JP2013209958A - Holding seal material, method for manufacturing the same, wound body, exhaust emission control device and method for manufacturing of exhaust emission control device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a holding seal material which can be kept wound around exhaust gas treating material even if being a holding seal material of high density and can prevent displacement thereof when accommodating an exhaust gas treating body wound around the holding seal material in a casing.SOLUTION: A holding seal material comprises a mat material containing inorganic fiber. The holding seal material includes a first and second side parts which are substantially rectangular in a plane view and parallel to each other in a longitudinal direction, and keeps a recessed and projected fitting parts which are disposed perpendicular to each other in a longitudinal direction. At least one hooking part is formed on each of the first and second side parts.

Description

The present invention relates to a holding sealing material, a method for manufacturing a holding sealing material, a wound body, an exhaust gas purification device, and a method for manufacturing an exhaust gas purification device.

Particulate matter (hereinafter also referred to as PM) is contained in exhaust gas discharged from an internal combustion engine such as a diesel engine. In recent years, it has been a problem that this PM is harmful to the environment and the human body. . Further, since the exhaust gas contains harmful gas components such as CO, HC and NOx, there is a concern about the influence of the harmful gas components on the environment and the human body.

Therefore, as an exhaust gas purification device that collects PM in exhaust gas or purifies harmful gas components, an exhaust gas treatment body made of a porous ceramic such as silicon carbide or cordierite, and a casing that houses the exhaust gas treatment body In addition, various exhaust gas purification apparatuses that include a holding sealing material disposed between an exhaust gas treating body and a casing have been proposed. This holding sealing material prevents the exhaust gas treating body from being damaged by contact with the casing covering the outer periphery due to vibrations or impacts caused by traveling of an automobile or the like, and exhaust gas from between the exhaust gas treating body and the casing. Is disposed mainly for the purpose of preventing leakage.

In order to achieve these objects, the bulk density of the holding sealing material is high, and when the exhaust gas treatment body around which the holding sealing material is wound is housed in the casing, there is a problem that housing is becoming increasingly difficult. is there.

With respect to such a problem, in Patent Document 1, the holding seal is applied after partially or entirely affixing a double-sided tape or an adhesive to the exhaust gas treatment body surface or the exhaust gas treatment body contact side surface of the holding seal material. There is disclosed a technique in which a material is wound around an exhaust gas treating body and accommodated in a casing.

Patent Document 2 discloses a technique in which a holding sealing material is wound around an exhaust gas treatment body, and the winding portion is fixed by a fixing member provided on the exhaust gas treatment body.

JP 2000-8844 A JP 2001-248430 A

In recent years, large-scale exhaust gas purification apparatuses used for large vehicles such as buses and trucks tend to increase. In this large exhaust gas purification device, the weight is large, and vibrations and impacts caused by traveling of an automobile are large. In addition, the pressure loss before and after the exhaust gas treatment body is high, and the back pressure is also high. Therefore, since the holding sealing material is required to have a higher holding force, the bulk density of the holding sealing material tends to be higher.

However, when the holding sealing material having a high bulk density is wound using the technique disclosed in Patent Document 1, the friction coefficient of the portion fixed with the double-sided tape or the adhesive is increased, so that the holding sealing material is kinked during press-fitting. Therefore, the holding sealing material may not be well accommodated in the casing. In addition, the holding sealing material having a high bulk density has a large force (restoring force) for returning to a flat plate shape when wound, and the tape or the like may be peeled off when fixed with a tape or the like.
Furthermore, when the holding seal material having a high bulk density is wound around the exhaust gas treatment body using the technique disclosed in Patent Document 2, the restoring force works strongly, and therefore the holding member cannot be fixed well with the fixing member. There is.

The present invention has been made to solve the above problem, and even a holding sealing material having a high bulk density can maintain a state of being wrapped around an exhaust gas treatment body. A holding sealing material capable of preventing displacement when the wound exhaust gas treating body is accommodated in the casing, a method for producing the holding sealing material, and a wound body in which the holding sealing material is wound around the exhaust gas treating body An object of the present invention is to provide an exhaust gas purifying apparatus in which the wound body is accommodated, and a method for manufacturing the exhaust gas purifying apparatus.

In order to achieve the above object, the holding sealing material according to claim 1 is composed of a mat containing inorganic fibers, is substantially rectangular in a plan view, and is parallel to the longitudinal direction (hereinafter referred to as first side portion). A holding sealing material having a second side surface portion (hereinafter also referred to as a second side surface portion) and convex and concave fitting portions at both ends perpendicular to the longitudinal direction. And
At least one hooking portion is formed on each of the first side surface portion and the second side surface portion.
In addition, although the said edge part says the part containing a convex-shaped and concave shape fitting part, when it says the distance from an edge part, it means the distance from the edge part which does not contain a fitting part.

In the holding sealing material according to claim 1, since at least one hooking portion is formed on each of the first side surface portion and the second side surface portion of the mat constituting the holding sealing material, the exhaust gas treating body. The mat constituting the holding sealing material is wound around the mat, and the string-like member is crossed over the end of the mat at least once by using the hook portion formed on the mat. By hooking on the hook portions formed on the one side surface portion and the second side surface portion, the state where the mat is wound around the exhaust gas treating body can be firmly maintained.

For this reason, this wound body can be easily accommodated in the casing, and the displacement of the mat can be prevented.
As described above, the hooking portion is a predetermined shape formed on the side surface of the mat so that the string-like member can be hooked, and is formed so that it can be hooked. Although it will not specifically limit if it is a thing, Usually, it is a notch part or a protrusion part. As a form other than the above of a hook part, the part etc. which fixed the ring-shaped thing to the side surface etc. are mentioned, for example.

In the holding sealing material according to claim 2, the hook portion is formed at a plurality of locations on the first side surface portion and / or the second side surface portion, respectively. Therefore, using the first side surface portion and / or the hook portion formed on the second side surface portion of the mat wound around the exhaust gas treating body, the string-like member is connected to the first side surface portion of the mat and By hooking on the plurality of hooks formed on the second side surface, the mat can be more securely maintained around the exhaust gas treating body, and this wound body can be easily placed in the casing. Can be accommodated.

In the holding sealing material according to claim 3, a cutout portion and / or a protruding portion is formed as a hook portion on the first side surface portion and the second side surface portion. Therefore, by hooking the string-like member around the notch or the protruding portion of the mat wound around the exhaust gas treating body, the state where the mat is wound around the exhaust gas treating body can be firmly maintained. It can be easily accommodated in the casing.

In the holding sealing material according to claim 4, the shape of the cutout in plan view is a quadrilateral shape, a triangular shape, a U shape, a J shape, an L shape, or a T shape. A string-like member can be easily hooked on the notch portion, and thus the state in which the mat is wound around the exhaust gas treating body can be firmly maintained.

In the holding sealing material according to claim 5, the shape of the cutout portion in plan view is configured such that a portion corresponding to the corner portion is a curve. Therefore, even when a string-like member is hooked on the cutout portion having the above shape, inconveniences such as formation of a tear in the cutout portion are unlikely to occur.

In the holding sealing material according to the sixth aspect, the hook portion is formed at a position where the distance from the end portion in the longitudinal direction of the mat is ¼ or less of the length in the longitudinal direction of the mat. Therefore, even if it does not lengthen the length of a string-like member, the hook part formed in the mat can be used and the state where the mat was wound around the exhaust gas treating body can be maintained firmly.

In the holding sealing material according to claim 7, a slit is formed on at least a part of the main surface of the holding sealing material and on a line connecting arbitrary hooking portions. Therefore, by using the slit and arranging the string-like member hooked on the hook portion along the slit, it is possible to prevent the possibility that the string-like member is detached from the hook portion. Even when the appendage is housed in the casing by press fitting or the like, the state in which the mat is wound around the exhaust gas treating body can be reliably maintained. Moreover, when a string-like member can be accommodated in the inside of a slit, it can be accommodated in the inside of a casing more smoothly.

In the holding sealing material according to claim 8, the depth of the slit is 1/5 to 4/5 of the thickness of the holding sealing material. Therefore, it is easy to store the string-like member inside the slit, the string-like member is difficult to be exposed on the outer surface of the holding sealing material, and the state where the mat is wound around the exhaust gas treating body is reliably maintained. can do. Moreover, a wound body can be accommodated in the inside of a casing more smoothly.
When the slit depth is less than 1/5 of the thickness of the holding sealing material, the slit depth is too shallow, and when the string-like member is disposed, the slit is placed on the outer surface of the holding sealing material. The string-like member may be exposed, and the string-like member may be detached from the hook when the wound body is stored in the casing by press fitting or the like.
When the depth of the slit exceeds 4/5 of the thickness of the holding sealing material, the depth of the slit may be too deep and the holding sealing material may be cut by the arranged string-like member.

In the manufacturing method of the holding sealing material according to claim 9, a preparation step of preparing a mat material containing inorganic fibers, a first side surface portion substantially parallel to the longitudinal direction in a substantially rectangular shape in plan view, and And having two convex portions on both ends perpendicular to the longitudinal direction, and at least one hook on each of the first side surface portion and the second side surface portion. And a punching step of punching out to form a part.

Since the holding sealing material having the hook portion according to claim 1 is formed by the above-described process, the effect described in claim 1, that is, the mat constituting the holding sealing material is wound around the exhaust gas treatment body, and the mat The hooks formed on the first and second side surfaces of the mat are used so that the hook members cross the end of the mat at least once. By hooking on the hanging portion, the state where the mat is wound around the exhaust gas treating body can be firmly maintained.

In the manufacturing method of the holding sealing material according to claim 10, in the punching step, the hooking portion is punched so that a plurality of portions are formed on the first side surface portion and / or the second side surface portion, respectively. Therefore, the string-like member is used as the first side surface of the mat by using the hook portion formed on the first side surface portion and / or the second side surface portion of the mat constituting the holding sealing material. By hooking on the plurality of hook portions formed respectively on the portion and the second side surface portion, it is possible to more securely maintain the state where the mat is wound around the exhaust gas treating body.

In the manufacturing method of the holding sealing material according to claim 11, punching is performed so that a hook portion is formed by forming a cutout portion and / or a protruding portion in the first side surface portion and the second side surface portion. Therefore, the state in which the mat is wound around the exhaust gas treating body can be firmly maintained by hooking the string-like member on the notch portion of the obtained mat.

In the manufacturing method of the holding sealing material according to claim 12, the shape of the cutout portion in plan view is a square shape, a triangular shape, a U shape, a J shape, an L shape, or a T shape. Punch out. Therefore, a string-like member can be easily hooked on the notched portion of the above-mentioned shape of the obtained mat, and thereby the state where the mat is wound around the exhaust gas treating body can be firmly maintained.

Moreover, in the manufacturing method of the holding sealing material according to claim 13, the shape of the cutout portion in plan view is punched so that a portion corresponding to the corner portion is configured by a curve. Therefore, even when the string-like member is hooked on the notched portion having the above shape of the obtained mat, it is difficult to cause inconvenience such as formation of a tear in the notched portion.

In the manufacturing method of the holding sealing material according to claim 14, after the punching step, at least one main surface is provided with a slit so that a slit is formed in at least a part on a line connecting arbitrary hooking portions. The slit formation process to form is performed. Therefore, by using the hook portion and the slit of the obtained mat and arranging the string member hooked on the hook portion along the slit, the string member is detached from the hook portion, etc. The fear can be prevented, and even when the wound body is stored in the casing by press fitting or the like, the state where the mat is wound around the exhaust gas treating body can be reliably maintained.

In the manufacturing method of the holding sealing material according to claim 15, the slit is formed so that the depth of the slit is 1/5 to 4/5 of the thickness of the holding sealing material. Therefore, it is easy to store the string-like member inside the slit of the obtained mat, the string-like member is hardly exposed on the outer surface of the holding sealing material, and the mat is wound around the exhaust gas treatment body. The state can be reliably maintained.

In the manufacturing method of the holding sealing material according to claim 16, at least one notch portion or projecting portion which is a hook portion is formed on the first side surface portion from the mat material, and the second side surface portion includes the A protrusion having the same shape as the notch is formed, or a notch having the same shape as the protrusion is formed, and the notch or the end of the protrusion is formed on the first side surface. Is punched out so that the formation position from the end is the same as the formation position from the end of the protruding part or the notch formed on the second side face part.

The mat pattern punched out by the above-described method is a pattern in which a plurality of mat patterns arranged side by side with each other are exactly the same pattern. The plurality of mats arranged through the end portions are the same pattern. Therefore, even if the mat has a hook portion on the side surface, a large number of mats having the same shape can be manufactured by punching once, and a holding sealing material (mat) can be efficiently manufactured.

A wound body according to a seventeenth aspect includes an exhaust gas treating body, the holding sealing material according to any one of claims 1 to 8 and a string-like member, and a convex shape and a concave shape of a mat constituting the holding sealing material. A winding in which the mat is wound around the exhaust gas treatment body and the mat is wound around the exhaust gas treatment body by the string-like member in a state where the shape fitting portion is fitted. The cord-like member is attached to a hook portion formed on the first side surface portion and the second side surface portion of the mat so that the cord-like member crosses the end of the mat at least once. It is characterized by being hung.

In the wound body according to claim 17, since the mat with the hook portion formed thereon is used and the state in which the mat is wound around the exhaust gas treatment body in the above-described manner by the string-like member is maintained. The state in which the mat is wound around the exhaust gas treating body can be firmly maintained, the wound body can be easily accommodated in the casing, and the displacement of the mat can be prevented.

In the wound body according to claim 18, the string-like member has two ends, and the ends are joined together, whereby the mat is wound around the exhaust gas treatment body. Maintained. For this reason, there is no possibility that the string-like member may come off from the mat, and the state where the mat is wound around the exhaust gas treating body can be reliably maintained.

In the wound body according to claim 19, the string-like member has an annular shape, and is hooked on at least two hook portions of the mat, and the inner side of the mat on the exhaust gas treatment body side and the exhaust gas treatment of the mat. It arrange | positions so that the outer side which is the opposite side to a body side may be passed.
Thus, since the string-like member present on the exhaust gas treating body side is sandwiched and fixed between the exhaust gas treating body and the mat, there is no possibility that the string-like member comes off from the mat, and the mat is wound around the exhaust gas treating body. Can be reliably maintained.

In the wound body according to claim 20, the string-like body is arranged along a slit formed in the main surface of the mat. Accordingly, it is possible to prevent the string-like member from being detached from the hooking portion, and even when the wound body is housed in the casing by press fitting or the like, the mat is wound around the exhaust gas treating body. It can be reliably maintained.

In the wound body according to claim 21, since the string-like body can be expanded and contracted, when the string-like member is disposed on the mat in an extended state, tension is applied to the string-like member, and the string-like body A force that presses the mat against the exhaust gas treatment body acts by the member. Therefore, the mat becomes easier to adhere to the exhaust gas treating body, and the state where the mat is wound around the exhaust gas treating body can be reliably maintained.
In addition, since the string-like member expands and contracts, the string-like member can be easily disposed, work efficiency can be improved, and the cutting force applied to the mat from the string-like member can be suppressed more than necessary. it can.

In the wound body according to claim 22, the stretch rate of the stretchable string-like member is 100% or more.
When the stretch rate of the string-like member is 100% or more, a strong tension acts on the string-like member, and the holding sealing material is more easily adhered to the exhaust gas treating body.

In the wound body according to claim 23, the load with respect to the elongation of the stretchable string-like member is 0.01 to 0.10 N / mm.
When the load with respect to the elongation of the string-like member is 0.01 to 0.10 N / mm, the holding sealing material can be firmly fixed to the exhaust gas treating body.
When the load with respect to the elongation of the string-like member is less than 0.01 N / mm, the force for fixing the holding sealing material to the exhaust gas treating body is too weak, and the holding sealing material may not be sufficiently fixed to the exhaust gas treating body. .
When the load with respect to the elongation of the string-like member exceeds 0.10 N / mm, the tension of the string-like member may damage the projecting portion and / or the notch portion of the mat and destroy it.

In the wound body according to claim 24, the string-like member has an average diameter of 0.2 to 1.5 mm.
When the average diameter of the string-like member is 0.2 to 1.5 mm, it becomes easy to store the string-like member inside the slit of the holding sealing material, and the mat is wound around the exhaust gas treating body. Can be reliably maintained.
If the average diameter of the string-like member is less than 0.2 mm, the string-like member may be too thin and cut.
If the average diameter of the string-like member exceeds 1.5 mm, the string-like member is likely to be exposed on the surface of the holding sealing material, and thus the holding sealing material may be displaced during housing.

In the wound body according to claim 25, irregularities are formed on the surface of the string-like member.
When unevenness is formed on the surface of the string-like member, the friction between the string-like member and the holding sealing material increases, and the string-like member is difficult to shift after the holding sealing material is wound around the exhaust gas treatment body.

In the wound body according to claim 26, the string member disappears by heating.
When the string-like member disappears due to heating, there is no force to bind the holding seal material to the exhaust gas treatment body. Therefore, in the exhaust gas purification apparatus in which the wound body is accommodated in the casing, the holding seal material is the exhaust gas treatment body at the original surface pressure. The exhaust gas treating body accommodated in the casing can be firmly held via the honeycomb fired body.

In the wound body according to Claim 27, the mat further includes identification information capable of identifying a surface in contact with the exhaust gas treatment body when the mat is wound around the exhaust gas treatment body on at least one surface. Have.
Since the mat has identification information for identifying which side is in contact with the exhaust gas treating body, a hooking portion is formed at an intended position, and a string-like member is arranged on the hooking portion. The installed wound body can be produced.

In the wound body according to claim 28, the string-like member that passes through the outside of the mat is configured to pass through the inside of the mat via a contact point B that is one point of the hook portion. When the mat is viewed in plan, the mat is perpendicular to the bisector A of the angle formed by the string-like member passing through the outside of the mat and the string-like member passing through the inside with the contact point B as the center, When a straight line C that is parallel to the principal surface and passes through the contact point B is drawn, mat members are arranged on the straight line portions on both sides of the contact point B.
Therefore, the string-like member hooked on the hook portion is not easily detached from the hook portion, and the state where the mat is wound around the exhaust gas treating body can be reliably maintained. In this case, the shape of the hook portion is not particularly limited, but the hook portion is preferably a notch portion formed of a straight line.
If the mat member is not disposed on the straight portions on both sides of the contact point B, the string-like member is easily detached from the hook portion.
In the following, whether or not the mat material is disposed on the straight portions on both sides of the contact point B described in claim 28 will be referred to as a criterion for the difficulty of detaching the string-like member.

In the holding sealing material according to a twenty-ninth aspect, a string-like member is disposed in advance in order to produce the wound body according to the seventeenth to twenty-eighth aspects.
Since the string-like member is previously fixed to the notch or the slit with an adhesive or the string-like member is wound around the holding seal material, the holding seal material is arranged in a wound body. When the above-mentioned string-like member is used, a wound body can be produced immediately.

In the exhaust gas purifying apparatus according to claim 30, the mat is wound around the exhaust gas treatment body in a state where the convex shape and the concave fitting portion of the mat constituting the holding sealing material are fitted, and the string shape 29. An exhaust gas purification apparatus comprising: a wound body in which a state in which the mat is wound around the exhaust gas treatment body by a member; and a casing that houses the wound body, The wound body according to any one of the above is housed in the casing.
Therefore, in the exhaust gas purifying apparatus according to claim 30, the exhaust gas treating body is reliably accommodated in the casing via the holding sealing material, and the function as the exhaust gas purifying apparatus can be sufficiently exhibited.

The manufacturing method of the exhaust gas purifying apparatus according to claim 31 includes a preparation step of preparing a mat material containing inorganic fibers, and a fitting portion having convex and concave shapes at both ends perpendicular to the longitudinal direction from the mat material. A punching step of punching out into a shape in which at least one hook portion is formed on each of the first side surface portion and the second side surface portion parallel to the longitudinal direction in a substantially rectangular shape in plan view, A winding step of winding the mat around the exhaust gas treatment body so that the mating convex and concave mating portions constituting the holding sealing material obtained by the punching step are fitted; A string-like member hooking step in which the string-like member is hooked to the hook portions formed on the first side surface portion and the second side surface portion of the mat so that the member crosses the end of the holding sealing material at least once. When,
And a housing step of housing the exhaust gas treating body around which the mat is wound in a casing.

In the manufacturing method of the exhaust gas purification apparatus, the wound body of the present invention is formed using the mat of the present invention manufactured by the manufacturing method of the holding sealing material of the present invention, and accommodated in the casing. Accordingly, a wound body that can maintain the state in which the mat is wound around the exhaust gas treatment body can be used, and the wound body can be easily accommodated in the casing, and thus an exhaust gas purification device can be easily manufactured. can do.
Further, the manufactured exhaust gas treating body has the exhaust gas treating body securely contained in the casing via the holding sealing material, and can fully exhibit the function as the exhaust gas purifying device.

FIG. 1 is a perspective view schematically showing an example of a holding sealing material according to the first embodiment of the present invention. 2A is a perspective view showing a state in which the holding sealing material shown in FIG. 1 is wound around the exhaust gas treating body to form a wound body, and FIG. 2B is a front view showing the state from the front. FIG. 3A to 3E are plan views schematically showing the shape of the notch formed in the mat constituting the holding sealing material according to this embodiment. FIG. 4 is a plan view schematically showing a punching pattern when the mat according to the first embodiment of the present invention is punched from the mat material. FIG. 5 is a perspective view showing how the wound body is housed in the casing. FIG. 6A is a perspective view schematically showing an example of the exhaust gas purifying apparatus, and FIG. 6B is a cross-sectional view of the exhaust gas purifying apparatus shown in FIG. FIGS. 7A to 7D are front views showing a holding sealing material having a hook portion of various modes and a wound body using the holding sealing material. It is an enlarged plan view of the string-like member in the wound body shown in FIG. FIG. 9 is a plan view schematically showing a punching pattern when a mat having a protruding portion is punched from the mat material. FIG. 10A is a plan view showing an example in which slits are formed on both main surfaces of the mat constituting the holding sealing material, and FIG. 10B is a cross-sectional view taken along line AA of the mat. FIG. 11 is a plan view schematically showing a state in which a slit is formed in a part on a line connecting the hook portions.

Hereinafter, embodiments of the present invention will be specifically described. However, the present invention is not limited to the following embodiments, and can be applied with appropriate modifications without departing from the scope of the present invention.

(First embodiment)
Hereinafter, the holding sealing material, the manufacturing method of the holding sealing material, the wound body, the manufacturing method of the exhaust gas purification device, and the first embodiment as an embodiment of the exhaust gas purification device of the present invention will be described.

First, the holding sealing material and the wound body according to the first embodiment of the present invention will be described.
The holding sealing material according to the first embodiment of the present invention is made of a mat containing inorganic fibers.
The mat has a first side surface portion and a second side surface portion that are substantially rectangular in a plan view and parallel to the longitudinal direction, and has a convex and concave fitting portions at both ends perpendicular to the longitudinal direction. It is a material, Comprising: At least 1 or more hook part is formed in the said 1st side part and said 2nd side part, respectively.

Further, the wound body according to the first embodiment of the present invention includes an exhaust gas treating body, a holding sealing material, and a string-like member, and the mat-shaped convex and concave fitting portions constituting the holding sealing material are provided. In the fitted state, the mat is wound around the exhaust gas treatment body, and the wound body maintains the state where the mat is wound around the exhaust gas treatment body by the string member,
The string-like member is hooked on the hook portions formed on the first side surface portion and the second side surface portion of the mat so that the string-like member crosses the end of the mat at least once. Features.

FIG. 1 is a perspective view schematically showing an example of a holding sealing material according to the first embodiment of the present invention.
2A is a perspective view showing a state in which the holding sealing material shown in FIG. 1 is wound around the exhaust gas treating body to form a wound body, and FIG. 2B is a front view showing the state from the front. FIG.

The holding sealing material 10 of the present embodiment shown in FIG. 1 is composed of one mat 11 having a substantially rectangular shape in plan view including inorganic fibers, and includes a first side surface portion 16a and a second side surface portion 16b that are parallel to the longitudinal direction. Have. Further, at both ends perpendicular to the longitudinal direction of the mat 11, a convex fitting portion 14b and a concave fitting portion 14a are provided. The mating portions 14a and 14b of the mat 11 are shaped so as to be fitted to each other when the mat 11 is wound around the exhaust gas treatment body in order to produce an exhaust gas purification device to be described later.

The first side surface portion 16a of the mat 11 is formed with two cutout portions 12a and 13a having a rectangular shape (hereinafter also referred to as a plan view shape) as a hooking portion. Also in 16b, two cutout portions 12b and 13b having a rectangular shape in a plan view are formed as hook portions.
The plan view shape of the cutout portion refers to a shape obtained by viewing the cutout portion in plan view when it is assumed that the cutout portion is formed by cutting the side surface of the rectangular mat 11 in plan view. In FIG. 1, since the cutout portion is formed by being cut out in a rectangular shape, the cutout portions 12 a and 13 a having a rectangular shape in plan view are described.
The mat 11 has a length in the longitudinal direction of L, a width of W, and a thickness of T.

FIG. 2 (a) shows a wound body 210 produced by using the mat 11 and the string-like member 3 shown in FIG. 1, and FIG. 2 (b) is a front view thereof.
In the wound body 210 shown in FIG. 2, the mat 11 shown in FIG. 1 is wound around the exhaust gas treatment body 130 with the fitting portions 14a and 14b fitted, and the string-like member 3 is pulled. The state in which the mat 11 is wound around the exhaust gas treatment body 130 is maintained by being hooked on the notches 12a, 12b, 13a, and 13b that are the hanging portions.

Specifically, using the notches 12a, 12b, 13a, and 13b formed in the mat 11, the annular string-like member 3 is hooked on the notches 12a, 12b, 13a, and 13b, from the notch 12a. The string-like member 3 is disposed so that the string-like member 3 is exposed to the outer surface of the mat 11 from the notch 12b and the notch 13a to the notch 13b. The string-like member 3 is parallel to the first side surface portion and the second side surface portion of the mat 11 and crosses the end portion of the mat 11 from the portion 13a and the notch portion 12b to the notch portion 13b. Is disposed between the exhaust gas treating body 130 and the mat 11.

The hooking method of the string-like member 3 may be the reverse of the case shown in FIG. 2, and the string-like member 3 is an exhaust gas treating body from the notch 12a to the notch 12b and from the notch 13a to the notch 13b. 130 and the mat 11, while the string-like member 3 is exposed on the outer surface of the mat 11 from the notch 12 a to the notch 13 a and from the notch 12 b to the notch 13 b. A string-like member 3 may be disposed on the surface.

Thus, after the mat 11 is wound around the exhaust gas treatment body 130, the first side surface portion 16a and the second side surface portion 16b of the mat 11 are arranged so that the string-like member 3 crosses the end portion of the mat 11 at least once. The wound body 210 is produced by being hooked on the formed notch. The wound body 210 configured as described above is firmly maintained in the state of being wound around the exhaust gas treating body 130 by the string-like member 3, and can be transported in the state of the wound body 210.

The exhaust gas treatment body 130 is for treating exhaust gas discharged from an internal combustion engine such as a vehicle. Specific examples thereof include a catalyst carrier and an exhaust gas filter.
In the present embodiment, the holding sealing material 10 is wrapped around the exhaust gas treatment body 130 to form a wound body 210, which is then transported to another location, and the wound body 210 is stored inside the casing at another location, and exhaust gas purification is performed. It can be a device or the like.

In the holding sealing material 10 shown in FIGS. 1 and 2, notches 12a, 12b, 13a, and 13b are formed as hooks on the mat 11, but project outward from the side surface of the mat 11 as hooks. A protrusion may be provided. The shape of the protrusion will be described in another embodiment.
When the notch is formed in the mat 11, the arrangement place of the string-like member 3 can be positioned inside the mat 11, so that the width of the mat 11 is as wide as possible within the range of the exhaust gas treating body. be able to.
On the other hand, when the hooking portion is a protruding portion, it is necessary to make the width of the mat 11 including the protruding portion narrower than the width of the exhaust gas treating body, so that the substantial width of the mat 11 is reduced.

The position where the hook portion is formed is not particularly limited. However, in order to maintain the state in which the holding sealing material is wound around the exhaust gas treatment body by the string-like member, the end portion in the longitudinal direction of the mat 11 is used. It is desirable that the distance from is 1/4 or less of the length of the mat 11 in the longitudinal direction.

When the distance of the hook portion from the longitudinal end of the mat 11 exceeds 1/4 of the length of the mat 11 in the longitudinal direction, when the wound body is produced, the hook in the longitudinal direction of the mat 11 is produced. Since the distance between the parts becomes longer, it is necessary to increase the length of the string-like member, and it becomes difficult to firmly maintain the state in which the holding sealing material 10 (mat 11) is wound around the exhaust gas treating body.

The length in the direction perpendicular to the longitudinal direction of the mat 11 of the notches 12a, 12b, 13a, 13b when the notches 12a, 12b, 13a, 13b having a rectangular shape in plan view as shown in FIG. -50 mm is desirable, and 10-30 mm is more desirable. The length in the direction parallel to the longitudinal direction of the mat 11 is desirably 0.5 to 30 mm, and more desirably 1 to 15 mm.

In FIG. 1, four notches 12a, 12b, 13a, and 13b are formed in the mat 11, but the number of notches is not particularly limited, and the first side surface 16a and the second side surface portion are not limited. It is sufficient that at least one location is formed on each 16b. Therefore, the number of notches may be two, three, or four or more, but preferably two to four.

In the present embodiment, the annular string-like member 3 is used to produce the wound body 210, but the string-like member may have a predetermined length having two ends. When the string-like member is of a predetermined length having two end portions, the mat is wound around the exhaust gas treating body, the string-like member is hooked on the hook portion, and then the end portions are arranged at a predetermined place. Are combined into a ring shape.

The average diameter of the string-like member 3 is desirably 0.2 to 1.5 mm. When the average diameter of the string-like member 3 is less than 0.2 mm, the string-like member 3 is too thin, so that the string-like member is easily cut. On the other hand, when the average diameter of the string-like member is larger than 1.5 mm, the wound body When press-fitting into the casing, friction between the string-like member and the casing occurs, and the string-like member is easily cut. Further, in the wound body, a string-like member is disposed between the mat and the exhaust gas treating body. However, if the string-like member is too thick, a gap is formed between the mat and the exhaust gas treating body. Therefore, the exhaust gas easily escapes between the mat and the exhaust gas treating body.

The material constituting the string-like member 3 may be anything that can be fixed, such as metal, ceramic, organic matter (resin, rubber), etc., for example, ABS resin, polyethylene, polypropylene, polystyrene, vinyl chloride resin, methacrylic resin , Polyamide, polycarbonate, polyacetal, polyester, polyurethane, polyphenylene ether, elastomer, polyphenylene sulfide, acrylonitrile styrene, acrylonitrile butadiene styrene, resin such as fluorine resin, nitrile rubber, hydrogenated nitrile rubber, fluorine rubber, silicone rubber, ethylene propylene rubber, Rubber such as chloroprene rubber, acrylic rubber, butyl rubber, urethane rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, aluminum, iron, copper, nickel Kell, and titanium or a metal wire or the like thereof alloys.

It is desirable that the string-like member 3 can be expanded and contracted in order to firmly maintain the state where the mat is wound around the exhaust gas treating body. The stretch rate of the stretchable string-like member 3 is desirably 100% or more, and more desirably 200 to 1000%. The amount of elongation is preferably 50 mm or more.

The load with respect to the stretchable string-like member 3 is preferably 0.01 to 0.10 N / mm, and more preferably 0.05 to 0.09 N / mm.
By using the string-like member having the above characteristics, the state where the mat is wound around the exhaust gas treating body can be firmly maintained.

As for the string-like member 3, it is desirable that the surface has unevenness. Examples of the string-like member having an uneven surface include sewing thread, yarn, rope, rubber, metal spring and the like.

The string-like member 3 is preferably made of an organic material such as resin, rubber, or elastomer that is a material that disappears when heated. When the string-like member disappears due to heating, there is no force to bind the holding seal material to the exhaust gas treatment body. Therefore, in the exhaust gas purification apparatus in which the wound body is accommodated in the casing, the holding seal material is the exhaust gas treatment body at the original surface pressure. The exhaust gas treating body accommodated in the casing can be firmly held via the holding sealing material.

The holding sealing material 10 is made of a mat 11 containing inorganic fibers.
The inorganic fibers constituting the mat 11 are not particularly limited, and may be alumina-silica fibers, alumina fibers, silica fibers, or the like. Moreover, glass fiber and biosoluble fiber may be sufficient. What is necessary is just to change according to the characteristics etc. which are required for holding sealing materials, such as heat resistance and wind erosion resistance, and it is preferable to use the thing of the large diameter fiber or fiber length which can adapt to the environmental regulation of each country.
Among these, low crystalline alumina inorganic fibers are desirable, and low crystalline alumina inorganic fibers having a mullite composition are more desirable. In addition, inorganic fibers containing a spinel compound are more preferable. A highly crystalline alumina material is hard and brittle, and is not suitable for a holding sealing material used as a cushioning material.
Further, in the case of an inorganic fiber containing a low crystalline alumina material and a spinel type compound, the crystallization rate is preferably in the range of 0.1 to 30%, and more preferably in the range of 0.4 to 20%. The holding sealing material made of this range of inorganic fibers has a high repulsive force and a high restoration surface pressure after a durability test, and has good performance. However, when the crystallization rate is less than 0.1% or exceeds 30%, the repulsive force and the restoring surface pressure are drastically reduced. The method for measuring the crystallization rate can be calculated from the integral intensity ratio of the mullite diffraction line (2θ = 26.4 °) and the γ-alumina diffraction line (2θ = 45.4 °).

The mat 11 is desirably a needle mat obtained by subjecting a base mat made of inorganic fibers to a needle punching process. The needle punching process refers to inserting and removing fiber entanglement means such as a needle with respect to the base mat.
In the mat 11 constituting the holding sealing material 10 shown in FIG. 1, inorganic fibers having a relatively long average fiber length are entangled three-dimensionally by the needle punching process. The mat 11 is needle punched in the width direction perpendicular to the longitudinal direction. However, the position where the needle punching process is performed is not limited to the width direction, but can be performed in various arrangements for controlling the restoring surface pressure and the thickness. In addition, the needle density can be increased only in a part of the mat. Since the mat surface can be made uneven by performing the needle treatment, the friction coefficient can be changed or adjusted by performing the needle punching treatment as described above.
In addition, in order to exhibit an entanglement structure, the inorganic fiber has a certain average fiber length. For example, the average fiber length of the inorganic fiber is desirably 4 mm to 120 mm. When the average fiber length is within this range, the fibers are entangled at the location where the needle treatment is performed, and the strength of the mat is increased. A preferable density of needle punches is 10 to 500 per 100 cm ² . When the density of needle punches is less than 10 per 100 cm ² , the sealing material is torn and separated. Also, when the density of needle punches exceeds 500 per 100 cm ² , the sealing material becomes difficult to bend, and when it is wound around the exhaust gas treatment body, the sealing material tends to be flat, and a string-like member is applied. This is not preferable because a large tension is applied to the string-like member and the string-like member is broken.
The surface density of the mat 11 ^is preferably a ^{400g / cm 2 ~2000g / cm 2} . If the surface specific gravity of the mat is less than 400 g / cm ² , the exhaust gas treating body cannot be sufficiently protected from vibrations during operation of the exhaust gas purifying apparatus, so that there are problems such as loss of the exhaust gas treating body and dropping from the casing. On the other hand, if it exceeds 2000 g / cm ² , the restoring force of the mat is too strong, so that it exceeds the strength of the exhaust gas treating body and is damaged.

The mat 11 constituting the holding sealing material 10 may have a single layer structure or a multilayer structure. When the mat 11 has a multilayer structure, it is desirable that the hooking portions are formed at the same position of the plurality of mats. By doing so, it is possible to prevent the mats having a plurality of string-like members from being peeled off. In ordinary multilayer mats, stitches and adhesives are used, so there is concern about an increase in organic content, and the man-hours become complicated, leading to an increase in defects and a decrease in work efficiency.
When the holding sealing material 10 is made of a single-layer mat, the thickness T of the mat 11 is preferably 5 to 15 mm.

The mat 11 constituting the holding sealing material 10 further has identification information capable of identifying a surface in contact with the exhaust gas treatment body when the mat 11 is wound around the exhaust gas treatment body on at least one surface. Is desirable.
As identification information, characters such as ink jet characters and barcodes, marking with an oil pen, tape, and the like can be used. The contents of the information displayed by the above information display are “this surface is inside”, “this surface is outside”, etc., but other information includes product name, product number, serial number, product type, weight, product At least one information selected from the size, the applicable vehicle type, the alert, the contact information, and the company name can be described. The character displayed in the character part is preferably at least one piece of information selected from alphabets, numbers, kanji, hiragana, katakana, symbols, and dots. In addition to the above, it is also possible to color the entire surface of one side of the mat, a part thereof, a plurality of locations, various color combinations, and the like, and discriminate them by comparing predetermined colors with information.

3A to 3E are plan views schematically showing the shape of the notch formed in the mat constituting the holding sealing material according to this embodiment. 3A to 3E, only the notch portion formed in the vicinity of the convex fitting portion is shown, but the notch portion formed in the vicinity of the concave fitting portion is The shape may be the same as or different from the illustrated fitting portion.

The shape in plan view of the notch that constitutes the holding sealing material according to the present embodiment is not particularly limited, and is rectangular (rectangular) like the notches 12a, 12b, 13a, and 13b shown in FIG. It may be a triangular notch 62a, 62b as shown in FIG.

Further, in the holding sealing material according to the present embodiment, the cutout portions may be U-shaped or semicircular cutout portions 72a and 72b as shown in FIG. 3B, and FIG. L-shaped cutout portions 82a and 82b as shown in FIG. 3 or long rectangular cutout portions 92a and 92b as shown in FIG. 3 (d) may be used, as shown in FIG. 3 (e). The cutouts 102a and 102b may be formed by cutting a part of a simple circle.
Reference numerals 60, 70, 80, 90, and 100 indicate holding sealing materials, reference numerals 61, 71, 81, 91, and 101 indicate mats, and reference numerals 64b, 74b, 84b, 94b, and 104b indicate fittings. A part (convex part) is shown.

Other shapes for the notch include a J-shape and a T-shape. Further, the notch portion shown in FIG. 3B corresponds to a shape in which a portion corresponding to a square corner portion is configured by a curve, but a corner portion such as an L shape shown in FIG. May be constituted by a curve.

Next, the manufacturing method of the holding sealing material according to the first embodiment of the present invention will be described.
The manufacturing method of the holding sealing material according to the first embodiment of the present invention includes a step of preparing a mat material containing inorganic fibers, and a first side surface portion that is substantially rectangular in plan view and parallel to the longitudinal direction from the mat material. And a second side surface portion, and having convex and concave fitting portions at both ends perpendicular to the longitudinal direction, and at least one or more locations on each of the first side surface portion and the second side surface portion. And a punching step of punching out to form a hook portion.

In the manufacturing method of the holding sealing material according to the first embodiment of the present invention, first, a mat material having a predetermined size is prepared. Since the mat material has been described above, the description thereof is omitted here.

A binder is attached to the mat material having the above-described configuration as necessary. By adhering the binder to the mat material, the entangled structure between the inorganic fibers can be strengthened, and the bulk of the mat material can be suppressed. The amount of the binder attached is preferably 0.01 to 10.0% based on the weight of the mat material. 0.05 to 3.0% is more desirable, and the range of 0.1 to 1.5% is most desirable.

As the binder, an emulsion prepared by dispersing acrylic latex or rubber latex in water can be used. The binder is sprayed uniformly on the entire mat material using a spray or the like, and the binder is adhered to the mat material. Moreover, although the said binder is an organic component, the inorganic binder containing an alumina particle etc. may be used with the said organic binder, and only the inorganic binder may be used without using the said organic binder.

Thereafter, the mat material is dried to remove moisture in the binder. As a drying condition, for example, it may be dried at 95 to 150 ° C. for 1 to 30 minutes. A mat member can be manufactured through a drying process. Desirably, a ventilation dryer is used for drying. By using a ventilation dryer, the drying speed of the mat material is increased, and further, the amount of binder attached is not uniform in the thickness direction of the mat material, and distribution can be achieved by resin migration. For example, it is possible to adjust the distribution such as increasing or decreasing the amount of resin in the central portion in the thickness direction of the mat material by setting various conditions such as the aeration speed and temperature of the aeration dryer.
Further, it is possible to dry under compression or decompression environment, and the drying time can be reduced.

Next, a punching process is performed.
FIG. 4 is a plan view schematically showing a punching pattern when the mat according to the first embodiment of the present invention is punched from the mat material.
A mat member 500 shown in FIG. 4 has an area capable of punching a plurality of mats 11 according to the present embodiment. The mat 11 is produced by cutting the mat member at the solid line portion in FIG. That is, the mat 11 is manufactured by punching so that the first side surface portion 16a and the second side surface portion 16b of the mat 11 are formed with the notches 12a, 12b, 13a, and 13b shown in FIG.

As shown in FIGS. 3A to 3E, the shape of the cutout in plan view changes variously such as a square shape, a triangular shape, a U shape, a J shape, an L shape, a T shape, Although the number of notches varies variously, a mat having a shape corresponding to the shape and number of notches can be produced by using the punching device described below.

The method of punching the mat material and the apparatus used for punching the mat material are not particularly limited, and a conventionally known method can be used.
For example, as the punching blade, a Thomson blade having a blade designed in the same shape as the punching pattern when the mat is punched can be used, and as the punching device, a hydraulic press machine or the like can be used.

Although a wound body is produced using the mat (holding sealing material) obtained by the above method, it is desirable to give identification information to the mat 11 before the winding step.
Examples of the information that provides the identification information include a method for performing ink jet printing. By giving identification information to the mat 11 before being wound around the exhaust gas treating body, it is possible to prevent a mistake in the surface when the mat 11 is wound around the exhaust gas treating body.

Next, the manufacturing method of the exhaust gas purification apparatus according to the first embodiment of the present invention will be described.
The manufacturing method of the exhaust gas purifying apparatus according to the first embodiment of the present invention includes a preparation step of preparing a mat material containing inorganic fibers, and fitting of convex and concave shapes from the mat material to both ends perpendicular to the longitudinal direction. A punching step of punching so that at least one hook portion is formed on each of the first side surface portion and the second side surface portion that have a joint portion, are substantially rectangular in plan view, and are parallel to the longitudinal direction; A winding step of winding the mat around the exhaust gas treatment body so that the convex and concave mating portions of the holding sealing material obtained by the punching step are fitted, and a string-like member A string-like member hooking step in which the string-like member is hooked to the hook portions formed on the first side surface portion and the second side surface portion of the mat so that the end portion of the holding sealing material is crossed at least once. After wrapping the mat Characterized in that it comprises a housing step of housing the exhaust gas treating body in the casing. Moreover, you may include the process of providing identification information, such as a barcode, a dot, and a color, to a string-like member somewhere in the said process.
For example, when the identification information includes identification information that can identify the direction in which the string-like member is arranged in the slit, it is possible to prevent an error in the direction in which the string-like member is arranged in the slit.
Moreover, when the said string-like member has the identification information which can identify the direction at the time of accommodating the said winding body in a casing, it can prevent mistaking the direction at the time of accommodating a winding body in a casing.
In the case of having identification information (particularly information relating to traceability such as a production lot), the identification information can be left even when the wound body is used at a high temperature.

In the method for manufacturing an exhaust gas purifying apparatus according to the first embodiment of the present invention, first, the preparation step and the punching step are performed in the same manner as the above-described manufacturing method of the holding sealing material, and the holding sealing material (mat) Is made.

Next, a winding step of winding the mat around the exhaust gas treatment body so that the convex shape and the concave fitting portion of the mat constituting the holding sealing material obtained by the punching step are fitted. The string-like member that hooks the string-like member on the hooks formed on the first side face and the second side face of the mat so that the string-like member crosses the end of the holding sealing material at least once. The hooking process is performed to produce a wound body.

Specifically, first, the exhaust gas treating body is formed such that the mat 11 shown in FIG. 1 manufactured in the manufacturing process of the holding sealing material is fitted with the concave fitting portion 14a and the convex fitting portion 14b. A winding step of winding around the outer periphery of 130 is performed.
Subsequently, the string-like member 3 is cut into the first side face portion 16a and the second side face portion 16b of the mat 11 so that the string-like member 3 crosses the end of the holding sealing material 10 at least once. , 12b, 13a, 13b (hanging portion) by performing a string-like member hooking process, by arranging the string-like member 3 so as to be in the mode shown in FIGS. 2 (a) and (b), A wound body 210 is produced.

After these steps, an accommodation step is performed.
FIG. 5 is a perspective view showing how the wound body is housed in the casing.
As shown in FIG. 5, the exhaust gas treating body (wound body 210) around which the mat 11 is wound is press-fitted into a casing 310 having a predetermined size and mainly made of metal or the like.

In order to exhibit a predetermined repulsive force (that is, a force for holding the honeycomb filter) by compressing the sealing material after the press-fitting, the inner diameter of the casing 310 is the holding sealing material 10 of the exhaust gas treating body 130 around which the holding sealing material 10 is wound. It is a little smaller than the outermost diameter including the thickness.

The method of accommodating the exhaust gas treating body wrapped with the holding sealing material in the casing is not limited to the press-fitting method (stuffing method), and includes a sizing method (swaging method), a clamshell method, and the like. .
In the sizing method (swaging method), an exhaust gas treatment body around which a holding sealing material is wound is inserted into the casing, and then compressed from the outer peripheral side so as to reduce the inner diameter of the casing. In the clamshell method, after the casing is separated into two parts, the first casing and the second casing, the exhaust gas treatment body around which the holding sealing material is wound is placed on the first casing. Cover and seal the second casing.
Among the methods for accommodating the exhaust gas treating body wrapped with the holding sealing material in the casing, the press-fitting method (stuffing method) or the sizing method (swaging method) is desirable. This is because in the press-fitting method (stuffing method) or the sizing method (swaging method), it is not necessary to use two parts as the casing, so the number of manufacturing processes can be reduced.

Next, the exhaust gas purifying apparatus according to the first embodiment of the present invention manufactured by the above process will be described.
In the exhaust gas purifying apparatus according to the first embodiment of the present invention, the mat is wound around the exhaust gas treatment body in a state where the convex and concave mating portions of the mat constituting the holding sealing material are fitted. An exhaust gas purification apparatus comprising a wound body in which a state in which the mat is wound around the exhaust gas treatment body by a string-like member and a casing that houses the wound body,
The wound body is accommodated in the casing.

Hereinafter, an example of the exhaust gas purifying apparatus according to the present embodiment will be described with reference to FIGS. 6 (a) and 6 (b).
FIG. 6A is a perspective view schematically showing an example of the exhaust gas purifying apparatus, and FIG. 6B is a cross-sectional view of the exhaust gas purifying apparatus shown in FIG.
As shown in FIGS. 6A and 6B, the exhaust gas purifying apparatus 600 according to the present embodiment has a large number of cells 131 arranged in parallel in the longitudinal direction with the cell walls 132 as exhaust gas treatment bodies. The columnar honeycomb filter 130, the casing 310 that houses the honeycomb filter 130, the holding sealing material 10 that is disposed between the honeycomb filter 130 and the casing 310, and that holds the honeycomb filter 130, and the holding sealing material 10 It is comprised from the provided string-like member 3 (not shown).
That is, the exhaust gas purification apparatus 600 according to the present embodiment includes the wound body 210 and the casing 310 according to the present embodiment shown in FIG.

Since the structure of the wound body 210 according to the present embodiment has already been described, a description thereof will be omitted.
The casing 310 shown in FIGS. 6A and 6B is mainly made of metal such as stainless steel, and has a cylindrical shape. The inner diameter is slightly shorter than the combined length of the diameter of the end face of the exhaust gas treatment body 130 and the thickness of the holding sealing material 10 wound around the exhaust gas treatment body 130. longitudinal direction (in FIG. 6 (a), the direction of the arrow W ₃₎ of the filter 130 has a length substantially the same in.

As shown in FIGS. 6 (a) and 6 (b), the exhaust gas purifying apparatus 600 according to the present embodiment is a honeycomb in which either one of the cells is plugged with a sealing material 138 as an exhaust gas treatment body. A filter 130 is used.
The honeycomb filter 130 is mainly made of a porous ceramic and has a cylindrical shape. Further, a sealing material layer 139 is provided on the outer periphery of the honeycomb filter 130 for the purpose of reinforcing the outer peripheral portion of the honeycomb filter 130, adjusting the shape, and improving the heat insulating property of the honeycomb filter 130.

A case where the exhaust gas passes through the exhaust gas purifying apparatus 600 having the above-described configuration will be described below with reference to FIG.
As shown in FIG. 6 (b), the exhaust gas discharged from the internal combustion engine and flowing into the exhaust gas purification device 600 (in FIG. 6 (b), the exhaust gas is indicated by G and the flow of the exhaust gas is indicated by an arrow) is the honeycomb. It flows into one cell 131 that is open on the exhaust gas inflow side end surface 130 a of the filter 130 and passes through the cell wall 132 that separates the cell 131. At this time, PM in the exhaust gas is collected by the cell wall 132, and the exhaust gas is purified. The purified exhaust gas flows out from the other cells 131 opened in the exhaust gas outflow side end face 130b and is discharged to the outside.

Below, it enumerates about the effect of the holding sealing material which concerns on 1st embodiment of this invention, the manufacturing method of a holding sealing material, a wound body, the manufacturing method of an exhaust gas purification apparatus, and an exhaust gas purification apparatus.
(1) In the holding sealing material according to the present embodiment, at least one hooking portion is formed on each of the first side surface portion and the second side surface portion of the mat constituting the holding sealing material. A mat constituting a holding sealing material is wound around the treatment body, and the string member is matted so that the string member crosses the end of the mat at least once using the hook portion formed on the mat. By hooking on the hook portions formed on the first side surface portion and the second side surface portion, the state where the mat is wound around the exhaust gas treating body can be firmly maintained. For this reason, this wound body can be easily accommodated in the casing, and the displacement of the mat can be prevented.

(2) In the holding sealing material according to the present embodiment, the hook portion is formed at a plurality of locations on the first side surface portion and / or the second side surface portion, respectively. Using the hooks formed on the first side surface and / or the second side surface of the mat, the string-like members are formed on the first side surface and the second side surface of the mat. By hooking on the plurality of hooks, the state where the mat is wound around the exhaust gas treating body can be maintained more securely, and the wound body can be easily accommodated in the casing.

(3) In the holding sealing material according to the present embodiment, the shape of the cutout in plan view is a quadrilateral shape, a triangular shape, a U shape, an L shape, and the like. The member can be easily hooked on the hook portion, whereby the state where the mat is wound around the exhaust gas treating body can be firmly maintained.

(4) In the holding sealing material according to the present embodiment, a portion corresponding to a corner portion of the shape of the cutout portion in plan view is configured by a curve. Therefore, even when a string-like member is hooked on the cutout portion having the above shape, inconveniences such as formation of a tear in the cutout portion are unlikely to occur.

(5) In the manufacturing method of the holding sealing material according to the present embodiment, from the preparation step of preparing a mat material containing inorganic fibers and the mat material, a first side surface portion that is substantially rectangular in plan view and parallel to the longitudinal direction And a second side surface portion, and having convex and concave fitting portions at both ends perpendicular to the longitudinal direction, and at least one or more locations on each of the first side surface portion and the second side surface portion. Since it includes the punching step of punching out so as to form the hook portion, the holding sealing material having the hook portion described above can be formed by the above step.

(6) The wound body according to the present embodiment includes an exhaust gas treating body, a holding sealing material, and a string-like member, and mated convex and concave mating portions constituting the holding sealing material are fitted. In this state, the mat is wound around the exhaust gas treatment body, and the wound body maintains the state where the mat is wound around the exhaust gas treatment body by the string-like member, The string-like member is hooked on a hook portion formed on the first side surface portion and the second side surface portion of the mat so that the member crosses the end portion of the mat at least once. Therefore, the holding sealing material can be reliably fixed to the exhaust gas treating body with a stronger force.

(7) In the wound body according to the present embodiment, the string-like member has an annular shape, and is hooked on at least two hook portions of the mat, and the inner side of the mat on the exhaust gas treatment body side and the mat. It arrange | positions so that the outer side which is the opposite side to the waste gas processing body side may be passed.
Therefore, the string-like member present on the exhaust gas treating body side is sandwiched and fixed between the exhaust gas treating body and the mat, so that the string-like member is not likely to come off from the mat, and the mat is wound around the exhaust gas treating body. Can be reliably maintained.

(8) In the wound body according to the present embodiment, since the string-like body can be expanded and contracted, when the string-like member is arranged on the mat in an extended state, tension acts on the string-like member, and the string A force for pressing the mat against the exhaust gas treating body acts by the shaped member. Therefore, the mat becomes easier to adhere to the exhaust gas treating body, and the state where the mat is wound around the exhaust gas treating body can be reliably maintained.

(9) In the wound body according to the present embodiment, the string member disappears by heating.
When the string-like member disappears due to heating, there is no force to bind the holding seal material to the exhaust gas treatment body. Therefore, in the exhaust gas purification apparatus in which the wound body is accommodated in the casing, the holding seal material is the exhaust gas treatment body at the original surface pressure. The exhaust gas treating body accommodated in the casing can be firmly held via the honeycomb fired body.

(10) In the exhaust gas purification apparatus according to the present embodiment, the mat is wound around the exhaust gas treatment body in a state in which the convex shape and the concave fitting portion of the mat constituting the holding sealing material are fitted. An exhaust gas purifying apparatus comprising: a wound body in which a state in which the mat is wound around the exhaust gas treating body by a string-like member; and a casing for housing the wound body, the wound body Is accommodated in the casing, and the exhaust gas treating body is reliably accommodated in the casing via the holding sealing material, so that the function as the exhaust gas purifying apparatus can be sufficiently exhibited.

(11) In the method for manufacturing an exhaust gas purification apparatus according to the present embodiment, a preparation step of preparing a mat material containing inorganic fibers, and fitting of convex and concave shapes from the mat material to both ends perpendicular to the longitudinal direction A punching step of punching in such a manner that at least one hook portion is formed in each of the first side surface portion and the second side surface portion that are substantially rectangular in plan view and are parallel to the longitudinal direction; A winding step for winding the mat around the exhaust gas treatment body so that the convex and concave mating portions of the holding sealing material obtained by the punching step are fitted; A string-like member hook that hooks the string-like member on the hook portions formed on the first side surface portion and the second side surface portion of the mat so that the shape member crosses the end of the holding sealing material at least once. Process and winding the mat And a housing step for accommodating the attached exhaust gas treating body in a casing, so that a wound body that can maintain the state in which the mat is wound around the exhaust gas treating body can be used, and the wound body can be easily casing. Therefore, it is possible to easily manufacture the exhaust gas purification device.

(Second embodiment)
Hereinafter, the holding sealing material, the manufacturing method of the holding sealing material, the wound body, the manufacturing method of the exhaust gas purification device, and the exhaust gas purification device according to the second embodiment of the present invention will be described.

Hereinafter, the holding sealing material and the wound body according to the second embodiment will be described first, but matters other than those described below are configured in the same manner as the holding sealing material and the wound body according to the first embodiment. Therefore, the holding sealing material and the wound body can be manufactured by the same method as in the first embodiment. The same applies to the exhaust gas purification device and the method of manufacturing the exhaust gas purification device.

The hooking portion formed in the holding sealing material according to the second embodiment of the present invention may be a notch, a protrusion, or a combination of the notch and the protrusion. Good.

FIGS. 7A to 7D are front views showing a holding sealing material having a hook portion of various modes and a wound body using the holding sealing material.
In the wound body 220 shown in FIG. 7 (a), a hooking portion including projecting portions 22a and 23a is formed on the first side surface of the mat 21 constituting the holding sealing material 20, and a notch is formed on the second side surface. The hook part which consists of the parts 22b and 23b is formed. The mat 21 is wound around the exhaust gas treatment body 130, and the annular string-like member 3 is hooked on the protrusions 22a and 23a and the notches 22b and 23b, whereby the wound body 220 is produced.
In this case, the wound body 220 is produced by using the annular string-like member 3. In this wound body 220, the state in which the mat 21 is wound around the exhaust gas treatment body 130 is reliably maintained. Can do.

The shape of the projecting portion is not particularly limited. In the case of the projecting portion, it is sufficient that a portion to be hooked is formed by projecting, and the shape of the projecting portion is not a problem. As shown to a), the shape of the part which protruded from the 1st side part and the 2nd side part is simple, and what is necessary is just shapes, such as a rectangle which is easy to form.

As shown in FIG. 7 (a), a wound body can be produced even if the hooking part is a combination of a protruding part and a notch part. Can be produced.

In the wound body 230 shown in FIG. 7 (b), two hooking parts including notches 32a and 33a are formed on the first side surface portion of the mat 31 constituting the holding sealing material 30, and the second side surface portion has The hook part which consists of the notch part 32b is formed in one place. The mat 31 is wound around the exhaust gas treatment body 130, and the annular string-like member 3 is hooked on the notches 32a and 33a and the notch 32b, whereby the wound body 230 is produced.
The wound body 230 is an example in which the wound body 230 is manufactured using a notch portion formed at two locations on one side surface and a notch portion formed at one location on the other side surface. The members 3 are arranged so as to form a triangular shape in plan view. Even in such a case, the wound body 230 can be produced, and the mat 31 is wound around the exhaust gas treating body 130. Can be reliably maintained.

In the wound body 240 shown in FIG. 7 (c), one hooking portion including a notch portion 43a is formed on the first side surface portion of the mat 41 constituting the holding sealing material 40, and the second side surface portion has a notch portion. One hook portion formed of the portion 42b is formed. The mat 41 is wound around the exhaust gas treatment body 130, and the annular string-like member 3 is hooked on the notch 43a and the notch 42b, whereby the wound body 240 is produced.

In this wound body 240, the wound body 240 is formed by using a notch formed at one place on one side surface and a notch formed near one end on the opposite side and at one place on the other side face. The annular string-like member 3 is arranged so as to pass through the main surface of the mat on the exhaust gas treatment body side and the main surface on the opposite side of the exhaust gas treatment body and form a straight line in plan view. However, even in such a case, the wound body 240 can be produced, and the state where the mat 41 is wound around the exhaust gas treating body 130 can be reliably maintained.

In the wound body 250 shown in FIG. 7D, the notch is formed in the same manner as the wound body 240 shown in FIG. That is, one hooking portion made of the cutout portion 53a is formed on the first side surface portion of the mat 51 constituting the holding sealing material 50, and one hooking portion made of the cutout portion 52b is formed on the second side surface portion. Has been. The mat 51 is wound around the exhaust gas treatment body 130, and the annular string-like member 3 is hooked on the notch 53a and the notch 52b, whereby the wound body 250 is produced.

In this wound body 250, the arrangement method of the string-like member 3 is different from the case of FIG. That is, the string-like member 3 is hooked on the notch 53a and passes through the fitting portion at the corner 54c where the convex fitting portion 54b is formed while passing through the main surface of the mat on the exhaust gas treatment body side. Then, after being exposed to the main surface on the side opposite to the exhaust gas treating body, it is hooked on the notch 52b and passes again through the main surface on the exhaust gas treating body side. Then, it protrudes from the opposite corner part 54d where the convex fitting part 54b is formed to the main surface on the opposite side to the exhaust gas treating body, and is hooked on the notch 53a.
Even in such a case, the wound body 250 can be manufactured, and the state where the mat 51 is wound around the exhaust gas treating body 130 can be reliably maintained.

FIG. 8 shows the wound body 230 shown in FIG. 7B. When the geometric shape of the string-like member 3 in the notch 33a is observed, the string-like member 3 passing outside the mat 31 is The cord 31 is configured to pass through the inside of the mat 31 through a contact point B that is one point of the notch 33a. When the mat 31 is viewed in plan, the cord passes through the outside of the mat 31 with the contact point B as the center. A straight line C that is perpendicular to the bisector A of the angle formed by the string-like member 3 and the string-like member 3 that passes through the inside of the mat 31, is parallel to the main surface of the mat 31, and passes through the contact point B Is drawn, the mat material is arranged on the straight portions on both sides of the contact point B.
Therefore, the string-like member 3 hooked on the notch 33a is not easily detached from the notch 33a, and the state where the mat 31 is wound around the exhaust gas treatment body 130 can be reliably maintained.
If the mat member is not disposed on the straight portions on both sides of the contact point B, the string-like member 3 is easily detached from the notch 33a.

When producing a holding sealing material in which protrusions are formed on at least a part of the first side surface portion or the second side surface portion, a method similar to the method described in the first embodiment is used, and the mat material is punched. The mat is manufactured by performing the process. However, if the holding sealing material in which the protruding portions are formed on both the first side surface portion and the second side surface portion is manufactured, the protruding portions collide with each other, which is useless to the mat. Part occurs. However, by properly combining the protruding portion and the notched portion, it is possible to punch without generating waste, and the mat can be efficiently manufactured.

FIG. 9 is a plan view schematically showing a punching pattern when a mat having a protruding portion is punched from the mat material.
The mat member 510 shown in FIG. 9 has an area where a plurality of mats 21 can be punched. The mat 21 is produced by cutting the mat member at the solid line portion in FIG. That is, the mat 21 is manufactured so that the protruding portions 22a and 23a are formed on the first side surface portion 26a of the mat 21 and the notches 22b and 23b are formed on the second side surface portion 26b.

In the pattern of the mat 21 shown in FIG. 9, the patterns of the plurality of mats 21 arranged side by side through the side surface portion are completely the same pattern. The plurality of mats 21 arranged through the end portions are also the same pattern. Therefore, even if the mat has protrusions and cutouts on the side surface, many mats having the same shape can be manufactured by punching once, and the labor for forming the hooking portion after the punching process can be saved. The holding sealing material (mat) can be efficiently produced.

Below, it lists about the effect of the holding sealing material which concerns on 2nd embodiment of this invention, the manufacturing method of a holding sealing material, a wound body, the manufacturing method of an exhaust gas purification apparatus, and an exhaust gas purification apparatus.
In the present embodiment, in addition to the effects (1) to (11) described in the first embodiment of the present invention, the following effects are exhibited.

(12) In the holding sealing material according to the present embodiment, since the protruding portion and / or the notch portion is formed as the hooking portion, the mat constituting the holding sealing material is wound around the exhaust gas treatment body, and the mat is formed on the mat. By using the protruding part and / or the notch part, the mat is exhausted by hooking the string member on the protruding part and / or the notch part so that the string member crosses the end of the mat at least once. The state wound around the treatment body can be firmly maintained.

(13) In the wound body according to the present embodiment, the string-like member that passes through the outside of the mat is configured to pass through the inside of the mat via a contact point B that is one point of the hook portion. When the mat is viewed in plan, it is perpendicular to the bisector A of the angle formed by the string-shaped member passing through the outside of the mat and the string-shaped member passing through the inside with the contact point B as the center. When a straight line C that is parallel to the main surface of the mat and passes through the contact point B is drawn, the mat member is disposed on the straight line portions on both sides of the contact point B. Therefore, the string-like member hooked on the hook portion is not easily detached from the hook portion, and the state where the mat is wound around the exhaust gas treating body can be reliably maintained.

(14) In the manufacturing method of the holding sealing material according to the present embodiment, at least one notch or projecting portion which is a hooking portion is formed on the first side surface portion from the mat material, and the second side surface portion is formed. A protrusion having the same shape as the notch is formed, or a notch having the same shape as the protrusion is formed, and the notch or the end of the protrusion is formed on the first side surface. Punching is performed so that the formation position from the portion is the same as the formation position from the end portion of the protruding portion or the notch portion formed on the second side surface portion.

The mat pattern punched out by the above-described method is a pattern in which a plurality of mat patterns arranged side by side with each other are exactly the same pattern. A plurality of mats lined up through the end are repeated in the same pattern, so even if the mat has notches or protrusions on the side, many mats with the same shape can be manufactured by punching once. The holding sealing material (mat) can be efficiently produced.

(Third embodiment)
Hereinafter, the holding sealing material, the manufacturing method of the holding sealing material, the wound body, the manufacturing method of the exhaust gas purification device, and the exhaust gas purification device according to the third embodiment of the present invention will be described.

Hereinafter, the holding sealing material and the wound body according to the third embodiment will be described first. However, matters other than those described below are configured in the same manner as the holding sealing material and the wound body according to the first embodiment. Therefore, the holding sealing material and the wound body can be manufactured by the same method as in the first embodiment. The same applies to the exhaust gas purification device and the method of manufacturing the exhaust gas purification device.

In the holding sealing material according to the third embodiment of the present invention, a slit is formed on at least a part of a line connecting at least one main surface and connecting an arbitrary hooking portion.
FIG. 10A is a plan view showing an example in which slits 15a and 15b are formed on both main surfaces of the mat 11 constituting the holding sealing material 10 shown in FIG. 1, and FIG. It is an AA sectional view taken on the line.

As shown in FIG. 10, when the wound body 210 is manufactured, the string-like member 3 can be arranged inside the slit 3 by forming the slits 15 a and 15 b in the portion through which the string-like member 3 passes. Further, it is possible to prevent a risk that the string-like member 3 is detached from the notches 12a, 12b, 13a, 13b, etc. Even when the wound body 210 is stored in the casing 310 by press fitting or the like, the mat 11 is exhausted. The state wound around the processing body 130 can be reliably maintained. Further, when the string-like member 3 can be accommodated in the slits 15a and 15b, it can be accommodated in the casing 310 more smoothly.

As shown in FIG. 10B, the slits 15a and 15b have a V-shaped cross section, but a slit having a rectangular or circular cross section may be formed.

FIG. 11 is a plan view schematically showing a state in which a slit is formed in a part on a line connecting the hook portions.
As shown in FIG. 11, the slits 15c and 15d may be formed in a part of the linear portion where the string-like member is disposed. By using the slits 15c and 15d and arranging the string-like member 3 along the slits 15c and 15d, it is possible to prevent the string-like member 3 from being detached from the notches 12a, 12b, 13a and 13b. Can do.

The depth of the slit is preferably 1/5 to 4/5 of the thickness of the holding sealing material. The slit depth t is preferably 2 to 8 mm. When the wound body is manufactured by setting the above-described depth, it is easy to store the string-like member in the slit, and the string-like member is difficult to be exposed on the outer surface of the holding sealing material. Can be reliably maintained around the exhaust gas treating body. Further, the wound body can be accommodated in the casing 310 more smoothly.
Furthermore, when the cross-sectional shape of the slit 15 is V-shaped, the width of the slit on the mat surface is desirably 2 to 15 mm.

When manufacturing the holding sealing material in which the slit is formed, after the punching step described in the first embodiment, at least a part of the slit on at least one main surface on a line connecting an arbitrary hooking portion is formed. A slit forming step for forming slits to be formed is performed.
The apparatus used when forming the slit is not particularly limited, and for example, a Thomson blade can be used. In addition, the slit may be formed by pressing with a mold.

Below, it lists about the effect of the holding sealing material which concerns on 3rd embodiment of this invention, the manufacturing method of a holding sealing material, a wound body, the manufacturing method of an exhaust gas purification apparatus, and an exhaust gas purification apparatus.
In the present embodiment, in addition to the effects (1) to (11) described in the first embodiment of the present invention, the following effects are exhibited.

(15) In the holding sealing material according to the present embodiment, a slit is formed on at least one of the main surfaces and on at least a part of a line connecting arbitrary hooking portions. Therefore, by using the slit and arranging the string-like member hooked on the hook portion along the slit, it is possible to prevent the possibility that the string-like member is detached from the hook portion. Even when the appendage is housed in the casing by press fitting or the like, the state in which the mat is wound around the exhaust gas treating body can be reliably maintained. Moreover, when a string-like member can be accommodated in the inside of a slit, it can be accommodated in the inside of a casing more smoothly.

(16) In the holding sealing material according to the present embodiment, the depth of the slit can be set to 1/5 to 4/5 of the thickness of the holding sealing material. In the holding sealing material having such a shape, it is easy to store the string-like member inside the slit, the string-like member is hardly exposed on the outer surface of the holding sealing material, and the mat becomes an exhaust gas treatment body. The wound state can be reliably maintained. Moreover, a wound body can be accommodated in the inside of a casing more smoothly.

(17) In the manufacturing method of the holding sealing material according to the present embodiment, after the punching step, at least one of the main surfaces is formed with a slit in at least a part on a line connecting an arbitrary hooking portion. A slit forming step for forming a slit is performed. Therefore, by using the hook portion and the slit of the obtained mat and arranging the string member hooked on the hook portion along the slit, the string member is detached from the hook portion, etc. The fear can be prevented, and even when the wound body is stored in the casing by press fitting or the like, the state where the mat is wound around the exhaust gas treating body can be reliably maintained.

(18) In the manufacturing method of the holding sealing material according to the present embodiment, the slit can be formed so that the depth of the slit is 1/5 to 4/5 of the thickness of the holding sealing material. In the mat thus obtained, it is easy to store the string-like member inside the slit, the string-like member is difficult to be exposed on the outer surface of the holding sealing material, and the mat becomes an exhaust gas treatment body. It is possible to reliably maintain the wound state

(Example)
Examples in which the embodiments of the present invention are disclosed more specifically are shown below, but the embodiments of the present invention are not limited to these examples.

Example 1
A substrate mat having a composition ratio of Al ₂ O ₃ : SiO ₂ = 72: 28 was prepared as an alumina fiber substrate mat having an alumina-silica composition. By subjecting this base mat to needle punching, a needle mat having a bulk density of 0.15 g / cm ³ and a basis weight of 1500 g / m ² was produced.

Separately, an acrylic latex emulsion was prepared by sufficiently dispersing acrylic latex in water, and this was used as a binder.

Next, the needle mat was cut into a total length of 1100 mm × width of 1280 mm in plan view. A binder was sprayed uniformly on the cut needle mat using a spray so as to be 1.0% by weight with respect to the amount of alumina fibers of the cut needle mat.

Then, the mat material was produced by carrying out 6 minutes ventilation drying of the needle mat to which the binder was adhered at the temperature of 140 degreeC.

Subsequently, a mat having a shape as shown in FIG. 7C was punched from the mat material.
The mat material was punched using a Thomson blade and a hydraulic press.
The dimensions of the punched mat are the longitudinal length L = 507 mm, the width W = 145 mm, the thickness T = 9.1 mm, and the longitudinal length of the concave and convex fitting portions is D = 50 mm. .
And, the first side surface portion at a position 60 mm from the end portion having the convex fitting portion has one cutout portion having a rectangular shape in plan view, and the second side surface at a position 60 mm from the end portion having the concave fitting portion. A cutout portion having a rectangular shape in plan view was formed in the portion, and the dimensions of the two rectangular cutout portions were both cut to 10 mm × 10 mm (see FIG. 7C).

Next, a mat was wound around an exhaust gas treatment body (SiC honeycomb filter) having a diameter of 152.4 mm (6 inches) and a length of 152.4 mm (6 inches).
Thereafter, as shown in FIG. 7 (c), by holding a rubber band (Kyowa Co., Ltd., Oband # 18, inner diameter 44.5 mm × width 1.1 mm) so as to be hooked to each notch, the holding sealing material Was fixed to the exhaust gas treating body to produce a wound body.

Finally, the wound body was accommodated in a casing (inner diameter: 164.4 mm, length: 180 mm) using a press-fitting method, and the manufacture of the exhaust gas purification apparatus was completed.
Table 1 shows the conditions for producing the wound body.
In Table 1, the shape and number of hooks are shown based on the shapes shown in the drawings. The presence of R chamfering indicates that a portion corresponding to a corner portion of the cutout portion in plan view is configured by a curve. In Table 1, the result of the determination of the difficulty of detachment of the string-like member described in claim 28 (whether or not the mat member is arranged on the straight portions on both sides of the contact point B) is shown. ○ indicates that the mat member is disposed on the straight portions on both sides of the contact point B, and the string-like member is difficult to come off, and × indicates that the mat member is disposed on the straight portions on both sides of the contact point B. This indicates that the string-like member is easily detached.

(Fixability when winding)
When the holding sealing material was wound around the exhaust gas treating body and the string-like member was arranged and fixed, it was visually evaluated whether or not the holding sealing material was fixed.
The evaluation criteria were evaluated in three stages: ○: firmly fixed, Δ: fixed but wrinkled, ×: difficult to fix. The results are shown in Table 2. In Example 1, the evaluation was “◯: firmly fixed”.

(Drift at the time of accommodation)
When the wound body was accommodated in the casing, the degree to which the holding sealing material was displaced was visually evaluated.
The evaluation criteria were evaluated in three stages: ○: no deviation, Δ: small occurrence, x: large deviation occurred. The results are shown in Table 2. In Example 1, the evaluation was “◯: no deviation”.

(Slit cut at the time of accommodation for mats with slits)
When the wound body was accommodated in the casing, it was visually evaluated whether or not the slit portion of the holding sealing material was broken.
The evaluation criteria were evaluated in three stages: ○: no break, Δ: easy to break, x: always cut. The results are shown in Table 2.

“Additional organic component due to string-like member” in Table 2 shows the content of the organic component as 100% of the weight of the entire holding sealing material when an organic component is used as a means for fixing the holding sealing material. Amount (%).
When there are many organic components, when the holding sealing material is exposed to a high temperature in the exhaust gas purification apparatus, malodor and toxic gas are generated from the exhaust gas. Accordingly, it is preferable that the content of the organic component is small.
In Example 1, since rubber bands were used as means for fixing the holding sealing material, this value was 0.14%.

To the casing when the organic component decomposed when using the exhaust gas purifying device due to the string-like member described in Table 2, the fixing property at the time of winding, the occurrence of deviation at the time of housing, and the slit is formed A comprehensive evaluation was performed based on the evaluation of the cut of the slit portion during housing, and the results are shown in Table 2.
In the comprehensive evaluation, the evaluation results are as follows.
A: No problem at all points, O: No problem, Δ: Some problem, ×: There is a problem, and it is difficult to produce a good wound body and exhaust gas purifying apparatus. It was evaluated that there was no problem.

(Examples 2 to 10)
A holding sealing material having the shape shown in Table 1 is produced, and then a wound body is produced. The obtained wound body is housed in a casing to produce an exhaust gas purification device. Evaluation was made regarding the occurrence of misalignment, and the slit cut when the slit was formed. In addition, the formation state of the hook part formed in Examples 2-10 was as having shown in drawing of Table 1, and conditions, such as a position of a hook part, were the same as that of Example 1. FIG.
The shape state of the hooking portions in Examples 2 to 10, the number of hooking portions, the presence or absence of chamfering, the difficulty of detaching the string-like member, the depth of the slit when forming the slit, the ratio of the slit to the thickness of the mat Etc. are shown in Table 1.
In Table 2, in Examples 2 to 10, the organic matter decomposed when using the exhaust gas purification device due to the string-like member, the fixability at the time of winding, the occurrence of deviation at the time of storage, and the formation of slits The result of the evaluation regarding the cutting of the slit portion and the comprehensive evaluation in the case of the above is shown.

(Comparative Example 1)
When forming the wound body without forming the notch portion on the first side surface portion and forming the notch portion similar to Example 1 only on the second side surface portion, the rubber band is hooked on the notch portion. The wound body was produced by simply hooking a rubber band on the first side surface portion having no notch, and then an exhaust gas purification device was produced. Conditions other than the above were the same as in Example 1.
The shape state of the hooking part in Comparative Example 1, the number of hooking parts, the presence or absence of chamfering, the difficulty of detaching the string-like member, the depth of the slit when forming the slit, the ratio of the slit to the thickness of the mat, etc. Table 1 shows.
Also, in Table 2, when organic components that are decomposed when using the exhaust gas purification device due to the string-like member in Comparative Example 1, fixing property at the time of winding, occurrence of deviation at the time of housing, slits are formed The result of the evaluation regarding the cutting | disconnection of the slit part and comprehensive evaluation is shown.

(Comparative Example 2)
A cut-out part was not formed on the mat, and a rubber band was simply hooked on the first side face part and the second side face part where the cut-out part does not exist to produce a wound body, and then an exhaust gas purification device was produced. Conditions other than the above were the same as in Example 1. In addition, the angle in the comparative example 2 is an angle made with the side surface.
The shape state of the hooking part in Comparative Example 2, the number of hooking parts, the presence or absence of chamfering, the difficulty of detaching the string-like member, the depth of the slit when forming the slit, the ratio of the slit to the thickness of the mat, etc. Table 1 shows.
Also, in Table 2, when the organic component decomposed when using the exhaust gas purification device due to the string-like member in Comparative Example 2, the fixing property at the time of winding, the occurrence of deviation at the time of housing, and the slit formed The result of the evaluation regarding the cutting | disconnection of the slit part and comprehensive evaluation is shown.

(Comparative Example 3)
Holding seal so that the main surface near the end of the holding sealing material (mat) wrapped around the double-sided tape is bonded to the side face of the exhaust gas treatment body without forming a notch in the mat. A material was wound to produce a wound body, and then an exhaust gas purification device was produced. Conditions other than the above were the same as in Example 1.
The shape state of the hooking part in Comparative Example 3, the number of hooking parts, the presence or absence of chamfering, the difficulty of detaching the string-like member, the depth of the slit when forming the slit, the ratio of the slit to the thickness of the mat, etc. Table 1 shows.
Also, in Table 2, when organic components decomposed when using the exhaust gas purification device due to the string-like member in Comparative Example 3, fixing property at the time of winding, occurrence of deviation at the time of housing, slits are formed The result of the evaluation regarding the cutting | disconnection of the slit part and comprehensive evaluation is shown.

(Comparative Example 4)
After the holding sealing material is wrapped around the exhaust gas treatment body without forming a notch in the mat, a tape with adhesive on one side is crossed across the end of the holding sealing material so that the wound state is fixed. The wound body was manufactured by sticking to the substrate, and then an exhaust gas purification device was manufactured. Conditions other than the above were the same as in Example 1.
The shape state of the hooking part in Comparative Example 4, the number of hooking parts, the presence or absence of chamfering, the difficulty of detaching the string-like member, the depth of the slit when forming the slit, the ratio of the slit to the thickness of the mat, etc. Table 1 shows.
Also, in Table 2, when organic components that are decomposed when using the exhaust gas purification device due to the string-like member in Comparative Example 4, fixing property at the time of winding, occurrence of deviation at the time of housing, slits are formed The result of the evaluation regarding the cutting | disconnection of the slit part and comprehensive evaluation is shown.

As is clear from the results of Examples 1 to 10 and Comparative Examples 1 to 4 in Table 2, a hook portion is formed on the holding sealing material, and the holding sealing material is wound around the exhaust gas treatment body, and then the hook portion formed. , A string-like member (rubber rubber) is hooked on the hook, and the string-like member is hooked on the hook so that the string-like member crosses the end of the mat at least once. The state in which the mat is wound around the exhaust gas treating body by the member is maintained.
Further, when the exhaust gas treating body wrapped with such a holding sealing material was accommodated in the casing, the holding sealing material was not displaced and the exhaust gas purification device could be produced smoothly.

On the other hand, as shown in Comparative Examples 1 and 2, when the hook part is formed only on one side surface of the holding sealing material, or when it is not formed at all, there is no portion where the string member such as the rubber band is caught, It was found that it was difficult to maintain the state where the holding sealing material was wound around the exhaust gas treatment body.
Further, as shown in Comparative Examples 3 and 4, it was found that even if an attempt was made to maintain the state where the holding sealing material was wrapped around the exhaust gas treating body using a double-sided tape or the like, misalignment or the like was likely to occur and fixing was difficult.

(Other embodiments)
The shape of the concave portion and the convex portion formed in the holding sealing material according to the embodiment of the present invention is not particularly limited as long as the concave portion and the convex portion can be fitted with each other. A convex fitting portion is formed over a size of width 10 mm × length 10 mm to width 300 mm × length 100 mm, and a concave fitting portion to be fitted to the fitting portion is formed. It is desirable that
When the exhaust gas purification apparatus is manufactured using the holding sealing material having such a fitting portion, the exhaust gas treating body can be reliably held by the holding sealing material, so that the handling property is excellent.
When the size of the convex fitting portion is smaller than width 10 mm × length 10 mm and larger than width 300 mm × length 100 mm, when the holding sealing material is wound around the exhaust gas treatment body, Since the contact area between the end surfaces of the holding sealing material is small, the end surfaces of the holding sealing material are hardly brought into contact with each other. As a result, it becomes difficult for the holding sealing material to hold the exhaust gas treating body.
In the holding sealing material according to the embodiment of the present invention, a plurality of fitting portions that fit each other may be formed on the short side of the holding sealing material, or the fitting portion is not formed. May be.

The shape of the exhaust gas treating body constituting the exhaust gas purifying apparatus according to the embodiment of the present invention is not particularly limited as long as it is a columnar shape, in addition to a substantially cylindrical shape, for example, an arbitrary shape such as a substantially elliptical columnar shape or a substantially prismatic shape, It may be of a size.

The exhaust gas treating body constituting the exhaust gas purifying apparatus according to the embodiment of the present invention may be an integral honeycomb structure made of cordierite or the like and integrally formed from one ceramic, or silicon carbide Is a collective honeycomb structure formed by bundling a plurality of columnar honeycomb fired bodies having a large number of through holes arranged in parallel in the longitudinal direction with partition walls therebetween, mainly through an adhesive layer containing ceramic. May be.

A catalyst may be supported on the exhaust gas treating body constituting the exhaust gas purifying apparatus according to the embodiment of the present invention.
Examples of the catalyst supported on the exhaust gas treating body include noble metals such as platinum, palladium and rhodium, alkali metals such as potassium and sodium, alkaline earth metals such as barium, and metal oxides such as cerium oxide. Can be mentioned. These catalysts may be used independently and may use 2 or more types together.

In the exhaust gas purifying apparatus according to the embodiment of the present invention, when the exhaust gas treating body is a honeycomb structure, the end portion of the cell may not be sealed without providing the cell with the sealing material. In this case, the exhaust gas treating body functions as a catalyst carrier that purifies harmful gas components such as CO, HC, or NOx contained in the exhaust gas by supporting a catalyst such as platinum.

The holding sealing material of the present invention is composed of a mat containing an inorganic fiber, has a substantially rectangular shape in plan view, and is parallel to the longitudinal direction, a first side surface portion (hereinafter also referred to as a first side surface portion) and a second side surface portion. (Hereinafter, also referred to as a second side surface portion) and a holding sealing material having convex and concave fitting portions at both ends perpendicular to the longitudinal direction, wherein the first side surface portion and the second side portion It is an essential component that at least one hook portion is formed on each of the side portions.

In addition, the wound body of the present invention includes an exhaust gas treating body, the holding sealing material, and a string-like member, and is a state in which the convex and concave mating portions constituting the holding sealing material are fitted. The mat is wound around the exhaust gas treating body, and the wound body maintains the state where the mat is wound around the exhaust gas treating body by the string-like member, and the string-like member is It is an essential component that the string-like member is hooked on the hook portions formed on the first side surface portion and the second side surface portion of the mat so as to cross the end portion of the mat at least once. is there.

Moreover, the manufacturing method of the holding sealing material of the present invention includes a preparation step of preparing a mat material containing inorganic fibers, and a first side surface portion and a second shape that are substantially rectangular in plan view and parallel to the longitudinal direction from the mat material. And a fitting portion having a convex shape and a concave shape at both ends perpendicular to the longitudinal direction, and at least one hook portion on each of the first side surface portion and the second side surface portion. It is an essential component to include a punching process in which punching is performed so as to be formed.
Moreover, in the exhaust gas purifying apparatus of the present invention and the method of manufacturing the exhaust gas purifying apparatus of the present invention, it is an essential component to use the holding sealing material and the wound body of the present invention.
Desired effects can be obtained by appropriately combining various components described in detail in the first to third embodiments of the present invention and the other embodiments of the present invention with such essential components.

3 String-like members 10, 20, 30, 40, 50, 60, 70, 80, 90, 100 Holding sealing material 11, 21, 31, 41, 51, 61, 71, 81, 91, 101 Mats 12a, 12b, 13a, 13b, 22b, 23b, 32a, 32b, 33a, 43a, 42b, 53a, 52b, 62a, 62b, 72a, 72b, 82a, 82b, 92a, 92b, 102a, 102b Notch 22a, 23a Protruding part 14a, 24a, 34a, 44a, 54a, fitting part (concave part)
14b, 24b, 34b, 44b, 54b, 64b, 74b, 84b, 94b, 104b Fitting part (convex part)
15a, 15b, 15c, 15d Slits 16a, 26a First side part 16b, 26b Second side part 130 Exhaust gas treatment body (honeycomb filter)
131 Cell 132 Cell wall 138 Sealing material 210, 220, 230, 240, 250 Winding body 310 Casing 500, 510 Mat material 600 Exhaust gas purification device

Claims (31)

Consisting of a mat containing inorganic fibers, having a first side surface portion and a second side surface portion that are substantially rectangular in plan view and parallel to the longitudinal direction, and convex and concave shapes at both end portions perpendicular to the longitudinal direction A holding sealing material having a fitting portion of
The holding sealing material, wherein at least one hook portion is formed on each of the first side surface portion and the second side surface portion. 2. The holding sealing material according to claim 1, wherein the hook portion is formed at a plurality of locations on the first side surface portion and / or the second side surface portion. 3. The holding sealing material according to claim 1, wherein the hook portion is formed by forming a cutout portion and / or a protruding portion in the first side surface portion and the second side surface portion. The holding sealing material according to claim 3, wherein the shape of the cutout in plan view is a quadrilateral shape, a triangular shape, a U shape, a J shape, an L shape, or a T shape. The holding sealing material according to claim 3, wherein a shape of the cutout portion in a plan view includes a curved portion at a portion corresponding to a corner portion. The holding sealing material according to any one of claims 1 to 5, wherein a distance from an end portion in the longitudinal direction of the mat is 1/4 or less of a length in the longitudinal direction of the mat. The holding sealing material according to any one of claims 1 to 6, wherein a slit is formed on at least a part of a line connecting at least one of the main surfaces and connecting an arbitrary hooking portion. The holding sealing material according to any one of claims 1 to 7, wherein a depth of the slit is 1/5 to 4/5 of a thickness of the holding sealing material. A preparation step of preparing a mat material containing inorganic fibers;
The mat member has a first side surface portion and a second side surface portion that are substantially rectangular in a plan view and are parallel to the longitudinal direction, and convex and concave fitting portions at both ends perpendicular to the longitudinal direction. And a punching step of punching out the first side surface portion and the second side surface portion so that at least one hooking portion is formed in each of the first side surface portion and the second side surface portion. A method of manufacturing the material. The method for manufacturing a holding sealing material according to claim 9, wherein in the punching step, the hooking portion is punched so that a plurality of portions are formed on the first side surface portion and / or the second side surface portion, respectively. The holding according to claim 9 or 10, wherein in the punching step, punching is performed so that a hook portion is formed by forming a cutout portion and / or a protruding portion in the first side surface portion and the second side surface portion. Manufacturing method of sealing material. The manufacturing method of the holding sealing material according to claim 11, wherein the shape of the cutout portion when viewed in plan is punched out so as to be a square shape, a triangular shape, a U shape, a J shape, an L shape, or a T shape. . The manufacturing method of the holding sealing material according to claim 11, wherein the shape of the cutout portion in plan view is punched so that a portion corresponding to a corner portion is configured by a curve. The slit forming step of forming a slit so that a slit is formed in at least a part of a line connecting an arbitrary hooking portion on at least one main surface after the punching step. A method for producing the holding sealing material according to claim 1. The method for producing a holding sealing material according to claim 14, wherein the slit is formed so that a depth of the slit is 1/5 to 4/5 of a thickness of the holding sealing material. From the mat material, at least one notch or protrusion as a hook is formed on the first side surface, and a protrusion having the same shape as the notch is formed on the second side surface. Alternatively, a cutout portion having the same shape as the protruding portion is formed, and the cutout portion formed in the first side surface portion or the formation position of the protruding portion from the end portion is the second side surface portion. The manufacturing method of the holding sealing material of Claim 15 punched out so that it may become the same as the formation position from the said edge part of the said protrusion part or the said notch part. The exhaust gas treating body and the holding sealing material according to any one of claims 1 to 8 and a string-like member,
The mat is wound around the exhaust gas treatment body in a state where the convex and concave fitting portions of the mat constituting the holding sealing material are fitted, and the exhaust gas treatment body is formed by the string member. A wound body in which the state wound around is maintained,
The string-like member is hooked on hooks formed on the first side face and the second side face of the mat so that the string-like member crosses the end of the mat at least once. A wound body characterized by that. The wound body according to claim 17, wherein the string-like member has two end portions, and the end portions are bound to each other. The string-like member has an annular shape and passes through an inner side of the mat that is an exhaust gas treatment body side and an outer side of the mat that is opposite to the exhaust gas treatment body side in a state where it is hooked on at least two hook portions of the mat. The wound body according to claim 17, wherein the wound body is disposed on the body. The wound body according to any one of claims 17 to 19, wherein the string-like body is disposed along a slit formed in a main surface of the mat. The wound body according to any one of claims 17 to 20, wherein the string-like body is extendable and contractible. The wound body according to claim 21, wherein the string-like body has an elongation percentage of 100% or more. The wound body according to claim 21 or 22, wherein the string-like body has a load with respect to elongation of 0.01 to 0.10 N / mm. The wound body according to any one of claims 17 to 23, wherein an average diameter of the string-like member is 0.2 to 1.5 mm. The wound body according to any one of claims 17 to 24, wherein the string-like member has an uneven surface. The wound body according to any one of claims 17 to 25, wherein the string-like member disappears by heating. The said mat further has the identification information which can identify the surface which contact | connects the said exhaust gas treatment body at the time of winding the said mat around the said exhaust gas treatment body on at least 1 surface. Winding body. The string-like member that passes through the outside of the mat is configured to pass through the inside of the mat via a contact point B that is one point of the hook portion, and when the mat is viewed in plan, the contact point Centered on B, perpendicular to the bisector A of the angle formed by the string-like member passing through the outside of the mat and the string-like member passing through the inside, parallel to the main surface of the mat, and The wound body according to any one of claims 17 to 27, wherein when a straight line C passing through the contact point B is drawn, a mat member is disposed on a straight line portion on both sides of the contact point B. The holding sealing material according to any one of claims 1 to 8, wherein a string-like member is disposed in advance in order to produce the wound body according to any one of claims 17 to 28. The mat is wound around the exhaust gas treatment body in a state where the convex and concave fitting portions of the mat constituting the holding sealing material are fitted, and the mat is wrapped around the exhaust gas treatment body by a string member. An exhaust gas purifying apparatus comprising a wound body that is maintained in a state wound around and a casing that houses the wound body,
The exhaust gas purifying apparatus, wherein the wound body according to any one of claims 17 to 28 is accommodated in the casing. A preparation step of preparing a mat material containing inorganic fibers;
From the mat material, it has convex and concave fitting portions at both ends perpendicular to the longitudinal direction, is substantially rectangular in plan view, and is formed on the first side surface and the second side surface parallel to the longitudinal direction. , A punching process of punching so that at least one hook part is formed into a shape,
A winding step of winding the mat around the exhaust gas treatment body so that the mated convex and concave mating portions constituting the holding sealing material obtained by the punching step are fitted;
A string-like shape that hooks the string-like member on the hooks formed on the first side face and the second side face of the mat so that the string-like member crosses the end of the holding sealing material at least once. Member hooking process;
And a housing step of housing the exhaust gas treating body around which the mat is wound in a casing.

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