig of FIG. 7 in use;

11 is a sectional view taken along line 11-11 of FIG. 10,

12 is a partially cutaway perspective view showing an exhaust gas purification device using the holding sealer according to the preferred embodiment;

13-15 is sectional drawing which shows another embodiment of a chamfering jig.

The present invention relates to a holding sealing material for covering an outer circumferential surface of an exhaust gas treating body contained in a metal shell, an exhaust gas purifying apparatus using the same, a chamfering jig for holding sealing material, and a manufacturing method of the holding sealing material.

The exhaust gas treating apparatus used for a vehicle is usually located in the middle of the exhaust passage of the vehicle. Diesel particle filters (DPFs) and exhaust gas purification catalytic converters for removing graphite particles called particles are conventionally known as examples of exhaust gas treatment devices. A typical exhaust gas treating apparatus includes an exhaust gas purifying body, a metal pipe (shell) surrounding the exhaust gas purifying body, and a holding sealer that fills a gap between the exhaust gas purifying body and the metal pipe.

The holding seal member should function to prevent the exhaust gas purifying body from being broken when it hits the metal pipe due to the vibration of the vehicle. The holding sealant should also function to prevent the exhaust gas purge from falling out or moving in the metal pipe when the exhaust gas pressure is applied. Moreover, the holding sealer should prevent the exhaust gas from leaking out of the gap between the metal pipe and the exhaust gas purifying body.

1 shows a conventional holding seal member 14p. 2 shows an exhaust gas treating apparatus using a conventional holding seal member 14p. This holding seal material 14p is formed by cutting the fiber mat 16 having a uniform thickness and elasticity. This holding sealing material 14p is wound around the outer circumferential surface of the exhaust gas purifying body 21. The exhaust gas purifying body 21 in which the holding sealing material 14p is wound around is pressed into the metal tubular shell 23. The exhaust gas treating apparatus is assembled in this manner (see Japanese Patent Laid-Open No. 2001-316965).

The exhaust gas purifying body is, for example, a catalyst carrier. Catalysis is temperature dependent. In order to ensure sufficient reactivity to the catalyst from the beginning of use, the fiber mat is required for the thermal insulation performance. Examples of the material of the fiber mat include inorganic fibers such as alumina fibers. Japanese Laid-Open Patent Publication No. 2003-20938 discloses a holding seal material having improved heat resistance, surface pressure retention under high temperature, and wind resistance. This holding seal material is made of an inorganic fiber having an adjusted mullite rate.

When the holding seal member 14p and the exhaust gas purifying body 21 are press-fitted into the shell 23, the shear force is applied to the inner surface 14n and the outer surface 14j of the holding seal member 14p to hold the holding seal member. (14p) is modified. As shown in Fig. 3, the protrusion 14k protrudes from the deformed holding seal member 14p. The protrusion 14k has an acute angle vertex between the outer surface 14j and the end surface 14d of the retaining seal member 14p. The angle of the projection part 14k behind the vertex of this acute angle faces the direction opposite to the direction in which the holding sealing material 14p and the exhaust gas purifying body 21 are press-fitted.

Although the holding seal material has improved wind resistance, the apex of the acute angle of the protrusion 14k is likely to be blown off by the exhaust gas and thus easily broken. The inorganic fibers separated from the broken protrusion 14k may enter the exhaust gas purifying body 21 and block the exhaust gas purifying body 21.

Recent improvements in engine performance increase exhaust gas pressure. Therefore, the holding sealing material 14p wraps around the entire outer circumferential surface of the exhaust gas purifying body 21 to hold the exhaust gas purifying body 21 even under high exhaust gas pressure. This causes a new problem that the protrusions 14k are easily generated and cause clogging of the exhaust gas purifying body.

In addition, if the projection 14k presses the holding seal member 14p into the shell 23 and is cut, the exhaust gas purifying body 21 and the shell 23 may be damaged. Therefore, it is not preferable to cut the holding seal material 14p after the holding seal material 14p is pressed into the shell 23.

SUMMARY OF THE INVENTION The present invention has been made to solve these conventional problems, and an object of the present invention is to provide a holding sealing material for an exhaust gas treating body which can prevent clogging of the exhaust gas treating body, an exhaust gas purifying apparatus using the same, and a chamfering jig for holding sealing material. It is to provide a method of manufacturing the sealing material, and holding.

According to one aspect of the invention, the holding sealer for wrapping around the exhaust gas purifying body, the holding seal for holding the exhaust gas purifying body in the tubular shell having an inlet through which the exhaust gas flows in and an outlet through which the exhaust gas flows out; Ash is provided. The holding seal member includes a first surface for contacting the exhaust gas purifying body during use of the holding seal material and a second surface for contacting the shell when the holding sealing material wraps around the exhaust gas purifying body. The chamfered end is positioned adjacent to the inlet of the exhaust gas purifying body in use of the holding sealer. This chamfered end includes an inclined surface that is inclined with respect to at least the second surface when no retaining seal material is used.

According to another aspect of the present invention, there is provided an exhaust gas purification apparatus having an exhaust gas purification body comprising an inlet for accommodating exhaust gas, an outlet for discharging exhaust gas, and a surrounding surface. The holding seal member includes a chamfered end having a first surface, a second surface, and an inclined surface that is inclined with respect to at least the second surface between the first and second surfaces. The holding sealer wraps around the exhaust gas purifying body with the first surface of the holding sealing material which is in contact with the outer circumferential surface of the exhaust gas purifying body. The chamfered end of the holding sealer is adjacent to the inlet of the exhaust gas purifying body. The tubular shell contains the exhaust gas purifying body. The holding sealer is in contact with both the exhaust gas purifying body and the tubular shell.

According to still another aspect of the present invention, a sheet-shaped holding sealing material for use with an exhaust gas purifying body having an inlet through which exhaust gas is introduced is provided. This holding seal material has a slanted inclined surface and a uniform thickness associated with the inlet of the exhaust gas purifying body during use of the holding seal material.

According to another aspect of the invention, there is provided a chamfering jig for use with a flat blade which can produce a holding seal material for wrapping around the exhaust gas purification body to hold the exhaust gas purification body in the tubular shell. This holding seal material is sheet-shaped and includes a side surface and a bottom surface. The chamfering jig includes a case having a side wall portion and a bottom wall portion for contacting the side surface and the bottom surface of the holding sealer, respectively. The case includes a recess defined by the side wall portion and the bottom wall portion. The cover covers the recess of the case. This recess and cover define a storage chamber for accommodating the holding sealer. The cover has a cover slit for forming a chamfer at one edge of the holding sealer accommodated in the recess. This slit can receive a flat blade to guide the movement of the flat blade.

According to another aspect of the present invention, there is provided a chamfering jig for use with a flat blade capable of manufacturing a holding sealer for wrapping around an exhaust gas purification body to hold the exhaust gas purification body in a tubular shell, wherein The retaining seal material in is sheet-shaped and includes a side surface and a bottom surface. The chamfering jig includes a case having a side wall portion and a bottom wall portion for contacting the side surface and the bottom surface of the holding sealer, respectively. The case includes a recess defined by the side wall portion and the bottom wall portion. The case includes a case slit for forming a chamfer on one side edge of the holding sealer when received in the recess to guide the movement of the flat blade.

According to another aspect of the present invention, a method for producing a holding sealer is provided. The method includes cutting the inorganic fiber mat to form a sheet shape comprising side surfaces, bottom surfaces, first and second surfaces, end surfaces, and edges between the second and end surfaces. The method further comprises positioning a chamfering jig comprising a case having a side wall portion and a bottom wall portion in contact with the side surface and the bottom surface of the sheet shape, wherein the side wall portion and the bottom wall portion receive the sheet shape. A recess is defined in the case to be described. The method also includes covering the case with a cover having a slit, inserting a flat blade through the slit, and chamfering an edge between the second surface and the end surface of the sheet to form a holding seal material. Thus moving the flat blade.

In one embodiment, the inclined surface is inclined with respect to the second surface at an angle of 105 degrees to 150 degrees.

In one embodiment, the inclined surface is inclined with respect to the second surface at an angle of 130 degrees to 140 degrees.

In one embodiment, this inclined surface is adjacent to the second surface.

In one embodiment, the chamfered end includes an end surface and an inclined surface perpendicular to the first surface and located between the inclined surface and the first surface, the inclined surface extending between the end surface and the second surface. .

In one embodiment, the holding seal material is a sheet of inorganic fibers. In one embodiment, this sheet is needle-punched. In one embodiment, the inorganic fiber is an alumina-silica-based fiber. In one embodiment, the inorganic fibers have an average fiber diameter of at least 6 μm. In one embodiment, this sheet contains an organic binder.

In one embodiment, the exhaust gas purifying body is an exhaust gas purifying filter which collects particles from a catalyst carrier or exhaust gas carrying a catalyst for purifying exhaust gas.

In one embodiment, the holding seal member is elastically deformed between the exhaust gas purifying member and the tubular shell.

In one embodiment, at least one of the side wall and the bottom wall of the recess in the case has a case slit for receiving a flat blade, where the case slit and cover slit lie along the same plane.

In one embodiment, the case slit is formed in the side wall portion of the recess.

In one embodiment, the cover can be detached from the case.

In one embodiment, the retaining seal material has a thickness and the inclined surface joins the second surface at a location on the end surface closer to the first surface than the midpoint of the retaining seal material thickness.

In one embodiment, the cover slit is inclined with respect to the end face at an angle of 30 degrees to 75 degrees.

In one embodiment, the flat blade comprises an intermediate portion and a tip portion, and the case slit includes a slit formed in the side wall portion to guide the intermediate portion of the flat blade and a slit formed in the bottom wall portion to receive the tip portion of the flat blade. do.

In one embodiment, moving the flat blade comprises forming an inclined surface connecting the end surface and the second surface of the retaining seal material.

Other aspects and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

Together with the objects and advantages of the present invention, the present invention may be best understood by reference to the following description of the preferred embodiments in conjunction with the accompanying drawings.

(Detailed Description of the Preferred Embodiments)

EMBODIMENT OF THE INVENTION Hereinafter, the holding | sealing sealing material for exhaust gas purification bodies which concern on preferred embodiment of this invention is demonstrated with reference to drawings.

As shown in Figs. 4A to 4C, the holding seal member (hereinafter referred to as 'holding seal member') 14 having a flat and uniform thickness has an inner surface (first surface) 14n and an outer surface ( Second surface) 14j. The holding seal member 14 is preferably made of inorganic fibers. One edge (the upper edge in FIG. 4A) of the holding seal member 14 is chamfered. As shown in FIG. 5A, the edge 14c (indicated by the broken line) between the second surface 14j and the end surface 14d is removed. As will be described later, the end of the holding seal member 14 from which the edge 14c is removed is referred to as a chamfer 14m. The chamfer 14m includes the inclined surface 14f. The edge 14c to be removed has a shape and dimensions corresponding to at least a portion of the protrusion 14k formed when the conventional holding seal member is pressed into the shell 23 (see FIG. 2). In other words, the holding sealing material 14 is a sealing material obtained by removing at least a part of the conventional protrusion 14k.

As shown in FIG. 12, the holding sealer 14 is wound around the exhaust gas purifying body 21. The holding seal member 14 has a length corresponding to the circumferential length of the exhaust gas purifying body 21, that is, the transverse dimension of FIG. 4A. The holding seal member 14 has a width corresponding to the longitudinal length of the gaseous gas purifying body 21, that is, the longitudinal dimension of FIG. 4A. The exhaust gas purifying body 21 to which the holding sealing material 14 is wound around is press-fitted into the shell 23. The chamfered portion 14m faces the direction opposite to the direction (indicated by the arrow) in which the exhaust gas purifying body 21 is pressed into the shell 23. In one embodiment, the direction in which the exhaust gas purifying body 21 is press-fitted is the same as the direction in which the exhaust gas flows into the exhaust gas purifying body 21.

A tab 14h and a recess 14g for accommodating at least a portion of the tab 14h are respectively formed on the transversely opposite ends of the holding seal member 14. When the holding seal member 14 is wrapped around the exhaust gas purifying body 21, at least a part of the tab 14h is received and coupled to the recess 14g. This prevents the formation of a linear gap extending in the axial direction of the shell 23 to prevent leakage of exhaust gas. The dimensions of the tab 14h and the recess 14g increase the tolerance for the circumferential length of the exhaust gas purifying body 21 which the holding seal member 14 can wind.

The holding seal material 14 is cut out of the inorganic fiber mat 16 having a uniform thickness (see FIG. 1). The chamfered portion 14m is then formed on the holding seal member 14. The inorganic fiber mat 16 has uniform elasticity (elasticity). As the inorganic fiber mat 16, a felt or a nonwoven fabric is preferable.

Examples of the fiber material that can be used for the inorganic fiber mat 16 include ceramic fibers such as alumina fibers, alumina-silica fibers, silica fibers, and glass fibers. Of these fibrous materials, alumina-silica-based fibers excellent in heat resistance, surface pressure retention at high temperatures, and wind resistance are preferred. The average fiber diameter of the fiber material is determined according to the type of the holding sealer, the wind resistance, and the like. For example, thick fibers having an average fiber diameter of 6 µm or more are suitable for preventing inorganic fibers from scattering from the holding sealer 14. The inorganic fiber mat 16 may be impregnated using a latex such as an acrylic resin, a water-soluble resin such as polyvinyl alcohol, acrylic rubber, nitrile rubber, or the like as an organic binder so as to have a predetermined thickness and repulsive force before cutting molding.

Hereinafter, an example of the manufacturing method of an inorganic fiber mat is demonstrated. In this embodiment, alumina-silica fibers are used as inorganic fibers. In the first step, a silica sol is blended with an aqueous basic aluminum chloride solution to form a precursor of alumina fibers. The aluminum content of the basic aqueous aluminum chloride solution is 75 g / L, and the atomic ratio of Al / Cl is 1.8. The amount of the silica sol to be blended is preferably adjusted so that the composition ratio of alumina and silica in the alumina fiber is 60:40 to 80:20, more preferably 70:30 to 74:26. As long as this composition ratio is in the above-mentioned range, the ratio of the mullite produced by alumina and silica is sufficient to achieve low thermal conductivity and sufficient thermal insulation.

An organic polymer, such as polyvinyl alcohol, is then added to the precursor of the alumina fiber and concentrated to prepare a spinning solution. The fibers are made from the spinning solution by the blowing method. The blowing method is a method of forming fibers by using air blown out of an air nozzle and a spinning solution extruded from a spinning solution supply nozzle.

The blowing method is preferably designed such that the air flow and the flow of the spinning liquid are parallel to each other so that the air flow is sufficiently rectified before contacting the spinning liquid. In this case, the diameter of the spinning nozzle is usually 0.1 to 0.5 mm, and the amount of the spinning solution extruded from one spinning solution supply nozzle is usually 1 to 120 mL / h, preferably 3 to 50 mL / h. The gas flow rate per slit from the air nozzle is usually 40 to 200 m / s. By optimizing the spinning conditions in this manner, the spinning liquid extruded from the spinning liquid supply nozzle is spun into sufficiently long fibers without being sprayed, and the fibers thus formed are not fused together. As a result, uniform alumina fibers with reduced fluctuations in fiber diameter can be obtained.

The alumina fibers have an average fiber length of at least 250 μm, preferably at least 500 μm. As long as the average fiber length is at least 250 μm, the fibers are entangled enough to provide a retaining seal material 14 having sufficient strength to tightly wrap around the catalyst carrier.

The alumina fibers spun from the alumina fiber precursor are laminated to form a laminated sheet of alumina fibers. The thickness of the laminated sheet is appropriately set by the kind of the holding sealer 14, the kind of the exhaust gas purifying body 21, the bulk density, and the like. The laminated sheet of alumina fibers is preferably subjected to a needle punch (needling) process. The needle punch process reduces the thickness of the laminated sheet to facilitate handling and allows the fibers in different layers of the laminated sheet to be more tightly intertwined. The needle punch treatment is preferably performed by inserting each needle in a direction intersecting the interface between the layers in the lamination sheet.

Hereinafter, a needle punch process will be described. Needle boards having a plurality of holes arranged at equal intervals are placed on a laminated sheet of alumina fibers. In one embodiment, the needle board has holes arranged at a density of 500 per 100 cm 2. The needles are inserted into the lamination sheet of alumina fibers through the holes of the needle board under room temperature. The laminated sheet is then heated and continuously fired to a maximum temperature of 1250 ° C. to obtain a continuous laminated sheet of alumina fibers having a predetermined weight per unit area.

The continuous laminated sheet of alumina fibers is cut for easy handling. At the time of cutting, the surrounding point is the content of the alumina spherical material called "shot" contained in the continuous laminated sheet of alumina fibers. The shot is produced during the blowing process using the spinning solution. If the continuous laminated sheet contains 7% or more shots, the alumina fibers are susceptible to damage when filled with a bulk density (GBD) of 0.2 to 0.55 g / cm 3. Holding sealants containing damaged alumina fibers are likely to cause the fibers to scatter when assembling the catalytic converter.

Subsequently, the organic binder is impregnated into the cut continuous laminated sheet. The organic binder facilitates assembly to the exhaust passage. Further, in the next step, the uneven shape can be transferred to the organic binder layer on the surface. As a kind of organic binder, an acryl-type (ACM), an acrylonitrile butadiene rubber (NBR), or a styrene butadiene rubber (SBR) resin etc. are mentioned, for example. Hereinafter, the impregnation treatment of the organic binder will be described. First, an aqueous dispersion containing an organic binder and water is prepared. This aqueous dispersion is poured onto a continuous lamination sheet conveyed on a conveyor. Subsequently, the resin (solid content) and moisture more than necessary amount are removed in a lamination sheet by a suction process.

Removal of moisture is performed by heat compression drying. The compression process is performed by two pressing plates having a predetermined uneven shape on the surface. The laminated sheet of alumina fibers is compressed between the two pressing plates. This removes excess moisture and simultaneously transfers the concavo-convex shape to both sides of the laminated sheet of alumina fibers. Compression reduces the volume of the laminated sheet of alumina fibers to facilitate handling. Furthermore, when exposed to exhaust gases during use, the organic binder is lost and the compressed laminate sheet of alumina fibers recovers its initial volume. Therefore, the holding sealing material 14 holds the exhaust gas purifying body 21 more firmly in the shell 23.

Next, the laminated sheet of alumina fibers is dried at 95 to 155 ° C. As long as the drying temperature is in the range of 95 ° C to 155 ° C, the laminated sheet can be completely dried in a short time without decomposing the organic binder, so that the production efficiency is not deteriorated. The drying operation is preferably performed for at least 100 seconds so that the laminated sheet of alumina fibers is sufficiently dried. The laminated sheet of alumina fibers can be compressed upon drying. Preferably, the laminated sheet of alumina fibers is compressed into a space of 4 to 15 mm. As long as this space is in the range of 4 to 15 mm, the volume reduction effect as described above is obtained without damaging the alumina fibers. The manufacture of the inorganic fiber mat 16 is completed in this manner.

Then, the inorganic fiber mat 16 is cut using a punching die or the like to obtain the holding sealing material 14r as shown in Fig. 9A. In this state, the inorganic fiber mat 6 has not yet been chamfered.

The chamfer 14m is described below. As shown in FIG. 5A, the inclined surface 14f faces the exhaust gas inlet. The inclined surface 14f is disposed between the first surface 14n of the holding seal member 14 in contact with the exhaust gas purifying body 21 and the second surface 14j in contact with the inner circumferential surface 23a of the shell. At least part of the surface. Preferably, the inclined surface 14f connects the second surface 14j with the position of the end surface 14d closer to the first surface 14n than the midpoint T2 of the thickness of the retaining seal member 14. . Most preferably, as shown in FIG. 5B, the inclined surface 14f connects the first surface 14n and the second surface 14j.

As described below, the angle θ3 formed between the inclined surface 14f and the second surface 14j is referred to as the chamfering angle or the angle of the inclined surface 14f. This angle θ3 is preferably 105 to 150 degrees, more preferably 130 to 140 degrees, and most preferably 135 degrees. When this angle [theta] 3 is 105 to 150 degrees, the projection 14k having an acute angle vertex is reduced in size or is not formed at all. This allows the holding sealer 14 to reliably hold the exhaust gas purifying body 21. In addition, clogging of the exhaust gas purifying body 21 is effectively prevented. In addition, since the performance of the holding seal member 14 for holding the exhaust gas purifying body 21 is not reduced, the holding sealing material 14 is caused to be out of position with respect to the exhaust gas purifying body 21 and into the shell. When pressed in, it is prevented from protruding from the end face of the exhaust gas purifying body 21. The angle θ4 formed between the inclined surface 14f and the end surface 14d is preferably 30 to 75 degrees, more preferably 40 to 50 degrees, and most preferably 45 degrees. For example, when the angle θ4 is 30 degrees, the angle θ1 is set to 60 degrees and the angle θ2 is set to 150 degrees.

Hereinafter, the production of the holding sealer 14, in particular, the formation of the chamfered portion 14m will be described. This chamfered portion 14m is formed by using the chamfering jig 11 as shown in Figs. The chamfering jig 11 includes the case 12 which has the recessed part 12a, and the cover 13 attached to the upper surface of the case 12 so that this recessed part 12a may be covered. When the cover 13 is attached to the case 12, the cover 13 and the recessed portion 12a define a housing chamber for accommodating the holding seal member 14r that has not yet been chamfered.

The case 12 and cover 13 are made of metal such as steel, stainless steel, or brass. The recessed part 12a has a shape corresponding to the shape of the holding sealing material 14r before chamfering. The side wall portion 12b and the bottom 12c of the recess 12a come into contact with the first surface 14n and the side surface of the unsealed holding seal member 14r. When the chamfered holding seal material 14r is accommodated in the recess 12a, the upper surface 12d of the case 12 is higher than the second surface 14j of the chamfered holding seal material 14r. desirable.

As shown in FIG. 9C, the sidewall portion 12b of the case 12 includes a sidewall portion 12e that faces the end surface 14d of the unsealed holding seal material 14r. A narrow groove, that is, a second slit 12f, is formed in the side wall portion 12e. The second slit 12f is inclined with respect to the side wall portion 12e at an angle θ2. The second slit 12f is preferably opened in the side wall portion 12e at a position lower than the midpoint T1 of the depth of the recessed portion 12a. More preferably, the second slit 12f is opened at the boundary between the side wall portion 12e and the bottom 12c. In this case, the inclined surface 14f is formed without reducing the width of the holding seal member 14.

The outer shape of the cover 13 is preferably the same as the outer shape of the case 12 in terms of alignment. The thickness of the cover 13 is set according to the size of the holding sealer 14 and the material of the cover 13.

The elongate opening, ie the first slit 13c, extends through the cover 13 from the upper surface 13a to the lower surface 13b. The first slit 13c is inclined with respect to the upper surface 13a or the lower surface 13b of the cover 13 at an angle θ1. The first slit 13c and the second slit 12f are laid along the same plane when the cover 13 is mounted on the case 12.

As shown in FIGS. 10 and 11, the inclined surface 14f ends through inserting the flat blade 15 through the first slit 13c and the second slit 12f and then moving the blade 15 as it is. It is formed on the surface 14d.

The angle θ1 of the first slit 13c, the position where the first slit 13c is opened in the upper surface 13a, and the position where the second slit 12f is opened in the sidewall portion 12e, It is appropriately set according to the inclined surface 14f to be formed. For example, when the angle θ3 of the inclined surface 14f is 135 degrees, the angle θ1 is set to 45 degrees and the angle θ2 is set to 135 degrees.

In order to form the chamfer 14m in the holding seal material 14, the chamfered holding seal material 14r cut out of the inorganic fiber mat 16 is located in the recess 12a of the case 12. As shown in FIG. The end surface 14d of the chamfered holding seal material 14r is adjacent to the side wall portion 12e including the second slit 12f. The cover 13 is fixed to the case 12 such that the first slit 13c and the second slit 12f lie along the same plane. The flat blade 15 is inserted through the first slit 13c until the tip of the flat blade 15 reaches the bottom (innermost part) of the second slit 12f. Then, the flat blade 15 is moved. This forms a chamfer 14m that includes a planar inclined surface 14f.

As shown in FIG. 12, the holding seal member 14 is wound around the exhaust gas purifying body 21 such that the inclined surface 14f is located on the outer side surface adjacent to the shell 23. The tab 14h is fitted in the recess 14g. A fastener such as the sealing tape 22 may be used to hold the recess 14g and the tab 14h together. The exhaust gas purifying body 21 to which the holding sealer 14 is wound around is press-fitted into the tubular shell 23 with the inclined surface 14f facing in the opposite direction to the press-in direction. Flange connected to the exhaust passage Is attached to each opening end of the tubular shell 23. This completes the manufacture of the exhaust gas purification device. An exhaust gas purification device is attached in the middle of the exhaust passage for use in a vehicle.

The holding sealer according to the preferred embodiment has the following advantages.

(1) The holding seal member 14 has a chamfered portion 14m including an inclined surface 14f. In the embodiment shown in FIG. 6A, the retaining seal member 14 deforms when pressed into the shell. Thus, a right angle, ie a substantially right angle, is formed between the inclined surface 14f and the outer surface 12j. In the conventional holding seal member 14p, the protrusion 14k is caused due to the friction with the shell inner peripheral surface 23a. However, the holding seal member 14 of the preferred embodiment does not have such a protrusion. In the embodiment shown in Fig. 6B, the protrusion 14k caused by the conventional holding seal member 14p is reduced in size. This prevents the exhaust gas purifying body 21 from being blocked by the inorganic fibers detached from the broken protrusion 14k.

(2) The protrusion 14k is not caused to the holding seal member 14. Or if it is caused, its size is reduced. Therefore, when attaching the shell 23 to the exhaust passage connecting flange, interference by the protrusion 14k does not occur.

(3) The inclined surface 14f is an edge between the second surface 14j and the end surface 14d so that the inclined surface 14f does not extend over the edge between the end surface 14d and the first surface 14n. It is formed by removing 14c. Therefore, the protrusion 14k can be removed or reduced in size without reducing the width of the holding seal member 14.

(4) The angle θ3 of the inclined surface 14f is 105 to 150 degrees. Therefore, by forming the chamfering portion 14m, it is possible to effectively prevent or minimize the formation of the protrusion 14k without deteriorating the function of the holding sealer 14, such as the characteristic for holding the exhaust gas purifying body 21. Can be.

(5) The chamfer 14m is formed by the chamfering jig 11 before pressing the holding sealing material 14 into the shell 23. Therefore, no damage is done to the exhaust gas purifying body 21 or the shell 23.

(6) The first slit 13c for guiding the movement of the flat blade 15 and the second slit 12f for guiding the movement of the tip of the flat blade 15 are laid along the same plane, and the predetermined It is inclined with respect to the upper surface 13a of the cover 13 at an angle. Thus, the inclined surface 14f is planar.

(7) The inorganic fiber mat 16 may contain an organic binder. The organic binder not only imparts a predetermined thickness and repulsive force to the inorganic fiber mat 16, but also prevents the scattering of the fibers, thereby facilitating the handling of the inorganic fiber mat 16.

(8) Inorganic fibers having an average fiber diameter of 6 µm or more are prevented from scattering in the air. In general, thick fibers tend to increase the probability of the presence of defects present in the fiber mat, reduce the mechanical strength of the fiber mat, and reduce the resistance to wind blowing caused by exhaust gases. When thick fibers having an average fiber diameter of 6 μm or more were used to produce the mat, such mats would be bulkier than mats made of fibers of the same mass per unit area and smaller average fiber diameters. This results in the large protrusion 14k being likely to occur. Such a factor prevents the use of thick fibers in the conventional holding seal material 14p, which inevitably results in the projection 14k. Conversely, with the retaining seal member 14 of the preferred embodiment having a chamfer portion 14m that prevents or minimizes the formation of the protrusion 14k, a thick fiber fiber mat having a large average fiber diameter can be used. .

(9) The holding sealer 14 is chamfered by moving the cutting blade along the first slit 13c of the chamfering jig 11. This prevents or minimizes the formation of the protrusion 14k.

(10) The second slit 12f extends into the side wall portion 12e of the recess 12a in the case 12. The tip of the flat blade 15 is inserted and moved into the second slit 12f to form the chamfer 14m.

(11) The chamfering jig 11 has a cover 13 that is detachable from the case 12. This facilitates the arrangement of the holding sealer 14 in the recess 12a. In addition, the cover 13 covering the case 12 prevents the holding sealer 14 from moving out of the recess 12a or deforming in the recess when chamfering the holding sealer 14.

(12) The shape of the recessed portion 12a is substantially the same as the shape of the holding sealer 14. This prevents the retaining seal material 14 from being arranged in the case 12 in the wrong manner.

Preferred embodiments may be modified as described below.

The inclined surface 14f has no planar shape and may be curved or stepped.

The inclined surface 14f is formed to connect the first surface 14n and the second surface 14j of the holding seal member 14 and may be inclined toward the exhaust gas inlet.

The inclined surface 14f of the holding seal member 14 may be formed by scissors or a knife instead of the chamfering jig 11.

One or more retaining seals 14 may be cut from a single inorganic fiber mat 16.

The holding sealer 14 is another form including a carrier carrying an exhaust gas purification filter such as a diesel particulate filter (DPF) for filtering particles in the exhaust gas and a catalyst for exhaust gas purification. Can be wound around the exhaust gas purification body.

Prior to pressing the retaining seal material 14 into the shell 23, a flange may be attached to the shell 23 at the opening end opposite the opening end into which the retaining seal material 14 is pressed.

In the embodiment shown in FIG. 5A, the inclined surface 14f connects the second surface 14j and the end surface 14d of the retaining seal material 14. However, the inclined surface 14f may connect the first surface 14n and the end surface 14d of the holding seal member 14. In this case, the holding seal member 14 is assembled into the shell 23 such that the first surface 14n of the holding seal member 14 is in contact with the inner circumferential surface 23a of the shell 23.

As long as the side wall portion 12e of the recessed portion 12a is in contact with the end surface 14d of the holding sealer 14, the shape of the recessed portion 12a is substantially the same as the shape of the holding sealer 14. It doesn't have to be.

Hereinafter, a modification of the chamfering jig 11 will be described with reference to FIGS. 13, 14, and 15.

In the embodiment shown in FIG. 13, the case 12 does not have a second slit 12f. In this case, the flat blade 15 is inserted and moved into the first slit 13c to form the chamfer portion 14m including the inclined surface 14f.

In the embodiment shown in FIG. 14, the chamfering jig 11 has an inclined slit 12g connecting the upper surface 12d and the side wall portion 12e of the case 12. The inclination angle and the formation position of the slit 12g are determined according to the inclined surface 14f to be formed. The flat blade 15 is inserted into the slit 12g0 such that the chamfer portion 14m including the inclined surface 14f is formed at the edge of the holding seal member 14 on the side close to the bottom 12c of the recess 12a. In the modification shown in Fig. 14, the holding seal member 14 is chamfered without using the cover 13.

In the embodiment shown in FIG. 15, the chamfering jig 11 has a slit 12g extending from the upper surface 12d of the case 12 and a slit 12h formed at the bottom 12c of the case 12. Has The slit 12h and the slit 12g are laid along the same plane. In this embodiment, the chamfer portion 14m including the inclined surface 14f is formed without being cut off and left. A cover 13 having a slit 13d may be used. In this case, the slit 13d, the slit 12h and the slit 12g are laid along the same plane. In this variant, the cover 13 prevents the holding seal member 14 from being deformed or protruding from the case 12. Thus, the chamfered portion 14m including the inclined surface 14f is formed without being cut off and left.

The cover 13 may be integrally formed with the case 12. The cover 13 may be connected to the case 12 by a hinge to open and close. If the cover 13 is formed integrally with the case 12, the case 12 preferably has an opening for inserting the holding seal member 14 into the recess 12a.

The experimental example of the holding sealing material will be described below.

Regarding Experimental Examples 1 to 7 of Table 1, the holding sealer was prepared by the method described below and attached to the metal shell. Then, the height of the protrusion caused by the holding sealer was measured and a wind test was conducted. The results are shown in Table 1.

(Method for producing alumina fiber mat)

First, in order to prepare a precursor of alumina fibers, silica sol was blended with a basic aqueous aluminum chloride solution. The aluminum content in the basic aqueous aluminum chloride solution is 75 g / L, and the Al / Cl atomic ratio is 1.8. The ratio between alumina and silica in the alumina fiber is Al ₂ O ₃ : SiO ₂ = 72 ± 2: 28 ± 2.

An organic polymer of polyvinyl alcohol is added to the precursor of alumina fibers and concentrated to prepare a spinning solution. The fibers are formed from the spinning solution by the blowing method. These fibers are cut to have an average fiber length of 12 mm. Laminated sheets of alumina fibers were prepared by folding the clumps of alumina fibers so as to overlap. This laminated sheet was needle punched at a density of 500 punches per 100 cm 2 and subsequently fired to a maximum temperature of 1250 ° C. The resulting laminated sheet of alumina Sungmu had a weight per unit area of 1160 g / cm 2, an average fiber diameter of 7.2 μm, and a minimum fiber diameter of 3.2 μm.

(Cutting of continuous laminated sheet of alumina fiber)

The continuous laminated sheet of alumina fibers was cut to refine the appearance to obtain a continuous laminated sheet having a vertical dimension of 12750 mm, a horizontal dimension of 1280 mm, and a thickness of 9 mm. The shot content in the continuous lamination sheet was measured using a sieve and a meter. The content rate of the 45 micrometers or more short in a continuous laminated sheet was 7 wt% or less of an alumina fiber mat.

(Resin impregnation)

An acrylic resin aqueous dispersion (product name LX803, manufactured by Zeon Corp., Japan) having a solid content concentration of 50 ± 10% and a pH value of 5.5 to 7.5 was prepared. This aqueous dispersion has a resin concentration of 4.5 wt%. The aqueous dispersion of the acrylic resin is poured onto the continuous laminated sheet of alumina fibers carried on the conveyor to impregnate the continuous laminated sheet of alumina fibers with the resin.

(Suction of solids)

In the continuous lamination sheet of the alumina fibers after the resin impregnation, a suction treatment was performed in order to remove excess solid content. The resin impregnation rate in the continuous laminate sheet after suction for 3 seconds was 10.0 wt%.

(dry)

After adjusting resin content, the continuous laminated sheet of alumina fiber was heat-compressed and dried. Drying was carried out at a temperature of 95-155 ° C. for at least 100 seconds. The compression interval during drying was 4 to 15 mm. After drying, the continuous laminated sheet was punched out to obtain a rectangular holding seal member 14r.

(Measure height of chamfers and protrusions)

The chamfered holding seal material 14 was obtained by removing the one side edge 14c of the holding seal material 14r obtained by the punching using the chamfering jig 11. This retaining seal member 14 has a sloped surface 14f that connects the edge between the first surface 14n and the end surface 14d to the second surface 14j, as shown in FIG. 5B. . As shown in Table 1, the angle θ3 formed between the second surface 14j and the inclined surface 14f is changed for each experimental example.

In each experimental example, the holding sealing material 14 was wound around the exhaust gas purifying body 21 and pressed into the shell 23. The height of the protrusion of the holding seal member 14 protruding from the end face of the exhaust gas purifying body 21 to the rear side (the side on which the exhaust gas is introduced) was measured. The measurement results are shown in Table 1.

(Style experiment)

Each holding seal member 14 was cut into a size of 25 × 50 mm to prepare a sample. The sample was clamped to a bulk density of 0.3 g / cm 3 and heated to 700 ° C. Then, the cutting surface caused by the air flow by exposing to a flow of air having a flow rate of 300 m / min, a pressure of 0.2 MPa, and 7000 pulse frequencies (on / off = 0.5 / 1.0) on the cutting surface. The erosion distance of was measured. This erosion distance measurement was repeated for five samples for each experiment, and the average of the measurements was obtained. The evaluation results are shown in Table 1. The result showing the erosion distance of 2.0 mm or less was evaluated as "good", the result showing the erosion distance of 2.1 to 6.0 mm was evaluated as "satisfaction", and the result showing the erosion distance of 6.1 mm or more was evaluated as "sufficient". .

Experimental Example Angle θ3 (degrees) Height of protrusion Appraisal One 135 0.00 Great 2 140 1.50 Great 3 130 1.30 Great 4 150 5.90 satisfied 5 105 5.90 satisfied 6 155 9.20 insufficiency 7 100 6.60 insufficiency

As can be seen from Table 1, the height of the projections decreases as the angle θ3 approaches 135 degrees. When the angle θ3 is outside the range of 105 to 150 degrees, the height of the protrusion is substantially increased, and the erosion distance is also increased. If the angle θ3 was less than 135 degrees, only very small protrusions were observed. When the angle θ3 is larger than 135 degrees, the holding performance of the holding sealer is slightly worsened, causing displacement with respect to the purifying body 21 and forming small protrusions.

Experimental Examples 8 to 10 shown in Table 2 are described below. In Experimental Examples 3-10, the angle (theta) 3 of the holding sealing material 14 was 130 degree | times. The average diameter of the fiber was measured by the method described later. In Experimental Examples 8-10, the holding sealing material 14 had the same conditions except the average fiber diameter. In addition, the protrusion height was measured in the same manner as in the experiment of Table 1.

(Measurement of Average Fiber Diameter)

In order to prepare a sample, alumina fibers were placed in a cylinder and pressure-pulverized at a pressure of 20.6 MPa. Samples were sorted by sieve. Gold etc. were deposited on the surface of the sample which passed the sieve. Then, a photograph of the sample was taken with an electron microscope of 1500 times. The diameter of at least 40 fibers shown in the photograph was measured. Five samples were prepared for each experimental example and photograph. The average fiber diameter is the average of five measurements. The results are shown in Table 2.

Experimental Example Average Fiber Diameter (μm) Height of protrusion (mm) 8 4.9 1.15 9 5.8 1.20 10 7.2 1.40

As can be seen from Table 2, the height of the protrusions slightly changed when the average fiber diameter was less than 6 μm. The height of the protrusions increased when the average fiber diameter was 6 μm or more. This shows that the holding sealer is bulkier when the average fiber diameter is large.

The contents of Japanese Patent Laid-Open Nos. 2001-316965 and 2003-20938 are incorporated herein by reference.

It will be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the description given herein, but may be modified within the scope of the appended claims and their identity.

According to the present invention as described above, there is provided a holding sealer for an exhaust gas treating body which can prevent clogging of the exhaust gas treating body, an exhaust gas purifying apparatus using the same, a chamfering jig for holding sealing material, and a manufacturing method of the holding sealing material. .

Claims (33)

A holding sealer 14 wrapped around an exhaust gas purifying body 21 having an inlet through which exhaust gas flows in and an outlet through which exhaust gas flows out, and for holding the exhaust gas purifying body in the tubular shell 23, wherein The maintenance seal material, A first surface 14n for contacting the exhaust gas purifying body when the holding sealer is in use; And A second surface 14j for contacting the shell when the holding sealer is wrapped around the exhaust gas purifying body; Including; The holding seal material, A chamfered end 14m positioned adjacent to the inlet of the exhaust gas purifying member during use of the holding seal material, wherein the chamfered end is at least inclined surface with respect to the second surface when the holding seal material is not used. (14f), The holding sealing material characterized by the above-mentioned. 2. The holding seal member as claimed in claim 1, wherein the inclined surface is inclined with respect to the second surface at an angle of 105 degrees to 150 degrees. The holding sealer as claimed in claim 1, wherein the inclined surface is inclined with respect to the second surface at an angle of 130 degrees to 140 degrees. The holding sealer as claimed in claim 1, wherein the inclined surface is adjacent to the second surface. 2. The chamfered end of claim 1, wherein the chamfered end comprises an inclined surface and an end surface 14d perpendicular to the first surface and located between the inclined surface and the first surface, the inclined surface being an end portion. A retaining seal material, characterized in that it extends between the surface and the second surface. The holding sealer according to claim 1, wherein the holding sealer is a sheet of inorganic fiber. 7. The holding sealing material according to claim 6, wherein the sheet is needle punched. 7. The holding sealing material according to claim 6, wherein the inorganic fiber is an alumina-silica-based fiber. 7. The holding sealing material according to claim 6, wherein the inorganic fiber has an average fiber diameter of 6 µm or more. The holding sealer according to claim 6, wherein the sheet contains an organic binder. The holding seal according to any one of claims 1 to 10, wherein the exhaust gas purifying body is a catalyst carrier carrying a catalyst for purifying exhaust gas or an exhaust gas purifying filter for collecting particles from the exhaust gas. ashes. As an exhaust gas purification device, An exhaust gas purifying body 21 including an inlet for introducing exhaust gas, an outlet for discharging exhaust gas, and a surrounding surface; The holding seal member (14) according to any one of claims 1 to 11; A tubular shell (23) for receiving the exhaust gas purifying body; It contains, The holding sealer is in contact with both the exhaust gas purifying body and the tubular shell. The exhaust gas purifying apparatus according to claim 12, wherein the holding seal member is elastically deformed between the exhaust gas purifying body and the tubular shell. A sheet-shaped holding sealing material 14 for use with an exhaust gas purifying body having an inlet through which exhaust gas flows, the holding sealing material having a uniform thickness, And a sloped surface (14f) inclined with respect to the inlet of the exhaust gas purifying member during use of the holding sealer. The method of claim 14, A first surface 14n for contacting the exhaust gas purifying body during use of the holding sealer; And Further comprising a second surface 14j opposite the first surface, The inclined surface is inclined with respect to the second surface at an angle of 105 degrees to 150 degrees. 16. The retention seal member of claim 15, wherein the inclined surface is inclined with respect to the second surface at an angle of 130 degrees to 140 degrees. 16. The retaining sealing material according to claim 15, wherein the inclined surface is adjacent to the second surface. 16. The retaining seal member according to claim 15, further comprising an end surface (14d) perpendicular to the first surface and located between the inclined surface and the first surface. The holding sealer according to claim 15, wherein the holding sealer is a sheet of inorganic fiber. 20. The holding sealing material according to claim 19, wherein the sheet is needle punched. 20. The holding sealing material according to claim 19, wherein the inorganic fiber is an alumina-silica fiber. 22. The holding sealer according to any one of claims 19 to 21, wherein the inorganic fiber has an average fiber diameter of 6 µm or more. As a chamfering jig 11 for use with the flat blade 15 to produce a holding seal material for wrapping around the exhaust gas purifying body to hold the exhaust gas purifying body 21 in the tubular shell 23. The holding seal member is sheet-shaped and includes a side surface and a bottom surface, wherein the chamfering jig includes: A case 12 having a side wall portion 12e and a bottom wall portion 12c for contacting the side surface and the bottom surface of the holding sealer, respectively, comprising a recess 12a defined by the side wall portion and the bottom wall portion. A case; And A cover 13 for covering the recess of the case; Including; The recess and the cover define a receiving chamber for accommodating the holding seal material, and the cover has a cover slit 13c for forming a chamfer 14m at one edge of the holding seal material accommodated in the recess. The slit is a chamfering jig, characterized in that for receiving the flat blade to guide the movement of the flat blade. 24. The apparatus of claim 23, wherein at least one of the side wall and the bottom wall of the recess in the case has a case slit 12f; 12g; 12h for receiving the flat blade, wherein the case slit and the cover slit have the same plane. Thus a chamfering jig characterized by being laid. 25. The chamfering jig according to claim 24, wherein the case slit is formed in the side wall portion of the concave portion. The chamfering jig according to claim 23, wherein the cover is detachable from the case. The method of claim 23, The exhaust gas purifying body includes an inlet through which exhaust gas flows in and an outlet through which exhaust gas flows out; The holding seal member has a first surface 14n for contacting the exhaust gas purifying body during use of the holding seal material, and a second surface 14j for contacting the shell when the holding sealing material is wound around the exhaust gas purifying body. And an end surface adjacent to the inlet of the exhaust gas purifying member during use of the holding seal material, wherein the end surface is chamfered to form an inclined surface connecting the second surface and the end surface. . 28. The method of claim 27, wherein the retaining seal material has a thickness and the inclined surface connects the second surface at a location on the end surface closer to the first surface than a midpoint of the retaining seal material thickness. Chamfer jig. The chamfering jig according to claim 23, wherein the cover slit is inclined with respect to the end surface of the holding seal member at an angle of 30 degrees to 75 degrees. A chamfering jig for use with a flat blade capable of producing a holding sealer for wrapping around the exhaust purge to hold the exhaust purge in the tubular shell, wherein the holding seal is sheet-shaped and has side surfaces and bottoms. A surface, wherein the chamfering jig, A case having a side wall portion and a bottom wall portion for contacting the side surface and the bottom surface of the holding sealer, respectively, the case including a recess defined by the side wall portion and the bottom wall portion, the case being the recessed portion. And a case slit for forming a chamfer on one side edge of the holding sealer and guiding the movement of the flat blade when received therein. 31. The flat blade of claim 30, wherein the flat blade comprises an intermediate portion and a tip portion, wherein the case slit is formed in the bottom wall portion to receive a slit formed in the side wall portion to guide the intermediate portion of the flat blade and the tip portion of the flat blade. Chamfer jig comprising a slit. A method for manufacturing a holding sealing material using a chamfering jig according to claim 23, wherein the manufacturing method is Cutting the inorganic fiber mat to form a sheet shape comprising a side surface, a bottom surface, first and second surfaces, an end surface, and an edge between the second surface and the end surface; Positioning the chamfering jig so as to contact the side surface and the bottom surface of the sheet-like article, respectively; Covering the case with the cover; Inserting a flat blade through the slit; And Moving the flat blade along the slit to chamfer an edge between the second surface and the end surface of the sheet-like to form the retaining seal material; Manufacturing method comprising a. 33. The method of claim 32, wherein moving the flat blade comprises forming an inclined surface connecting the end surface and the second surface of the retaining seal material.

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