JP2009281233A - Method of manufacturing catalyst holding seal member, and catalyst converter with catalyst holding seal member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a catalyst holding seal member which can excellently exhibit restoring force of a fiber raw material and has excellent holding force and sealability. <P>SOLUTION: This method of manufacturing a catalyst holding seal member is characterized to perform following processes in order: a fiber forming process for obtaining formed inorganic fibers by forming an inorganic material (S11); a piling process for obtaining a layered inorganic fiber aggregate by piling the formed inorganic fibers (S12); a burning process for obtaining a burned inorganic fiber aggregate by burning the layered inorganic fiber aggregate (S13); an overlapping process for obtaining an overlapped fiber aggregate by overlapping an organic fiber aggregate with the burned inorganic fiber aggregate (S14); a needle punching process for obtaining a confounded fiber aggregate by confounding organic fibers contained in the organic aggregate with inorganic fibers contained in the burned inorganic fiber aggregate by punching a needle into the overlapped fiber aggregate (S15); and a forming process for obtaining a formed fiber aggregate by forming the confounded fiber aggregate (S17). <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a catalyst holding seal member incorporated in a catalytic converter that purifies exhaust gas from a vehicle, and a catalytic converter including the catalyst holding seal member.

  Conventionally, as a method of manufacturing this type of catalyst holding seal member, as shown in FIG. 16, a spinning process (S1) in which a spinning solution is continuously ejected from a nozzle of a spinning device into the air to spin fibers, and spinning. Laminating step (S2) for laminating the obtained fibers to obtain a fiber assembly, needle punching step (S3) for subjecting the fiber assembly obtained in the laminating step to needle punching, and fibers subjected to needle punching treatment A method including a firing step (S4) of firing the aggregate under predetermined conditions is known (see, for example, Patent Document 1).

A binder impregnation step (S5) for impregnating an organic binder with respect to the fiber assembly manufactured by this manufacturing method, and a mat having a predetermined shape by cutting the fiber assembly impregnated with the binder by this binder impregnation step The catalyst holding sealing member incorporated in the catalytic converter is manufactured by adding the mat forming step (S6) to be molded into the catalyst converter.
JP 2002-129455 A

  However, in the conventional method for producing a catalyst holding seal member, the needle punching process is performed on the fiber assembly obtained in the laminating process, and the fibers in which the needles are driven by the needle punching process The mat is entangled and compressed by the fibers oriented in the thickness direction of the fiber assembly, so that the thickness of the mat having the predetermined shape is determined. As a result, the bending stress (MPa) of the fiber assembly is suppressed, and there is a problem that the surface pressure (MPa) obtained by the restoring force of the mat cannot be effectively used.

  That is, in the needle punching process, since the needle is driven so that the needle penetrates the fiber assembly, a part of the alumina fiber precursor made of alumina-silica-based ceramic fiber in the fiber assembly is longitudinal in the thickness direction. Oriented in the direction, the fibers will be entangled. In this case, the fiber aggregate is bound and compressed by a part of the longitudinal alumina fiber precursor, and the thickness of the fiber aggregate is determined by a part of the longitudinal alumina fiber precursor.

  The catalyst holding seal member is incorporated between a catalyst member and a case of a catalytic converter composed of an annular catalyst member and a case accommodating the annular catalyst member, and the catalyst member has a predetermined surface pressure (MPa) in the case. keeping.

  In this catalytic converter, the catalyst holding seal member formed in a flat plate shape is bent into an annular shape so as to surround the annular catalyst member so that the catalyst member is securely held, and is pressed into the catalytic converter and incorporated. A predetermined surface pressure is generated in the catalyst holding seal member in the catalytic converter. Therefore, this surface pressure is generated by the action of a restoring force against compression that the catalyst holding seal member tries to restore in the thickness direction and a restoring force against bending that tries to restore in the circumferential direction. In this regard, in the conventional catalyst holding seal member, in the needle punching process, many fibers in the fiber assembly are oriented in the thickness direction as the longitudinal direction, the fiber assembly is compressed, and the thickness of the fiber assembly is reduced. As a result, the number of fibers oriented in the transverse direction perpendicular to the thickness is reduced. When the amount of lateral fibers is reduced, the restoring force against bending caused by the lateral fibers is weakened. That is, the restoring force against bending of the fiber assembly is suppressed by the needle punching process, and the surface pressure is reduced as a whole when incorporated in the catalytic converter. Therefore, the surface pressure that the catalyst holding seal member should have is reduced. There was a problem that it could not be obtained sufficiently.

  As described above, since the needle punching process is performed on the fiber assembly obtained in the laminating process for laminating the fibers, the restoring force possessed by the material of the catalyst holding seal member manufactured through each process There was a problem that it was not possible to demonstrate effectively. That is, since the needle punching process is performed subsequent to the laminating process, there is a problem in that the restoring force of the material of the catalyst holding seal member is suppressed.

  An object of the present invention is to solve the above-described conventional problems and achieve the following objects. That is, an object of the present invention is to provide a method for producing a catalyst holding seal member that can effectively exhibit the restoring force of a fiber material and has excellent holding force and sealing performance.

  In order to achieve the above object, the method for producing a catalyst holding seal member according to the present invention includes: (1) a spinning step of spinning an inorganic material to obtain a spun inorganic fiber; and laminating the spun inorganic fiber to form a laminated inorganic fiber. A laminating step for obtaining a fiber aggregate, a firing step for firing the laminated inorganic fiber aggregate to obtain a calcined inorganic fiber aggregate, and an organic fiber aggregate superimposed on the calcined inorganic fiber aggregate. An entangled fiber assembly, and a entangled fiber assembly in which a needle is driven into the superimposed fiber assembly to entangle the organic fiber in the organic fiber assembly with the inorganic fiber in the fired inorganic fiber assembly. A needle punching step for obtaining a body, and a molding step for forming the entangled fiber assembly into a predetermined shape to obtain a shaped fiber assembly.

  With this configuration, unlike a general needle punching process in which a needle punching process is performed on a laminated inorganic fiber aggregate in which spun inorganic fibers are laminated, the laminated inorganic fiber aggregate is directly processed without needle punching. A fired inorganic fiber aggregate is manufactured by a firing step, and the obtained fiber aggregate is subjected to a needle punching process so that the inorganic fiber in the fired inorganic fiber aggregate is converted into an organic fiber in the organic fiber aggregate. Are finally entangled to produce a catalyst holding seal member.

  The catalyst holding seal member obtained by this manufacturing method is temporarily compressed by the needle punching process so that the organic fibers in the laminated organic fiber assembly are entangled with the inorganic fibers in the sintered inorganic fiber assembly and compressed in the thickness direction. Yes. When this catalyst holding seal member is placed in a high temperature environment, the organic fiber inside burns and disappears, so that the catalyst holding seal member is released from the binding by the organic fiber and the elasticity is increased. That is, the inorganic fiber and the organic fiber are entangled, and the inorganic fiber is released from the bent state by the organic fiber, so that the restoring force for restoring the inorganic fiber to the original state without bending is increased. The elasticity of the catalyst holding seal member against bending is increased, and for example, the repulsive force of the catalyst holding seal member is improved when the catalyst holding seal member is molded and pressed.

  In the method for producing a catalyst holding seal member according to (1), preferably, (2) the spinning step includes a step of spinning an organic material to obtain a spun organic fiber, and the laminating step includes the step of It includes a step of laminating spun organic fibers to obtain a laminated organic fiber aggregate, and the superposing step is configured to superimpose the laminated organic fiber aggregate and the laminated inorganic fiber aggregate.

  With this configuration, not only a spun inorganic fiber aggregate but also a spun organic fiber aggregate can be obtained by the spinning process, and a laminated organic fiber aggregate obtained from the spun organic fiber aggregate in the lamination process can be obtained. In the overlapping step, the laminated inorganic fiber aggregate can be superimposed. As a result, finally, a catalyst holding seal member capable of obtaining excellent mechanical properties having high elasticity can be efficiently manufactured.

  In the method for producing a catalyst holding seal member according to (1) or (2), preferably, (3) a binder impregnation step of obtaining an impregnated fiber aggregate by impregnating the entangled fiber aggregate with a binder. Consists of.

  With this configuration, the entangled fiber assembly subjected to needle punching is molded after being impregnated with a binder, and a molded fiber assembly is obtained, so that the mechanical strength of the portion impregnated with the binder is increased, For example, when the catalyst holding seal member is incorporated in an apparatus such as a catalytic converter, damage such as breakage is prevented.

  In order to achieve the above object, the catalytic converter according to the present invention includes (4) a catalyst carrier that purifies exhaust gas discharged from an internal combustion engine, a case that accommodates the catalyst carrier, and surrounding the catalyst carrier. In the catalytic converter including the catalyst holding seal member interposed between the catalyst carrier and the case, the catalyst holding seal member is the catalyst holding seal member according to the above (1) or (2). The entangled fiber assembly is manufactured by the manufacturing method described above.

  With this configuration, the catalyst converter is formed by directly firing the laminated inorganic fiber aggregates, performing needle punch processing on the obtained inorganic fiber aggregates obtained, and forming the resulting entangled fiber aggregates. A holding seal member is incorporated. As a result, since the thickness direction of the catalyst holding seal member is compressed by the needle punch process, the thickness becomes relatively small, and when the catalyst holding seal member is press-fitted into the catalytic converter, the workability of the press-in is improved, It is possible to prevent the catalyst holding seal member from being damaged during the press-fitting. Further, after the catalyst holding seal member is incorporated into the catalytic converter, the catalyst carrier is reliably held in the case, and the gap between the catalyst carrier and the case is reliably sealed.

  When this catalytic converter is installed in an exhaust pipe of an internal combustion engine, high-temperature exhaust gas discharged from the internal combustion engine is added to the catalyst holding seal member obtained by the manufacturing method according to (1) or (2) of the present invention. When the heat of the gas is transferred, the internal organic fibers are burned out, and the catalyst holding seal member is released from the binding by the organic fibers, thereby increasing the elasticity. That is, the inorganic fiber and the organic fiber are entangled, and the inorganic fiber is released from the bent state by the organic fiber, so that the restoring force for restoring the inorganic fiber to the original state without bending is increased. , The elasticity of the catalyst holding seal member is increased, and when it is molded into a cylindrical shape and incorporated in the catalytic converter, a high surface pressure is obtained, and the catalyst carrier is securely held in the case and reliably Sealed.

  In order to achieve the above object, the catalytic converter according to the present invention includes (5) a catalyst carrier for purifying exhaust gas exhausted from an internal combustion engine, a case for housing the catalyst carrier, and surrounding the catalyst carrier. In the catalytic converter including the catalyst holding seal member interposed between the catalyst carrier and the case, the catalyst holding seal member is formed by the method for manufacturing a catalyst holding seal member described in (3) above. It is characterized by comprising the manufactured impregnated fiber assembly.

  With this configuration, when the heat of the high-temperature exhaust gas discharged from the internal combustion engine is transferred to the catalyst holding seal member, similarly to the catalyst holding seal member obtained by the manufacturing method according to (1) of the present invention. The internal organic fibers are burned out, and the catalyst holding seal member is released from the binding by the organic fibers, thereby increasing the elasticity. That is, the inorganic fiber and the organic fiber are entangled, and the inorganic fiber is released from the bent state by the organic fiber, so that the restoring force for restoring the inorganic fiber to the original state without bending is increased. , The elasticity of the catalyst holding seal member is increased, and when it is molded into a cylindrical shape and incorporated in the catalytic converter, a high surface pressure is obtained, and the catalyst carrier is securely held in the case and reliably Sealed. Furthermore, since the catalyst holding seal member is constituted by the impregnated fiber aggregate that is impregnated with the binder in the binder impregnation step, the mechanical strength of the portion impregnated with the binder is increased, and the catalyst holding seal member is replaced with an apparatus such as a catalyst converter. When assembled in the case, damage such as breakage is prevented in advance. Moreover, since it has excellent mechanical strength, when the catalyst holding seal member is incorporated in an apparatus such as a catalytic converter, the catalyst carrier is more reliably held in the case and is more reliably sealed.

  ADVANTAGE OF THE INVENTION According to this invention, the restoring force which the fiber raw material has can be exhibited effectively, and the manufacturing method of the catalyst holding | maintenance sealing member which has the outstanding holding power and sealing performance can be provided.

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1 is a cross-sectional view of a catalytic converter 10 to which a catalyst holding seal member 20 manufactured by a method for manufacturing a catalyst holding seal member 20 according to an embodiment of the present invention is applied, and FIG. It is a disassembled perspective view.

  The catalyst holding seal member 20 according to the embodiment of the present invention constitutes a catalytic converter 10, and the catalytic converter 10 constitutes an exhaust gas aftertreatment device for a vehicle (not shown). It is composed of an internal combustion engine consisting of a four-cylinder known gasoline engine. The engine specifications of this internal combustion engine, such as its type and model, are arbitrarily selected. For example, a gas that uses gas, a liquid such as light oil or ethanol, or a natural gas as a raw material may be used as fuel.

  As shown in FIG. 1, the catalytic converter 10 includes a catalyst carrier 11, a case 12 that accommodates the catalyst carrier 11, and a catalyst holding seal member 20 that is incorporated between the catalyst carrier 11 and the case 12. And is installed in the exhaust gas passage so as to remove harmful components of the exhaust gas discharged from the internal combustion engine.

  The catalyst carrier 11 is, for example, a known one made of a honeycomb made of ceramic such as cordierite or a metal such as alumina and having a plurality of spaces penetrating in the axial direction so as to allow exhaust gas to pass therethrough. . A reduction catalyst made of an active metal that purifies exhaust gas components such as platinum, palladium, and rhodium is supported on the inner surface of the honeycomb, and the chemical reaction of the exhaust gas flowing through the honeycomb is promoted. ing.

  The case 12 includes a catalyst carrier accommodating portion 13, an upstream connecting portion 15 that is joined to one end of the catalyst carrier accommodating portion 13 and connected to the upstream exhaust pipe 14, and a catalyst carrier accommodating portion 13. It has a downstream connection part 17 joined to the other end part and connected to the downstream exhaust pipe 16.

As shown in FIG. 2, the catalyst carrier accommodating portion 13 is made of, for example, an upper accommodating portion 13u having a flange 13a made of heat resistant stainless steel and protruding around an edge portion, and the upper accommodating portion 13u. It is formed in a two-part structure formed by a lower accommodating portion 13s having a flange 13b.
Between the upper housing portion 13u and the lower housing portion 13s, the catalyst carrier 11 and the catalyst holding seal member 20 are housed, and the flanges 13a and 13b are joined and integrated to form an annular shape such as a circle or an ellipse. It is formed in a cylindrical shape having a cross section.

  The upstream side connection portion 15 has an exhaust gas passage 15g through which exhaust gas flows, and includes a cylinder 15t and a flange 15f connected to the exhaust pipe 14 and having a plurality of mounting holes 15h. Similarly to the upstream side connection part 15, the downstream side connection part 17 has an exhaust gas passage 17g for circulating exhaust gas therein, is connected to the cylinder 17t and the exhaust pipe 16, and has a plurality of mounting holes 17h. And a flange 17f.

The catalyst holding seal member 20 is mainly made of an inorganic fiber, is formed of an elastic material including an organic fiber, and has high heat resistance and elasticity. The catalyst holding seal member 20 is formed of a plate-like body having a uniform thickness t. When the catalyst holding seal member 20 is assembled between the catalyst carrier 11 and the case 12, a predetermined surface pressure P (MPa) is generated and the catalyst is retained. The carrier 11 is configured to be securely held in the case 12. Specifically, the packing density of the catalyst holding member 20 in the case 12 (g / cm ^{3) of,} for example, so as to be 0.1 to 1 g / cm ^3, the bulk density of the catalyst holding member 20 (g / cm ³ ) has been adjusted.

If the packing density is too small, the predetermined surface pressure P cannot be obtained, and the positions of the catalyst holding seal member 20 and the catalyst carrier 11 may be shifted. If the packing density is too large, the insertion work into the case 12 is performed. Is difficult, or the compressive stress (MPa) after assembly becomes high, and the inorganic fibers may be broken and scattered. In addition, each numerical value of the packing density of 0.1 to 1 g / cm ³ is not limited to this, and can be appropriately set based on setting conditions such as the characteristics, structure, shape, and size of the catalytic converter 10. .

Next, a method for manufacturing the catalyst holding seal member 20 of the present embodiment will be described.
FIG. 3 is a flowchart of the manufacturing method of the catalyst holding seal member 20 according to the present embodiment.
As shown in FIG. 3, the catalyst holding seal member 20 is manufactured by a spinning process (S11), a laminating process (S12), a firing process (S13), an overlapping process (S14), a needle punching process (S15), a binder. It includes each step performed in the order of the impregnation step (S16) and the molding step (S17).

  The spinning step (S11) is a known step for obtaining a spun inorganic fiber and organic fiber by spinning an inorganic material and an organic material, respectively, preparation of a solution and a solvent for preparing a spinning solution, setting of a spinning device, etc. The preparation process is also included.

When an inorganic material is spun to obtain a spun inorganic fiber, in the spinning step (S11), for example, a basic aluminum chloride aqueous solution prepared by dissolving aluminum in hydrochloric acid is mixed with a silica sol and an organic polymer in a predetermined ratio. Mixed and a spinning solution is prepared. In this case, the alumina fiber as the inorganic fiber finally obtained from the spinning solution, for example, the weight ratio of aluminum oxide (Al ₂ O ₃ ) to silicon dioxide (SiO ₂ ) is preferably about 80:20. Thus, silica sol (SiO ₂ ) is added to the basic aluminum chloride (AlCl ₃ ) aqueous solution.

The reason why the weight ratio of Al ₂ O ₃ and SiO ₂ is about 80:20 is that if there is too much silicon component (SiO ₂ ) in the spinning solution, fiberization will be easy but the heat resistance will be significantly reduced, This is because if the silicon component is too small, the heat resistance is improved, but the fibers are easily embrittled. Furthermore, in order to improve spinnability, additives such as water-soluble organic polymers such as polyvinyl alcohol, polyethylene glycol, starch, and cellulose derivatives are appropriately added as necessary. The obtained spinning solution is subjected to predetermined pretreatments such as decompression and concentration, and is prepared to be a solution suitable for spinning such as a predetermined concentration (% by weight), temperature (° C.), and viscosity (P: poise). To obtain a spinning solution for spinning. For example, the viscosity is adjusted to 10P to 100P.

  You may make it prepare a spinning solution so that the inorganic fiber finally obtained from the spinning solution in this Embodiment may become things other than an alumina fiber. For example, the spinning solution may be prepared so as to be glass fiber, ceramic fiber, or alumina-silica ceramic fiber.

  This spinning solution is set in a spinning device and spun. This spinning device has, for example, a supply nozzle that supplies a spinning solution, supplies the spinning solution from the supply nozzle in a high-speed spinning airflow, and has a thickness of several μmm and a length of several tens to several hundreds of μmm. Spinning is performed by a so-called blowing method in which a yarn-like fiber is formed, and the spinning airflow containing the fiber is made to collide with a fiber accumulation portion such as a belt having a flat surface and collected.

  Further, the spinning device is not limited to the blowing method, and may be another known spinning method. For example, the spinning solution is continuously ejected into the air from a nozzle provided in the spinning device, and the formed fibers are collected while being wound up while being stretched, and the solvent is dried by a heated gas, so that the yarn is A dry spinning method may be used. In the case of this dry spinning method, the winding speed is fast, the spinning conditions can be set widely, and the solvent can be easily recovered.

  When spinning an organic material to obtain a spun organic fiber, in the spinning step (S11), for example, the raw material polymer compound is heated and melted and extruded into air at a constant speed from a nozzle of a spinneret to form a fiber. It may be a melt spinning method in which fibers are produced by cooling and solidification. Since no solvent or coagulating liquid is used, spinning at high speed is possible, but the melt is oxidized and susceptible to thermal decomposition, and its fluidity depends on the temperature, so the time required for dissolution is shortened and the temperature is accurate. Done by control. Specifically, melt lattice spinning method for spinning polyamide fiber and polyester fiber, nylon fiber, polyester fiber, vinylidene chloride copolymer fiber, screw extrusion spinning method for spinning polyolefin fiber, continuous polymerization spinning for spinning nylon 6 fiber This is done by law.

  Alternatively, a wet spinning method may be used in which the stock solution is extruded into a coagulation bath from a nozzle of a spinning port and is solidified therein to form a yarn. Specifically, it is performed by a centrifugal method, a bobbin method, a continuous method, or the like, and viscose fiber, vinylon fiber, acrylic fiber, or the like can be spun. Alternatively, a spunbond method in which a thermoplastic polymer is melted and discharged from a nozzle into a continuous long fiber may be used.

The laminating step (S12) is a laminated fiber assembly composed of alumina fiber precursors as inorganic fiber precursors obtained by laminating the spun inorganic fibers and the organic fibers obtained in the spinning step (S11). And a known process for obtaining a laminated organic fiber assembly composed of organic fibers. For example, in the case of a spun inorganic fiber aggregate manufactured by a blowing method, a thin layer of spun fiber aggregates accumulated in a sheet shape in a fiber accumulation part is folded and repeatedly stacked, and a thin layer of 10 to 100 layers A sheet-like laminated fiber assembly having a predetermined bulk density (g / cm ³ ) made of a sheet can be obtained.

In the case of a spun inorganic fiber manufactured by the dry pressure spinning method, the fiber-like inorganic fiber obtained by the spinning process is chopped into a predetermined length to make a relatively short fiber. Dispersion, and the obtained fiber dispersion is poured into a forming jig and pressed and dried to obtain a laminated fiber aggregate having a predetermined bulk density (g / cm ³ ) composed of laminated fibers. Can do.

  In the case of the spun organic fiber obtained by the organic fiber spinning method described above, the lamination step (S12) for laminating the organic fiber can be performed together with the spinning step (S11). In the above-described spinning step (S11), a laminated organic fiber aggregate can also be obtained in the production process of obtaining the spun organic fiber from the organic material. For example, in the process of producing fibers by extruding into the air at a constant speed from the nozzle of the spinneret and making it into a fiber and cooling and solidifying, the fiber is laminated when the spinning solution is made into a fiber and cooled and solidified. Then, it may be formed into a sheet shape.

  FIG. 4 is a perspective view of an inorganic fiber assembly and an organic fiber assembly in the embodiment of the present invention, (a) shows a laminated inorganic fiber assembly Wm, and (b) shows a laminated organic fiber. The aggregate Wu is shown, and (c) shows a state in which the fired inorganic fiber aggregate Ws and the laminated organic fiber aggregate Wu are overlapped.

As shown in FIG. 4 (a), the laminated inorganic fiber aggregate Wm is set in conditions such as the subsequent manufacturing process and the shape, size, and structure of the completed catalyst holding seal member 20 during or after lamination. Is formed into a sheet having a width Lw, a length Ld, and a thickness tw.
Further, as shown in FIG. 4B, the laminated organic fiber aggregate Wu also has a predetermined thickness t ₁ and is substantially the same as the laminated inorganic fiber aggregate Wm, like the laminated inorganic fiber aggregate Wm. It is formed in the same shape.

  In the firing step (S13), the laminated inorganic fiber aggregate made of the alumina fiber precursor obtained in the lamination step (S12) is dried and sintered by baking at a high temperature, and has high heat resistance and is applied with a compressive load. This is a known process for obtaining a fired inorganic fiber aggregate made of alumina fibers having high elasticity at the time.

  In the firing step, for example, the laminated inorganic fiber aggregate is fired at 1,000 ° C. to 1,500 ° C. Specifically, the laminated inorganic fiber aggregate is heated, held at about 300 ° C. for several hours, increased from 300 ° C. to 600 ° C. at 2 ° C. to 3 ° C. per minute, and further, 500 ° C. to 1,500 Firing is carried out by sequentially raising the temperature from 4 ° C. to 6 ° C. per minute at 1 ° C., and holding several tens of minutes at 1,000 ° C. to 1500 ° C. When this firing temperature is less than 1,000 ° C. or exceeds 1,500 ° C., or when the firing time is less than a predetermined time or exceeds a predetermined time, the fiber assembly can be sufficiently dried and sintered. Therefore, there is a possibility that high heat resistance and high elasticity at the time of applying a compressive load cannot be obtained.

  The superimposing step (S14) is a step of superimposing the laminated organic fiber aggregate Wu on the fired inorganic fiber aggregate Ws to obtain a superposed fiber aggregate Wk.

As shown in FIG. 4C, in the superimposing step (S14), the laminated organic fiber aggregate Wu is simply joined to the lower surface side of the fired inorganic fiber aggregate Ws by a joining means such as a superposition adhesive. Thus, the laminated fiber assembly Wk having a thickness tw + t ₁ is manufactured. Note that the laminated fiber assembly Wk may be manufactured by superimposing the laminated organic fiber assembly Wu on the upper surface side of the fired inorganic fiber assembly Ws.

In the needle punching step (S15), the overlapped fiber aggregate Wk obtained in the overlapping step (S14) is subjected to a needle punching process by, for example, a known needle punching device 30, and the fired inorganic fiber aggregate In this step, the organic fibers in the laminated organic fiber aggregate Wu in the body Ws are entangled with each other and compressed in the thickness direction to obtain an entangled fiber aggregate having a predetermined bulk density (g / cm ³ ). A part of the organic fibers in the laminated organic fiber aggregate Wu by the needle punching process is hooked and drawn into the fired inorganic fiber aggregate Ws by the return formed in the needle, and inside the fired inorganic fiber aggregate Ws. Are intertwined with each other.

This organic fiber is configured to burn when it reaches a high temperature. When the organic fiber is burned out, the fired inorganic fiber aggregate Ws is released from being bound by the organic fiber, and the elasticity is increased. Yes. In addition, the laminated organic fiber aggregate Wu of the superimposed fiber aggregate Wk shown in FIG. 4C is also burned and disappears at a high temperature.
Therefore, the thickness t ₁ of the laminated organic fiber aggregate Wu is a thickness that does not affect the elasticity of the calcined inorganic fiber aggregate Ws obtained after being burned out at a high temperature.

  Here, the high temperature means, for example, that the fired inorganic fiber aggregate Ws is molded through the subsequent steps to produce the catalyst holding seal member 20, the catalyst holding seal member 20 is incorporated into the catalytic converter 10, and further, the catalytic converter When 10 is mounted on a vehicle, it refers to the temperature of exhaust gas that is discharged from the engine during high-load operation of the vehicle and flows through the catalytic converter 10, and is about several hundred degrees Celsius.

  This organic fiber has a mechanical strength capable of sufficiently binding the fired inorganic fiber aggregate Ws obtained in the firing step (S13), and is configured to have flammability that burns away at a high temperature. Specifically, organic fibers include olefin fibers such as polypropylene and polyethylene, polyester fibers such as polyethylene terephthalate, polyamide fibers such as nylon 6 and nylon 66, polyacrylonitrile fibers, polyvinyl alcohol fibers, and polyvinylidene chloride. Thermoplastic resin fibers such as fibers can be used.

  The manufacturing method of the catalyst holding seal member 20 according to the present embodiment is different from a general needle punching process in which a needle punching process is performed on a fiber assembly made of an alumina fiber precursor obtained in the lamination process (S12). It is characterized in that needle punching is performed on the fired inorganic fiber aggregate Ws made of alumina fibers obtained in the firing step (S13). Therefore, this needle punching process has a so-called temporary fixing effect, and can improve the assembling workability when the manufactured catalyst holding seal member 20 is assembled into the catalytic converter 10 by press fitting.

  FIG. 5 is a plan view of the needle punch device 30 used in the needle punching process in the method for manufacturing the catalyst holding seal member 20 according to the present embodiment, and FIG. 6 is a cross-sectional view showing the AA cross section of FIG. FIG. 7 is a cross-sectional view showing a BB cross section of FIG. 5.

  As shown in FIG. 5, the needle punch device 30 is provided on the upstream side of the first needle punch portion 31, the second needle punch portion 32, and the first needle punch portion 31, and the overlapped fiber assembly Wk is An upstream conveyor 33 that transports the first needle punch unit 31, an intermediate conveyor 34 that transports the overlapped fiber aggregate Wk processed by the first needle punch unit 31 to the second needle punch unit 32, and a second needle A downstream conveyor 35 is provided on the downstream side of the punch portion 32 and conveys the overlapped fiber assembly Wk processed by the second needle punch portion 32 to the downstream side.

  As shown in FIG. 6, the first needle punch portion 31 is conveyed with a needle board 31b and a plurality of needles 31n arranged at equal intervals on the bottom surface portion 31t of the needle board 31b and fixed at one end to the needle board 31b. An upper support plate 31p having a plurality of upper insertion holes 31u formed so as to pass through the needle 31n and support the upper surface side of the overlapped fiber assembly Wk indicated by the two-dot chain line, and the overlapped fiber assembly The lower support plate 31q having a plurality of lower insertion holes 31s formed so as to penetrate the needle 31n and support the lower surface side of the Wk.

  In the first needle punch portion 31 of the present embodiment, the plurality of needles 31n and the upper insertion hole 31u and the lower insertion hole 31s through which the needles 31n are inserted are orthogonal to the direction in which the overlapped fiber assembly Wk is conveyed. A plurality of rows may be formed in such a direction.

  In the vicinity of the tip portion of each needle 31n, "return" for hooking a part of the organic fibers of the overlapped fiber assembly Wk when stabbed into the stacked organic fiber assembly Wu of the overlapped fiber assembly Wk. Is formed. After the needle 31n is lowered and stabbed into the laminated organic fiber aggregate Wu, when the needle 31n rises and returns to its original position, a part of the organic fiber of the overlapped fiber aggregate Wk is caught in the return and fired. The organic fibers drawn into the inorganic fiber aggregate Ws and entangled with the inorganic fibers in the fired inorganic fiber aggregate Ws are entangled.

  As described above, the laminated fiber aggregate Wk is placed on the upstream conveyor 33 so that the laminated organic fiber aggregate Wu is positioned below the calcined inorganic fiber aggregate Ws. The overlapped fiber assembly Wk may be placed on the upstream conveyor 33 so that the laminated organic fiber assembly Wu is positioned above the assembly Ws. In this case, the needle 31n descends and first punctures the laminated organic fiber aggregate Wu, and then stabs the baked inorganic fiber aggregate Ws. When the body Wu is pierced, the organic fiber inside is hooked and drawn into the fired inorganic fiber aggregate Ws.

  The setting conditions of the needle punching process such as the number, arrangement interval, and thickness of the needles 31n can be appropriately set based on the setting conditions such as the characteristics, structure, shape and size of the catalytic converter 10.

  In the first needle punch portion 31, the needle board 31b is lowered by receiving a vertical driving force from a driving source (not shown), and the upper support plate 31p is lowered to press the overlapped fiber assembly Wk, and at the same time, each needle 31n passes through each upper insertion hole 31u, passes through the overlapped fiber assembly Wk, and further passes through each lower insertion hole 31s. Furthermore, after each needle 31n passes through each lower insertion hole 31s, that is, after the needle punching operation, the needle 31n rises and returns to the original position. A feeding operation for conveying Wk by a predetermined distance is performed. The needle punching operation and feeding operation of these needles 31n are repeatedly performed.

  In this way, the needle punching process was performed uniformly over the entire overlapped fiber assembly Wk, and the inorganic fibers in the overlapped fiber assembly Wk were entangled with the organic fibers, thereby being bound and compressed. An entangled fiber assembly Wp is obtained. The feed amount per one feeding operation of the overlapped fiber assembly Wk in the needle punching process, for example, coincides with the needle pitch representing the interval between the needles 31n, and the longitudinal and lateral directions of the overlapped fiber assembly Wk. Are subjected to needle punching at equal intervals to obtain a uniformly entangled fiber assembly Wp.

  As shown in FIG. 7, the second needle punch portion 32 is arranged on the needle board 32b and the bottom surface portion 32t of the needle board 32b so as to be alternately dense and coarse as shown in FIG. A plurality of needles 32n whose one ends are fixed to the needle board 32b and a plurality of needles 32n formed so as to pass through the needles 32n while supporting the upper surface side of the overlapped fiber assembly Wk indicated by the two-dot chain line conveyed. An upper support plate 32p having an upper insertion hole 32u and a lower support plate having a plurality of lower insertion holes 32s formed so as to support the lower surface side of the overlapped fiber assembly Wk and penetrate the needle 32n. 32q.

  In the overlapped fiber assembly Wk needle-punched in the second needle punch portion 32, the portion indicated by the region A in FIG. 5 is needle punched more than the other portions. The inorganic fibers and the organic fibers are entangled with each other and compressed densely, and the mechanical strength is relatively higher than other portions.

  Specifically, the portion indicated by region A in FIG. 5 that has been subjected to the needle punching process by the second needle punching portion 32 has the catalyst holding seal member 20 incorporated in the catalytic converter 10, and the catalytic converter 10 is mounted on the vehicle. In this case, it is a portion around the upstream end in the exhaust gas flow direction and around the downstream end. Each needle 32n is spaced at an interval shorter than the needle pitch between the needles in the first needle punch portion 31, for example, at an interval of 1/3 of the needle pitch, so that needle punching processing at a high density is performed only on this portion. Is arranged.

  In the second needle punch portion 32 of the present embodiment, similar to the first needle punch portion 31, the plurality of needles 32n, the upper insertion holes 32u through which the needles 32n are inserted, and the lower insertion holes 32s are overlapped to form a fiber assembly. A plurality of rows may be formed in a direction orthogonal to the direction in which Wk is conveyed.

In the vicinity of the tip of each needle 32n, similar to the first needle punch portion 31, when pierced into the laminated organic fiber aggregate Wu of the superimposed fiber aggregate Wk, a part of the overlapped fiber aggregate Wk A “return” for hooking organic fibers is formed. After the needle 32n descends and is stabbed into the laminated organic fiber aggregate Wu, when the needle 32n rises and returns to the original position, some of the organic fibers of the overlapped fiber aggregate Wk are caught in the return and fired. The organic fibers drawn into the inorganic fiber aggregate Ws and entangled with the inorganic fibers in the fired inorganic fiber aggregate Ws are entangled.
Further, the setting conditions of the needle punching process such as the number, the arrangement interval, and the thickness of the needles 32n can be appropriately set based on the setting conditions such as the characteristics, structure, shape and size of the catalytic converter 10.

  In the second needle punch portion 32, as in the first needle punch portion 31, the needle board 32 b is lowered by receiving a driving force in the vertical direction from a driving source (not shown), and the upper support plate 32 p is lowered to overlap the fiber bundle. At the same time as pressing the body Wk, each needle 32n passes through each upper insertion hole 32u, passes through the overlapped fiber assembly Wk, and further passes through each lower insertion hole 32s. Furthermore, after each needle 32n passes through each lower insertion hole 32s, that is, after the needle punching operation, the needle 32n rises and returns to the original position, and the intermediate conveyer 34 and the downstream conveyer 35 allow the overlapped fiber assembly. A feeding operation for conveying Wk by a predetermined distance is performed. The needle punching operation and feeding operation of these needles 32n are repeatedly performed.

  In this way, the needle punching process that partially reinforces the overlapped fiber aggregate Wk is performed, and the entangled fiber aggregate Wp that is bound and compressed by the entanglement of the inorganic fiber with the organic fiber is obtained. Similar to the first needle punch portion 31, the feed amount per feed of the overlapped fiber assembly Wk in the needle punch process coincides with the needle pitch representing the interval between the needles 31n.

  In this needle punch device 30, the overlapped fiber assembly Wk conveyed by the upstream conveyor 33 is subjected to a first needle punch process by the first needle punch unit 31 and compressed in the thickness direction. It is conveyed by the intermediate conveyor 34, and after the second needle punching process 32 is performed and reinforced by the second needle punch unit 32, it is conveyed by the downstream conveyor 35 toward the equipment installed on the downstream side. It has become.

  In the binder impregnation step (S16), the entangled fiber assembly Wg obtained by the needle punching step (S15) is further impregnated with an organic binder by the binder impregnation device 40, and reinforced impregnated fiber assembly Wg. It is a known process for obtaining

  FIG. 8 is a plan view of a binder impregnation apparatus 40 used in the binder impregnation step in the method for manufacturing the catalyst holding seal member 20 according to the embodiment of the present invention, and FIG. 9 is a cross-sectional view taken along the line CC in FIG. FIG. 10 is a cross-sectional view taken along the line DD of FIG.

  As shown in FIG. 8, the binder impregnation apparatus 40 is provided on the upstream side of the first binder impregnation part 41, the second binder impregnation part 42, and the first binder impregnation part 41, and the entangled fiber assembly Wp is disposed in the first part. An upstream conveyor 43 that transports the first binder impregnation unit 41, an intermediate conveyor 44 that transports the entangled fiber aggregate Wp processed by the first binder impregnation unit 41 to the second binder impregnation unit 42, and a second binder impregnation unit And a downstream conveyor 45 that conveys the impregnated fiber aggregate Wg processed by the second binder impregnation unit 42 to the downstream side. The upstream conveyor 43, the intermediate conveyor 44, and the downstream conveyor 45 may be connected and integrated to form a single conveyor.

  As shown in FIG. 9, the first binder impregnation unit 41 includes a shower board 41b and three binder showers 41s arranged at equal intervals on the bottom surface part 41t of the shower board 41b and fixed at one end to the shower board 41b. It is configured to include.

  The binder shower 41 s has a nozzle 41 n formed at the tip, and emits a liquid binder from the nozzle 41 n toward the upper surface of the entangled fiber assembly Wp. The binder radiated from the nozzle 41n of each binder shower 41s is applied so as to be evenly applied over the entire upper surface of the entangled fiber assembly Wp, and is applied to the entangled fiber assembly Wp. The applied binder is uniformly impregnated throughout.

  The binder is continuously radiated from the nozzles 41n of the binder showers 41s, and the entangled fiber aggregates Wp are continuously conveyed by the upstream conveyor 43 and the intermediate conveyor 44, so that the entire binder is uniform. Applied and impregnated.

  As shown in FIG. 10, the second binder impregnating portion 42 includes two binders arranged at predetermined intervals at the center of the shower board 42 b and the bottom surface portion 42 t of the shower board 42 b and having one end fixed to the shower board 42 b. The shower 42s, two binder showers 42r arranged at both ends of the bottom surface part 42t and fixed at one end to the shower board 42b, and the binder discharged from the binder shower 42s and the binder shower 42r are applied in a predetermined range. A through hole is formed so as to include a masking board 42m disposed on the top of the entangled fiber assembly Wp.

  The binder shower 42 s has a nozzle 42 n formed at the tip, and radiates a liquid binder from the nozzle 42 n toward the through hole of the masking board 42 m. The binder shower 42r is formed with a nozzle 42z having a smaller binder discharge amount than the binder shower 42s at the tip of the binder shower 42s, and radiates a liquid binder from the nozzle 42z toward the through hole of the masking board 42m. It is supposed to let you.

  Binders radiated from the nozzles 42n of the binder showers 42s and the nozzles 42z of the binder showers 42r pass through the through holes of the masking board 42m and adhere to the upper surface of the entangled fiber assembly Wp.

  The binder is continuously emitted from the nozzles 42n of the binder showers 42s and the nozzles 42z of the binder showers 42r, and the entangled fiber aggregates Wp are continuously conveyed by the intermediate conveyor 44 and the downstream conveyor 45. Therefore, it is uniformly applied and impregnated in a predetermined range.

  This binder is made of a known organic binder such as rubber latex, prepared to be a latex solution having a predetermined viscosity suitable for coating, and supplied to the first binder impregnation unit 41 and the second binder impregnation unit 42. The

  The setting conditions of the binder impregnation process such as the number of binder showers 41s, 42s, 42r, the arrangement interval, the amount of binder discharged from the nozzles 41n, 42n, 42z and the nozzles 41n, 42n, 42z are as follows. It can be appropriately set based on setting conditions such as characteristics, structure, shape and size.

  FIG. 11 is an explanatory diagram for explaining a molding process for obtaining a shaped fiber assembly Wf having a predetermined shape by cutting the impregnated fiber assembly Wg in the present embodiment, and (a) is an impregnated product before processing. It is a top view of fiber aggregate Wg, and (b) is a top view of processed fiber aggregate Wf after processing.

  The forming step (S17) is a known step of cutting the impregnated fiber assembly Wg impregnated with the binder in the binder impregnation step (S16) and forming it into a predetermined shape to obtain a mat-shaped formed fiber assembly Wf. is there.

  In the forming step (S17), the impregnated fiber assembly Wg is cut by a cutter device (not shown) as shown in FIG. 11 (a), and has a rectangular plane as shown in FIG. 11 (b). Thus, a mat-shaped molded fiber assembly Wf having one end in the longitudinal direction formed in a convex shape and the other end formed in a concave shape is obtained.

As shown in FIG. 11 (a), 12 shaped fiber aggregates Wf whose longitudinal side surfaces are reinforced by needle punching and binder impregnation are obtained from one impregnated fiber aggregate Wg. It is done.
You may form both ends of this shape | molded fiber assembly Wf in shapes other than uneven | corrugated shape. For example, it may be formed at both flat end portions without unevenness, may be formed at inclined both end portions, or may be formed at both wave-shaped end portions. Moreover, the both ends may not be formed at the ends in the longitudinal direction. For example, you may form so that it may have both ends in the transversal direction, ie, the direction orthogonal to a longitudinal direction.

  Next, a method for manufacturing the catalytic converter 10 to which the catalyst holding seal member 20 of the present embodiment is applied will be described.

  FIG. 12 is an explanatory diagram of a method for manufacturing the catalytic converter 10 in the present embodiment, where (a) shows a state before the molded fiber aggregate Wf is wound around the catalyst carrier 11, and (b) Shows a state where the catalyst carrier 11 is placed on the molded fiber aggregate Wf, and (c) shows a state where the molded fiber aggregate Wf is wound around the catalyst carrier 11. FIG. 13 is an explanatory diagram of a method for manufacturing the catalytic converter 10, wherein (a) shows an exploded perspective view of the catalyst carrier 11 and each component wound with the molded fiber aggregate Wf, and (b) The perspective view of the assembled catalytic converter 10 is shown.

  First, as shown in FIGS. 12 (a) and 12 (b), the molded fiber assembly Wf is wound around the catalyst carrier 11, and as shown in FIG. 12 (c), the molded fiber assembly Wf The convex part t and the concave part o are fitted. Next, the catalyst carrier 11 is sandwiched between the upper housing portion 13u and the lower housing portion 13s, the flange 13a of the upper housing portion 13u and the flange 13b of the lower housing portion 13s are brought into contact with each other, and bonding such as spot welding is performed. The flange 13a and the flange 13b are joined by the means. Next, one end of the joined catalyst carrier housing portion 13 and the end portion 15a of the upstream connection portion 15 are joined by a joining means such as arc welding, and further, the other end portion of the catalyst carrier housing portion 13 and the downstream side thereof. The end portion 17a of the side connecting portion 17 is joined by joining means such as arc welding, so that the catalytic converter 10 is obtained as shown in FIG.

Since the catalyst holding seal member 20 according to the present embodiment is manufactured by the above manufacturing method, the following effects can be obtained.
FIG. 14 is a cross-sectional view of the catalytic converter 10 in which the catalyst holding seal member 20 according to the present embodiment is incorporated.

  That is, the manufacturing method of the catalyst holding seal member 20 according to the present embodiment includes a spinning step (S11) of spinning an inorganic material and an organic material to obtain a spun inorganic fiber and an organic fiber, and a spun inorganic fiber and an organic fiber. Lamination process (S12) for obtaining laminated inorganic fiber aggregates Wm and organic fiber aggregates Wu by laminating fibers, and firing process for firing sintered inorganic fiber aggregates Wm to obtain calcined inorganic fiber aggregates Ws (S13), a superposition step (S14) of superposing the laminated organic fiber aggregate Wu on the fired inorganic fiber aggregate Ws to obtain a superposed fiber aggregate Wk, and a needle on the superposed fiber aggregate Need to obtain the entangled fiber aggregate Wp by entangled the organic fibers in the laminated organic fiber aggregate Wk with the inorganic fibers in the fired inorganic fiber aggregate. A punching step (S15), a binder impregnation step (S16) for impregnating the entangled fiber aggregate Wp with a binder to obtain an impregnated fiber aggregate Wg, and cutting the impregnated fiber aggregate Wg into a predetermined shape and molding And a molding step (S17) for obtaining a finished fiber assembly Wf.

  As a result, the problem that the surface pressure that the catalyst holding seal member should have cannot be obtained as in the conventional catalyst holding seal member is solved.

  That is, in the manufacturing method of the catalyst holding seal member 20 of the present embodiment, the laminated inorganic fiber is different from the general needle punching process in which the needle punching process is performed on the laminated inorganic fiber aggregate obtained in the laminating process. A sintered inorganic fiber aggregate Ws is produced by a firing step (S13) in which the fiber aggregate Wm is directly fired without needle punching, and the obtained inorganic fiber aggregate Ws is subjected to needle punching. The catalyst holding seal member 20 is finally manufactured by entanglement of the organic fibers in the laminated organic fiber aggregate Wu with the inorganic fibers in the sintered inorganic fiber aggregate WS. The catalyst holding seal member 20 obtained by this manufacturing method is entangled with the organic fibers in the laminated organic fiber aggregate Wu and the inorganic fibers in the temporarily burned inorganic fiber aggregate Ws by the needle punching process. Compressed in the direction. When the catalyst holding seal member 20 is incorporated in the catalytic converter 10, the restoring force of the fiber material can be effectively exhibited, a suitable surface pressure can be obtained, and an excellent holding force and seal can be obtained. The catalyst carrier can be held with good properties.

  As shown in FIG. 14, in this catalytic converter 10, when the catalytic converter 10 is mounted on a vehicle, high-temperature exhaust gas discharged during high-load operation of the vehicle flows in the direction of the arrow and is converted to the catalytic converter. When the gas flows through the exhaust gas 10, high heat energy of the exhaust gas is transmitted to the catalyst holding seal member 20 of the catalytic converter 10, and the organic fibers of the catalyst holding seal member 20 are combusted by this heat energy. Since the organic fibers are burned and lost, the catalyst holding seal member 20 is released from the binding by the organic fibers, and the elasticity of the catalyst holding seal member 20 is increased.

  That is, the inorganic fiber and the organic fiber are entangled, and the inorganic fiber is released from the bent state by the organic fiber, so that the restoring force for restoring the inorganic fiber to the original state without bending is increased. Further, the elasticity of the catalyst holding seal member 20 against bending is increased, and for example, the repulsive force when molded and pressed into a cylindrical shape is improved.

  As shown in FIG. 14, the catalyst holding seal member 20 formed in a circular shape in the catalytic converter 10 increases the pressing force Fo that presses the inner wall surface of the case 12 as shown in FIG. The pressing force Fi that presses the outer peripheral surface of the carrier 11 is increased. As a result, a high surface pressure (MPa) of the catalyst holding seal member 20 is obtained, and the catalyst carrier 11 is reliably held in the case 12. At the same time, there is no gap between the catalyst carrier 11 and the case 12 due to the catalyst holding seal member 20, and the effect of improving the exhaust gas sealing performance in the gap between the catalyst carrier 11 and the case 12 is achieved. is there.

  Further, the catalytic converter 10 according to the present embodiment includes a catalyst carrier 11 that purifies exhaust gas discharged from the internal combustion engine, a case 12 that houses the catalyst carrier 11, and a catalyst carrier that surrounds the catalyst carrier 11. A catalyst holding seal member 20 interposed between the body 11 and the case 12, and the catalyst holding seal member 20 is constituted by the catalyst holding seal member 20 manufactured by the method for manufacturing the catalyst holding seal member 20 described above. It is characterized by that.

  As a result, as described above, when the catalytic converter 10 is mounted on the vehicle, the organic fibers of the catalyst holding seal member 20 are burned out, and the catalyst carrier 11 is securely held by the catalyst holding seal member 20 in the case 12. In addition, the catalytic converter 10 having high sealing performance can be obtained.

  In the catalytic converter 10 according to the present embodiment, the case has been described in which the catalyst carrier accommodating portion 13 of the case 12 has a two-part structure constituted by the upper accommodating portion 13u and the lower accommodating portion 13s. In the catalytic converter according to the present invention, the catalyst carrier accommodating portion of the case may be configured with a single cylindrical structure.

FIG. 15 is an exploded perspective view showing a modification of the catalyst carrier housing portion of case 12 in catalytic converter 10 according to the present embodiment.
As shown in FIG. 15, a catalytic converter 100 according to a modification of the present embodiment is assembled between a catalyst carrier 11, a case 112 that houses the catalyst carrier 11, and a catalyst carrier 11 and the case 112. The catalyst holding seal member 20 is configured.

  The case 112 includes a catalyst carrier accommodating portion 113, an upstream connecting portion 115 joined to one end of the catalyst carrier accommodating portion 113 and connected to the upstream exhaust pipe 14, and one part of the catalyst carrier accommodating portion 113. It has a downstream connection part 117 joined to the other end part and connected to the downstream exhaust pipe 16. The catalyst carrier accommodating portion 113 is made of heat resistant stainless steel and has a cylindrical single structure, and the catalyst carrier 11 and the catalyst holding seal member 20 are press-fitted and accommodated therein. ing.

  In the catalytic converter 100, for example, one end of the catalyst carrier accommodating portion 113 and the upstream connecting portion 115 are joined by joining means such as arc welding, and then the catalyst carrier 11 and the catalyst carrier containing portion 113 are connected to the catalyst carrier accommodating portion 113. After the catalyst holding seal member 20 is press-fitted, the other end of the catalyst carrier housing portion 113 and the downstream connection portion 117 are assembled and joined by a joining means such as arc welding.

  With this configuration, as described above, when the catalytic converter 100 is mounted on a vehicle, the organic fiber of the catalyst holding seal member 20 is burned out and the surface pressure increases, and the catalyst carrier 11 is sealed in the case 112 with the catalyst holding seal. A catalytic converter 100 that is reliably held by the member 20 and has high sealing performance is obtained.

  In the method for producing the catalyst holding seal member 20 according to the present embodiment, the spun organic fibers obtained in the spinning step (S11) are laminated in the laminating step (S12), and the obtained laminated organic fiber aggregate Wu and The case where the laminated inorganic fiber aggregate Wm is overlaid has been described.

  However, in the spinning step in the method for producing the medium holding seal member of the present invention, a known organic fiber assembly having a predetermined mechanical property is used in place of the spun organic fiber obtained by spinning, and this organic The fiber aggregate and the laminated inorganic fiber aggregate Wm may be overlapped to produce the overlapped fiber aggregate Wk.

  Moreover, in the manufacturing method of the catalyst holding seal member 20 according to the present embodiment, in the needle punching step (S13), the needle punching device 30 is replaced with the first needle punching portion 31 and the second needle punching portion 32. A case has been described in which it is composed of various types of needle punch portions and partially reinforced by performing different needle punch treatments on the overlapped fiber assemblies Wk.

  However, in the manufacturing method of the catalyst holding seal member of the present invention, one type of needle punching process is performed by one type of needle punch unit by one needle punch device on the overlapped fiber aggregate Wk. The efficiency of the needle punch process may be increased.

  Further, in the method for manufacturing the catalyst holding seal member 20 according to the present embodiment, in the needle punching step (S13), the overlapped fiber aggregate Wk is attached, and the laminated organic fiber aggregate Wu is attached to the lower surface portion thereof. The case where it consists of things was explained.

  However, in the needle punch process of the present invention, the overlapped fiber aggregate Wk is composed of only inorganic fibers, that is, the overlap process is omitted, and the inorganic fiber aggregate transported in the needle punch device. You may make it arrange | position an organic fiber sheet part on the lower side of a body. In this case, when the inorganic fiber aggregate is needle punched by the needle of the needle punching device, the needle penetrates the organic fiber sheet portion, and the return of the organic fiber sheet portion of the organic fiber sheet portion is provided at the tip of the needle. A part of the inorganic fibers may be hooked and drawn into the inorganic fiber aggregate, and the organic fiber may be entangled with a part of the inorganic fiber in the inorganic fiber aggregate.

  Moreover, in the manufacturing method of the catalyst holding seal member 20 according to the present embodiment, in the binder impregnation step (S16), the binder impregnation device 40 is replaced with two of the first binder impregnation part 41 and the second binder impregnation part 42. A case has been described in which a binder impregnation part of a kind is used, and the entangled fiber assembly Wp is partially reinforced by performing different binder impregnation treatments.

  However, in the method for producing the catalyst holding seal member of the present invention, one type of binder impregnation treatment is performed on the entangled fiber assembly Wp by one binder impregnation device to increase the efficiency of the binder impregnation treatment. Also good.

  Moreover, in the manufacturing method of the catalyst holding seal member 20 according to the present embodiment, the case where the binder impregnation step (S16) is performed between the needle punching step (S15) and the molding step (S17) has been described.

  However, in the method for manufacturing the catalyst holding seal member of the present invention, the binder impregnation step may be omitted, and the molding step may be performed subsequent to the firing step to further increase the efficiency of the catalyst holding seal member manufacturing step.

  As described above, according to the present invention, it is possible to provide a method for producing a catalyst holding seal member that can effectively exhibit the restoring force of a fiber material and has excellent holding force and sealing performance. This is useful for all catalyst holding seal members used in catalytic converters.

It is sectional drawing of the catalytic converter to which the catalyst holding seal member manufactured by the manufacturing method of the catalyst holding seal member which concerns on embodiment of this invention is applied. 1 is an exploded perspective view of a catalytic converter to which a catalyst holding seal member according to an embodiment of the present invention is applied. It is a flowchart of the manufacturing method of the catalyst holding | maintenance sealing member which concerns on embodiment of this invention. It is a perspective view of an inorganic fiber aggregate and an organic fiber aggregate in an embodiment of the present invention, (a) shows a laminated inorganic fiber aggregate, (b) shows a laminated organic fiber aggregate, (C) shows the state which laminated | stacked the baked inorganic fiber aggregate and the laminated fiber aggregate. It is a top view of the needle punch apparatus used for the needle punch process in the manufacturing method of the catalyst holding seal member concerning an embodiment of the invention. It is sectional drawing which shows the AA cross section of FIG. It is sectional drawing which shows the BB cross section of FIG. It is a top view of the binder impregnation apparatus used for the binder impregnation process in the manufacturing method of the catalyst holding seal member which concerns on embodiment of this invention. It is sectional drawing which shows CC cross section of FIG. It is sectional drawing which shows the DD cross section of FIG. It is explanatory drawing explaining the shaping | molding process which cut | disconnects the impregnated fiber aggregate in embodiment of this invention, and obtains the shape-formed fiber aggregate of a predetermined shape, (a) is the impregnated fiber aggregate before a process. It is a top view, (b) is a top view of the shape | molded fiber assembly after a process. It is explanatory drawing of the manufacturing method of the catalytic converter in embodiment of this invention, (a) shows the state before winding a shape | molded fiber assembly around a catalyst carrier, (b) is a catalyst carrier. Is a state in which is placed on the molded fiber assembly, and (c) shows a state in which the molded fiber assembly is wound around the catalyst carrier. It is explanatory drawing of the manufacturing method of the catalytic converter in embodiment of this invention, (a) shows the catalyst support body by which the shape | molded fiber assembly was wound, and the disassembled perspective view of each component, (b) is The perspective view of the assembled catalytic converter is shown. It is sectional drawing of the catalytic converter in which the catalyst holding | maintenance sealing member in this Embodiment was integrated. It is a disassembled perspective view which shows the modification of the catalyst carrier accommodating part of the case in the catalytic converter which concerns on embodiment of this invention. It is a flowchart which shows the manufacturing method of the conventional catalyst holding | maintenance sealing member.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10,100 Catalytic converter 11 Catalyst carrier 12, 112 Case 13, 113 Catalyst carrier accommodating part 14, 16 Exhaust pipe 15, 115 Upstream side connection part 17, 117 Downstream side connection part 20 Catalyst holding seal member 30 Needle punch device 31 1st needle punch part 32 2nd needle punch part 33, 43 Upstream conveyor 34, 44 Intermediate conveyor 35, 45 Downstream conveyor 40 Binder impregnation device 41 1st binder impregnation part 42 2nd binder impregnation part

Claims (5)

A spinning process of spinning inorganic materials to obtain spun inorganic fibers;
A laminating step of laminating the spun inorganic fibers to obtain a laminated inorganic fiber aggregate;
A firing step of firing the laminated inorganic fiber aggregate to obtain a fired inorganic fiber aggregate;
A superposition step of superposing an organic fiber aggregate on the fired inorganic fiber aggregate to obtain a superposed fiber aggregate;
A needle punch step of obtaining a entangled fiber aggregate by driving a needle into the superimposed fiber aggregate to entangle the organic fiber in the organic fiber aggregate with the inorganic fiber in the fired inorganic fiber aggregate;
A molding step of molding the entangled fiber assembly into a predetermined shape to obtain a molded fiber assembly;
The manufacturing method of the catalyst holding sealing member characterized by including.   The spinning step includes a step of spinning an organic material to obtain a spun organic fiber, and the laminating step includes a step of laminating the spun organic fiber to obtain a laminated organic fiber aggregate. The method for producing a catalyst holding seal member according to claim 1, wherein the step of superimposing the laminated organic fiber aggregate and the laminated inorganic fiber aggregate is performed.   The method for producing a catalyst holding seal member according to claim 1 or 2, further comprising a binder impregnation step of impregnating the entangled fiber assembly with a binder to obtain an impregnated fiber assembly. A catalyst carrier for purifying exhaust gas discharged from an internal combustion engine, a case for housing the catalyst carrier, and a catalyst holding member interposed between the catalyst carrier and the case so as to surround the catalyst carrier In a catalytic converter provided with a seal member,
A catalytic converter, wherein the catalyst holding seal member is constituted by an entangled fiber assembly manufactured by the method for manufacturing a catalyst holding seal member according to claim 1. A catalyst carrier for purifying exhaust gas discharged from an internal combustion engine, a case for housing the catalyst carrier, and a catalyst holding member interposed between the catalyst carrier and the case so as to surround the catalyst carrier In a catalytic converter provided with a seal member,
A catalytic converter, wherein the catalyst holding seal member is constituted by an impregnated fiber assembly manufactured by the method for manufacturing a catalyst holding seal member according to claim 3.

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