JP2020033900A - Method for manufacturing mat material - Google Patents

Abstract

To provide a method for manufacturing a mat material, capable of obtaining many mat materials with excellent winding property from one large-sized sticker.SOLUTION: A method for manufacturing a mat material comprises two kinds of mat materials that comprise: a base mat made of inorganic fibers; and an organic sheet made of an organic material, which is provided on the surface of the base mat, and have a longitudinal direction that is a winding direction and a short direction that is orthogonal to the longitudinal direction. The method for manufacturing a mat material executes the steps of: preparing a sheet-like member made of inorganic fibers; preparing an organic sheet member made of an organic material and having different tensile strength orientations in vertical and horizontal directions; for the organic sheet member, forming a slit extending in a direction inclined to a strong orientation direction of tensile strength; and attaching the organic sheet member to the sheet-shaped member to obtain an attached body.SELECTED DRAWING: Figure 7

Description

The present invention relates to a method for manufacturing a mat member.

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

Therefore, as an exhaust gas purifying device for collecting PM in exhaust gas or purifying harmful gas components, an exhaust gas treating body made of porous ceramic such as silicon carbide or cordierite, and a casing containing the exhaust gas treating body. There have been proposed various exhaust gas purifying apparatuses each including an exhaust gas treating body and a holding sealing material provided between a casing and the casing. The holding sealing material prevents the exhaust gas treatment body from being damaged by contact with the casing covering the outer periphery thereof due to vibration or impact generated by the traveling of the automobile or the like, and prevents the exhaust gas from flowing between the exhaust gas treatment body and the casing. It is provided mainly for the purpose of preventing leakage of the gas.

As a holding sealing material used in such an application, a mat material made of inorganic fibers is used. A mat material made of inorganic fibers is also used for heat insulation and soundproofing used by being wound around a pipe of an automobile or the like.

Patent Literature 1 discloses a composite mat used by being wound around an exhaust gas treating body (catalytic converter) having a small diameter. As the composite mat, a mat composed of an inorganic fiber, a binder, and a flexible sheet attached to at least one surface of a layer of the inorganic fiber is disclosed.

JP-T-2001-521847

In Patent Literature 1, the flexible sheet is provided to prevent the mat member from breaking during winding.
However, when the flexible sheet is provided, the mat member is harder and harder to bend than when the flexible sheet is not provided, and it becomes difficult to wind the mat material when wound around a columnar exhaust gas treatment body or the like. There was a problem.

As a method of manufacturing such a mat material, a method of punching out with a punching die having a punching blade (also referred to as punching processing) has been conventionally used.
In this step, a sheet-shaped member made of inorganic fibers and a large-sized pasted body to which a flexible sheet is pasted are prepared, and a large number of mat members are obtained by a single punching process by punching the pasted body. Can be.

The mat member has a longitudinal direction that is a winding direction and a short direction that is orthogonal to the longitudinal direction.
When obtaining such a mat material from one large-sized pasted body, the place where the mat material is punched out in a direction in which the longitudinal direction of the pasted body becomes the longitudinal direction of the mat material, and the lateral direction of the pasted body is aligned with the longitudinal direction of the mat material. In combination with a place where the mat material is punched in a certain direction, as much mat material as possible can be obtained from one large-sized pasted body.
In this case, two types of mat members having different relationships between the longitudinal and lateral directions of the patch and the longitudinal direction of the mat member are obtained.

Here, when an organic sheet having different tensile strength orientations in the vertical and horizontal directions is used as the flexible sheet, there are two types of relationship between the longitudinal direction of the mat material and the tensile strength orientation of the organic sheet. Mat material is obtained.
More specifically, a mat material (hard mat material) in which the longitudinal direction of the mat material and the orientation direction in which the organic sheet has a high tensile strength is aligned, and the longitudinal direction of the mat material and the orientation in which the organic sheet has a low tensile strength. Two types of mat materials (easy mat materials) having the same direction are obtained.

Hard mat material means that when the mat material is wound around an exhaust gas treatment body, the longitudinal direction of the mat material is aligned with the strong orientation direction of the tensile strength of the organic sheet. In addition, the mat member has a high resistance due to the tensile strength of the organic sheet, the entire mat member is hardly bent, and the winding property is poor.
On the other hand, with the easy mat material, since the longitudinal direction of the mat material and the orientation direction of the organic sheet having low tensile strength are aligned, the mat material is wound around the exhaust gas treatment body or the like with the longitudinal direction of the mat material as the winding direction. In this case, the resistance due to the tensile strength of the organic sheet is weak, the entire mat member is easily bent, and the mat member has a good winding property.

If the winding properties of the two types of mat materials obtained are different, the hard mat material becomes a nonstandard product due to the poor winding property, and as a result, the number of mat materials that can be obtained as good products from one large-sized pasted body Will decrease.

The present invention has been made in view of such a problem, and an object of the present invention is to provide a method for manufacturing a mat material that can obtain a large number of mat materials having good winding properties from a single large-sized pasted body. And

The method for producing a mat material of the present invention comprises a base mat made of inorganic fibers, and an organic sheet made of an organic material provided on the surface of the base mat,
A method for producing a mat material, wherein two types of mat materials having a longitudinal direction that is a winding direction and a short direction orthogonal to the longitudinal direction are produced.
A step of preparing a sheet-like member made of inorganic fibers,
A step of preparing an organic sheet member made of an organic material and having different tensile strength orientations in the vertical and horizontal directions,
For the organic sheet member, a step of forming a slit extending in a direction inclined to a strong orientation direction of tensile strength,
A step of attaching the organic sheet member to the sheet-shaped member to obtain an attached body,
A first mat member in which a punching process is performed on the pasted body, a longitudinal direction of the pasted body is a longitudinal direction of the mat member, and a lateral direction of the pasted body is a lateral direction of the mat member; A step of obtaining a second mat member in which the lateral direction of the mat member is the longitudinal direction of the mat member and the longitudinal direction of the patch is the short direction of the mat member.

In the method for producing a mat material, slits extending in a direction inclined with respect to an orientation direction having a high tensile strength are formed in an organic sheet member having different tensile strength orientations in the vertical and horizontal directions.
If the slit is formed in a direction inclined with respect to the orientation direction in which the organic sheet member has a high tensile strength, the slit is formed in a direction in which the tensile strength of the organic sheet member is reduced.
When such an organic sheet member is used, a mat material obtained by punching at a position where a hard mat material is formed in a conventional method becomes a mat material which is easily bent and has good winding properties.
Therefore, a large number of mat materials having good wrapping properties can be obtained from one large-sized pasted body.

In the method for producing a mat member of the present invention, the organic sheet member is made of an organic fiber having an orientation, and the orientation direction of the organic fiber is an orientation direction having a high tensile strength,
In the step of forming the slit, it is preferable to form a slit extending in a direction inclined with respect to the orientation direction of the organic fiber.

When the organic sheet member is an organic fiber having an orientation, the orientation direction of the organic fiber is an orientation direction having a high tensile strength.
In such a case, if the slit is formed in a direction inclined with respect to the orientation direction of the organic fiber, the slit will be inserted in the direction in which the fiber is cut, so that it is caused by the tensile strength generated by the orientation of the organic fiber during winding. Resistance can be reduced. Therefore, the effect of improving the winding property of the mat member is further increased.

In the method for manufacturing a mat member according to the present invention, it is preferable that an angle between at least a part of the slit and an orientation direction having a high tensile strength of the organic sheet member is more than 0 degree and 90 degrees or less.

In the method for producing a mat member according to the present invention, it is preferable that an angle between at least a part of the slit and an orientation direction having a high tensile strength of the organic sheet member is 45 degrees or more and 90 degrees or less.

In the method for producing a mat member according to the present invention, the organic sheet member is preferably a nonwoven fabric made of organic fibers.

In the method for producing a mat member according to the present invention, it is preferable that the density of the slit formed in the step of forming the slit is 25 to 100 places / 100 cm ² .

In the method for producing a mat member of the present invention, the length of the slit formed in the step of forming the slit is 10 to 70% of the width of the organic sheet member in the direction orthogonal to the orientation direction in which the tensile strength is strong. Is preferred.

In the method for manufacturing a mat member according to the present invention, it is preferable that the top shape of the slit be a U shape, a V shape, a straight shape, or a cross shape.

In the method of manufacturing a mat member according to the present invention, it is preferable that the slit has a shape obtained by dividing a straight line into a plurality of line segments.

In the method for manufacturing a mat member according to the present invention, it is preferable that the slits are arranged in a staggered manner.

In the method for producing a mat member according to the present invention, 10% of the first organic sheet provided on the surface of the first mat member and 10% of the second organic sheet provided on the surface of the second mat member It is preferable that the ratio of the tensile strength at the time of elongation is (organic sheet having higher tensile strength / organic sheet having lower tensile strength) ≦ 4.

The fact that the ratio of the tensile strength of the organic sheet in the two types of mat materials obtained by the method for producing a mat material of the present invention is within the above range means that two types of mat materials having similar winding properties can be obtained. This means that a large number of mat materials having good wrapping properties can be obtained from one large-sized pasted body.

FIG. 1 is a perspective view schematically illustrating an example of a sheet-like member. FIG. 2 is a perspective view schematically illustrating an example of the organic sheet member. FIG. 3 is a perspective view schematically illustrating an example of an organic sheet member having a slit formed therein. FIG. 4 is a top view schematically illustrating an example of the shape of the slit. FIG. 5 is a top view schematically illustrating an example of the shape and arrangement of the slits. FIG. 6 is a perspective view schematically showing an example of the patch. FIG. 7 is a top view schematically showing a process of obtaining two types of mat members by punching. FIG. 8A is a top view schematically illustrating a first mat member, and FIG. 8B is a top view schematically illustrating a second mat member.

(Detailed description of the invention)
Hereinafter, the method for producing a mat member and the wound body of the present invention will be specifically described. However, the present invention is not limited to the following configuration, and can be appropriately modified and applied without changing the gist of the present invention. It should be noted that a combination of two or more individual desirable configurations of the present invention described below is also the present invention.

The method for producing a mat material of the present invention comprises a base mat made of inorganic fibers, and an organic sheet made of an organic material provided on the surface of the base mat, and a longitudinal direction serving as a winding direction and the longitudinal direction. A method for producing a mat material, which produces two types of mat materials having a transverse direction perpendicular to the direction, wherein a step of preparing a sheet-like member made of inorganic fibers and an organic material, wherein the orientation of tensile strength is A step of preparing an organic sheet member that is different in length and width, a step of forming a slit extending in a direction inclined with respect to the orientation direction having a high tensile strength for the organic sheet member, and forming the organic sheet member in the sheet-like member. A step of obtaining a pasted body by pasting, and performing a punching process on the pasted body, a longitudinal direction of the pasted body is a longitudinal direction of the mat member, and a lateral direction of the pasted body is a short side of the mat member. A step of obtaining a first mat member to be oriented and a second mat member in which the lateral direction of the patch is the longitudinal direction of the mat member and the longitudinal direction of the patch is the lateral direction of the mat member. It is characterized by the following.

FIG. 1 is a perspective view schematically illustrating an example of a sheet-like member.
The sheet member 110 is made of an inorganic fiber.
The sheet-shaped member is a large-sized sheet from which a large number of mat members to be described later can be obtained by punching.
The inorganic fiber constituting the sheet member is not particularly limited, and may be an alumina-silica fiber, an alumina fiber, a silica fiber, or the like. Further, glass fibers or biosoluble fibers may be used. What is necessary is just to change according to the characteristics required of a mat material, such as heat resistance and wind erosion resistance, and it is preferable to use a fiber with a large diameter or a fiber length that can conform to the environmental regulations of each country.

Among them, low-crystalline alumina-based inorganic fibers are preferable, and low-crystalline alumina-based inorganic fibers having a mullite composition are more preferable. In addition, inorganic fibers containing a spinel-type compound are more preferable.

The sheet-shaped member can be obtained by various methods, and for example, can be manufactured by a papermaking method or a needling method.
In the case of the papermaking method, for example, it can be produced by the following method.
The inorganic fibers are opened, and the opened inorganic fibers are dispersed in a solvent to form a mixed solution. The mixed solution is poured into a forming device having a mesh for filtration formed on the bottom surface, and the solvent in the mixed solution is desolvated to obtain an inorganic fiber aggregate. Then, a sheet-like member can be obtained by drying the inorganic fiber aggregate.
In the case of needling, for example, it can be manufactured by the following method.
A mixture for spinning using a basic aluminum chloride aqueous solution and silica sol as raw materials is spun by a blowing method to prepare an inorganic fiber precursor having an average fiber diameter of 3 to 10 μm. Subsequently, the above-mentioned inorganic fiber precursor is compressed to produce a continuous sheet-like material having a predetermined size, and a baking treatment is performed to obtain a sheet-like member. Needle punching treatment is performed before or after this baking treatment, and the inorganic fibers are entangled with each other.

The thickness of the sheet-like member is desirably 2 to 30 mm.
If the thickness of the sheet-shaped member is less than 2 mm, the thickness is too thin, so that the heat insulating performance and the soundproofing performance are reduced. On the other hand, if the thickness of the sheet-like member exceeds 30 mm, the flexibility is reduced, and the mountability to the member to be mounted is reduced.

The bulk density of the sheet-like member is not particularly limited, but is desirably 0.05 to 0.30 g / cm ³ . If the bulk density of the sheet-shaped member is less than 0.05 g / cm ³ , the entanglement of the inorganic fibers is weak, and the inorganic fibers are easily peeled off. Therefore, it is difficult to maintain the shape of the sheet-shaped member in a predetermined shape. On the other hand, when the bulk density of the sheet-shaped member exceeds 0.30 g / cm ³ , the sheet-shaped member becomes hard, the mountability to the member to be mounted is reduced, and the sheet-shaped member is easily broken.

FIG. 2 is a perspective view schematically illustrating an example of the organic sheet member.
The organic sheet member 120 is made of an organic material.
The organic sheet member is a large-sized sheet from which many mat members to be described later can be obtained by punching.
The organic material is not particularly limited. For example, paper, a resin film, a nonwoven fabric made of organic fibers, and the like can be given.
In particular, a nonwoven fabric made of organic fibers is preferable.
Examples of the non-woven fabric made of organic fibers include those obtained by fusing PET (polyethylene) powder to PET (polyethylene terephthalate) fibers.
Other organic fibers that can be used include PP (polypropylene), rayon, and the like.
When the organic sheet member is a resin film, examples of the organic material constituting the resin film include PET (polyethylene terephthalate), PP (polypropylene), and PE (polyethylene).

The basis weight of the organic sheet is not particularly limited, but is preferably 10 g / m ² or more, and more preferably 30 g / m ² or less.
When the basis weight of the organic sheet is 10 g / m ² or more, the effect of preventing the mat member from cracking by providing the organic sheet is sufficiently exhibited.
Further, when the basis weight of the organic sheet is 30 g / m ² or less, a decrease in the holding power during the softening of the binder due to the heat of the exhaust gas is small.

The thickness of the organic sheet member is not particularly limited, but is preferably 0.05 mm or more, and more preferably 0.3 mm or less.
When the thickness of the organic sheet member is 0.05 mm or more, the effect of preventing the mat material from cracking by providing the organic sheet is sufficiently exhibited.
Further, when the thickness of the organic sheet member is 0.3 mm or less, the winding property of the mat member becomes good.

The organic sheet member has different tensile strength orientations in the vertical and horizontal directions.
That is, the organic sheet member has an orientation.
When the organic sheet member contains organic fibers, the direction in which the length directions of the organic fibers are aligned is the orientation direction.
When the organic sheet member is a resin film, the stretching direction of the resin film is the orientation direction.
When the organic sheet member has an orientation, the tensile strength in the direction along the orientation direction becomes relatively strong, and the tensile strength in the direction orthogonal to the orientation direction becomes relatively weak.
An organic sheet member having a different tensile strength depending on the measurement direction can be said to be an organic sheet member having an orientation, and the direction in which the tensile strength is highest is defined as the orientation direction of the organic sheet member.
The organic sheet member 120 shown in FIG. 2 has an orientation, and the orientation direction is the direction indicated by reference numeral 125. That is, the orientation direction of the organic sheet member 120 is the horizontal direction.

In the method for producing a mat member according to the present invention, a slit is formed in the organic sheet member so as to extend in a direction inclined with respect to the orientation direction having a high tensile strength.
The method for forming the slit is not particularly limited, but is performed by preparing a member in which a number of slit-shaped blades are arranged on a plate material, and penetrating the blade through the organic sheet in the manner of punching. be able to.

FIG. 3 is a perspective view schematically illustrating an example of an organic sheet member having a slit formed therein.
FIG. 3 shows a state in which a plurality of slits 130 are formed in the organic sheet member 120.
The slit 130 extends in a direction perpendicular to the orientation direction of the organic sheet member 120, that is, in the longitudinal direction of the organic sheet member 120.

FIG. 3 shows an example in which the direction in which the slit extends is a direction orthogonal to the orientation direction of the organic sheet member. However, in the method for producing a mat member according to the present invention, the direction in which the slit extends is not necessarily required to be such an “orthogonal” direction.
In the method for manufacturing a mat member according to the present invention, the direction in which the slit extends may be inclined with respect to the orientation direction of the organic sheet member.
This means that the direction in which the slit extends may be any direction other than the direction extending in the horizontal direction (parallel direction) with respect to the orientation direction of the organic sheet member.
When the direction in which the slit extends is a direction extending in the horizontal direction (parallel direction) with respect to the orientation direction of the organic sheet member, the effect of reducing the resistance due to the tensile strength caused by the orientation of the organic sheet member is provided by providing the slit. Although it cannot be obtained, in other directions, the effect of improving the winding property can be obtained by providing slits to reduce the resistance due to the tensile strength caused by the orientation of the organic sheet member.

Further, the shape of the slit is not limited to a linear shape (line segment). When the shape of the slit is not linear (line segment), a part of the direction in which the slit extends is different from the direction in which the slit extends in the horizontal direction (parallel direction) with respect to the orientation direction of the organic sheet member. Therefore, when a slit having a shape other than a linear shape (line segment) is provided, the requirement that “the direction in which the slit extends is inclined with respect to the orientation direction of the organic sheet member” is satisfied.

The shape of the slit need not be linear (line segment), but may be another shape.
For example, a slit having a U-shape, a V-shape, a straight shape, or a cross shape may be used.
FIG. 4 is a top view schematically illustrating an example of the shape of the slit.
The organic sheet member 120 shown in FIG. 4 has a horizontal orientation (direction indicated by reference numeral 125).
In FIG. 4, as examples of the slit, a line segment shaped slit 130, a slit 131 extending in a line segment shape having different directions, a cross shaped slit 132, a U-shaped slit 133, a V-shaped slit 134, a U-shaped slit A slit 135 extending in a different shape and extending in a V-shape is shown.
Although not shown in FIG. 4, a slit having a shape in which two line segments face each other may be used.
In the method for producing a mat member of the present invention, the shape of the slit provided in one organic sheet member may be one or plural. Also, slits of the same shape may be provided with their inclinations changed.

In the method for producing a mat member according to the present invention, it is preferable that an angle between at least a part of the slit and an orientation direction having a high tensile strength of the organic sheet member is more than 0 degree and 90 degrees or less. Further, it is more preferable that the angle formed by at least a part of the slit and the orientation direction in which the organic sheet member has a high tensile strength is more than 45 degrees and 90 degrees or less. Further, it is more preferable that an angle between at least a part of the slit and an orientation direction in which the organic sheet member has a high tensile strength is orthogonal (90 degrees).

In the line-shaped slits 130 and 131 shown in FIG. 4, the angle between the direction of the line and the orientation direction of the organic sheet member having a high tensile strength is at least part of the slit and the orientation direction of the organic sheet member having a high tensile strength. The angle between
In the cross-shaped slit 132 shown in FIG. 4, the angle between the direction of one of the line segments constituting the cross and the orientation direction in which the tensile strength of the organic sheet member is strong is at least a part of the slit, and the angle of the organic sheet member is This is the angle between the orientation directions having a high tensile strength.
In the slits 133, 134, 135, and 136 having other shapes shown in FIG. 4, at least a part of the slit and an angle formed by the orientation direction in which the organic sheet member has high tensile strength are various, and at least a part of the slit is formed. The angle formed by the orientation direction having a high tensile strength of the organic sheet member exceeds 0 degree and is 90 degrees or less.
FIG. 4 shows an angle between a line connecting one end and the other end of each slit and an orientation direction in which the organic sheet member has high tensile strength.
The slit 130 is 90 degrees (orthogonal), and the slits 131, 132, and 134 are 45 degrees. The slit 136 is at 60 degrees.
The slits 133 and 135 show positions where the angle between the orientation directions in which the tensile strength of the organic sheet member is strong is 90 degrees (orthogonal).

The density of the slit is not particularly limited, but is preferably 25 to 100 places / 100 cm ² .
Further, the length of the slit is preferably 10 to 70% of the width of the organic sheet member in the direction orthogonal to the orientation direction in which the tensile strength is strong, and more preferably 25 to 50%.
Preferably, the slit has a shape obtained by dividing a straight line into a plurality of line segments.
Preferably, the slits are arranged in a staggered manner.
These preferred embodiments of the slit will be described with reference to FIG.

FIG. 5 is a top view schematically illustrating an example of the shape and arrangement of the slits.
The organic sheet member 120 shown in FIG.
The slits 130 are arranged in a staggered manner.
In the example shown in FIG. 5, the slits 130a, 130b, 130c, 130d, 130e, and 130f arranged in the same row can be said to have a shape obtained by dividing one straight line into a plurality of line segments.
When considering the relationship between the length of the slit and the width of the mat member in the lateral direction, the length of the slit is considered as the sum of the lengths of the slits in the same row.
That is, the total w of the lengths wa, wb, wc, wd, we, and wf of the slits 130a, 130b, 130c, 130d, 130e, and 130f arranged in the same row is compared with the vertical width W of the mat member. , (W / W) × 100 = 10-70%, more preferably 25-50%.
In the organic sheet member 120 shown in FIG. 5, the direction perpendicular to the orientation direction (horizontal direction) where the tensile strength is strong is the vertical direction.

In the method for producing a mat member according to the present invention, an organic sheet member is attached to a sheet-like member to obtain an attached body.
The bonding of the organic sheet and the substrate mat may be performed via an adhesive different from the organic sheet, or may be performed by heat laminating the organic sheet itself without using an adhesive.

FIG. 6 is a perspective view schematically showing an example of the patch.
FIG. 6 shows an attached body 150 in which the organic sheet member 120 is attached to the sheet member 110.

In the method for producing a mat member according to the present invention, a punching process is performed on the pasted body, and the longitudinal direction of the pasted body is the longitudinal direction of the mat member, and the lateral direction of the pasted body is the short direction of the mat member. A mat member and a second mat member in which the lateral direction of the patch is the longitudinal direction of the mat member and the longitudinal direction of the paste member is the lateral direction of the mat member.

FIG. 7 is a top view schematically showing a process of obtaining two types of mat members by punching.
The pasting body 150 shown in FIG. 7 is punched to obtain two types of mat members.
The left side of FIG. 7 shows that the first mat member 1 is obtained in which the longitudinal direction of the patch 150 is the longitudinal direction of the mat member and the lateral direction of the paste member is the lateral direction of the mat member.
On the right side of FIG. 7, it is shown that the second mat member 2 in which the longitudinal direction of the patch 150 is the short direction of the mat member and the lateral direction of the paste member is the longitudinal direction of the mat member.

Two types of mat members obtained by the method for producing a mat member of the present invention will be described.
Each of the first mat member and the second mat member includes a base mat made of inorganic fibers and an organic sheet made of an organic material provided on the surface of the base mat.
The substrate mat is derived from a sheet-like member, and the organic sheet is derived from an organic sheet member.
The organic sheet has an orientation caused by the orientation of the organic sheet member. Each of the first mat member and the second mat member has an orientation caused by the orientation of the organic sheet.
That is, both the first mat member and the second mat member are mat members having different tensile strengths in the longitudinal direction and the transverse direction.

FIG. 8A is a top view schematically illustrating a first mat member, and FIG. 8B is a top view schematically illustrating a second mat member.
8A and 8B, the direction indicated by a double arrow L is the longitudinal direction of the mat member, and the direction indicated by a double arrow W is the short direction of the mat member.
The first mat member 1 shown in FIG. 8A has a structure in which a first organic sheet 20a is overlaid on a base mat (not shown).
The base mat has a convex portion at the first end, which is one end, of the end portions on the longitudinal direction side (in the direction indicated by the double-headed arrow L in FIG. 8A) of the base mat. The second end, which is the other end, has a recess.
Similarly, also in the first organic sheet 20a, the first organic sheet 20a is one of the ends on the longitudinal direction side (the direction indicated by the double arrow L in FIG. 8A). A convex portion 21a is formed at one end, and a concave portion 22a is formed at a second end, which is the other end.
The protrusions and recesses of the first mat member are shaped so as to be fitted to each other when the first mat member is wound around an exhaust gas purifying device, an exhaust gas treatment body or an exhaust pipe having a cylindrical outer periphery. I have.
The first organic sheet 20a is made of an organic material, and has an orientation in the short direction of the first mat member 1 (the direction indicated by the double arrow W in FIG. 8A).
The orientation direction of the first organic sheet 20a is indicated by reference numeral 25a.
Further, a slit 30 is provided in the first organic sheet 20a.

The first mat member 1 is a mat member in which the longitudinal direction of the mat member and the orientation direction in which the organic sheet has a low tensile strength are aligned, and can be said to be an easy mat member.
Therefore, when the mat material is wound around the exhaust gas treatment body or the like with the longitudinal direction of the mat material as the winding direction, the resistance due to the tensile strength of the organic sheet is weak, the entire mat material is easily bent, and the winding material is a good mat material. is there.

The second mat member 2 shown in FIG. 8B has a structure in which a second organic sheet 20b is stacked on a base mat (not shown).
The first organic sheet 20a and the second organic sheet 20b are both derived from the same organic sheet member, and have the same configuration except that the orientation with respect to the shape of the mat member is different.
The base mat has a convex portion at the first end, which is one end, of the end portions on the longitudinal direction side (the direction indicated by the double-headed arrow L in FIG. 8B) of the base mat. The second end, which is the other end, has a recess.
Similarly, the second organic sheet 20b is also one of the ends on the longitudinal side (the direction indicated by the double-headed arrow L in FIG. 8B) of the second organic sheet 20b. A convex portion 21b is formed at one end, and a concave portion 22b is formed at a second end, which is the other end.
The protrusions and recesses of the second mat member are shaped so as to be fitted to each other when the first mat member is wound around the exhaust gas purifying device, the exhaust gas treating body or the exhaust pipe having a cylindrical outer periphery. I have.
The second organic sheet 20b is made of an organic material, and has an orientation in the longitudinal direction of the second mat member 2 (the direction indicated by the double arrow L in FIG. 8B).
The orientation direction of the second organic sheet 20b is indicated by reference numeral 25b.
Further, slits 30 are provided in the second organic sheet 20b.

The second mat member 2 is a mat member in which the longitudinal direction of the mat member and the orientation direction in which the organic sheet has a high tensile strength are aligned, and can be said to be a hard mat member.
When the mat material is wound around the exhaust gas treatment body or the like with the longitudinal direction of the mat material as the winding direction, the hard mat material has a strong resistance due to the tensile strength of the organic sheet, the entire mat material is hard to bend, and the winding property is poor. As the mat member, the second mat member 2 is provided with a slit 30 extending in a direction orthogonal to the orientation direction of the second organic sheet 20b.
By extending the slit 30 in such a direction, it is possible to reduce the resistance due to the tensile strength generated by the orientation of the second organic sheet 20b. Therefore, even a hard mat material can be obtained as a mat material having good winding property.

As described above, according to the method for manufacturing a mat member of the present invention, both types of mat members, the first mat member and the second mat member, can be obtained as mat members having good winding properties.
Therefore, a large number of mat materials having good wrapping properties can be obtained from one large-sized pasted body.
In the method for producing a mat member of the present invention, two types of mat members having different tensile strengths are obtained, but it is preferable that the difference between the two types of mat members has a small tensile strength.
The difference in the tensile strength of the mat member can be determined as a ratio of the tensile strength of the organic sheet provided on the surface of the mat member.
Specifically, the ratio of the tensile strength at 10% elongation between the first organic sheet provided on the surface of the first mat member and the second organic sheet provided on the surface of the second mat member Is preferably (organic sheet having higher tensile strength / organic sheet having lower tensile strength) ≦ 4.
The tensile strength of the organic sheet is determined as the tensile strength when pulled in the direction along the longitudinal direction of the mat member.
In the relationship between the first mat member 1 and the second mat member 2 shown in FIGS. 8A and 8B, the tensile force of the first organic sheet constituting the first mat member, which is an easy mat member, is obtained. Strength is reduced. Therefore, it can be said that the ratio of the tensile strength preferably satisfies (the second organic sheet / the first organic sheet) ≦ 4.

The mat material obtained by the method for producing a mat material of the present invention is used as a holding sealing material, a heat insulating material, a soundproofing material, etc. by winding the mat material around a cylindrical exhaust gas purifying device, an exhaust gas treating body or an exhaust pipe. Can be used for

(Example)
Hereinafter, examples that more specifically disclose the present invention will be described. Note that the present invention is not limited to only these examples.

(Example 1)
As an organic sheet, a nonwoven fabric made of organic fibers was prepared. This is a nonwoven fabric in which PE powder is fused to PET fiber, and has orientation in the direction in which the length direction of the PET fiber is arranged.
Then, a linear slit having a length of 5 mm was formed in a direction perpendicular to the orientation direction of the organic sheet.
The density of the slit is 50 places / 100 cm ² .
The slits are arranged in a staggered manner and have a shape obtained by dividing one straight line into a plurality of line segments.
This organic sheet was used as a sample for a tensile strength test of Example 1.

(Tensile strength test)
The sample for the tensile strength test of Example 1 was cut into 140 mm × 50 mm so that the orientation direction of the organic sheet became the longitudinal direction, to prepare a longitudinal orientation test piece.
In addition, the sample for the tensile strength test of Example 1 was cut into a size of 140 mm × 50 mm so that the orientation direction of the organic sheet was in the transverse direction, to prepare a transverse orientation test piece.
For the longitudinally oriented test piece and the transversely oriented test piece, the longitudinal direction side (140 mm side) of the test piece was chucked, the interval between chucks was set to 100 mm, and the tensile speed was 100 mm / min using a tensile strength tester. A tensile test was performed, and the tensile strength at the time of elongation of 10% was measured.
Table 1 shows a schematic diagram and a tensile strength of a longitudinally oriented test specimen (longitudinal orientation) and a laterally oriented specimen (short orientation). In addition, since the tensile strength of the longitudinally oriented test piece was higher, the (tensile strength of the longitudinally oriented test piece / tensile strength of the transversely oriented test piece) was shown as the “longitudinal / transverse ratio”.

(Examples 2 to 7)
Samples for tensile strength tests of Examples 2 to 7 were made in the same manner as in Example 1 except that the shape of the slit formed in the organic sheet was changed.
In the same manner as in Example 1, a longitudinally oriented specimen and a laterally oriented specimen were prepared, and the tensile strength was measured.
Table 1 shows a schematic diagram of the longitudinally oriented test piece (longitudinal orientation) and the transversely oriented test piece (shortly oriented), tensile strength, and “longitudinal / shorter ratio” in each example.
The density of the slits is the same as in Example 1, and the arrangement of the slits is staggered.

(Comparative Example 1)
The organic sheet before forming the slit in Example 1 was used as a sample for the tensile strength test of Comparative Example 1.
In the same manner as in Example 1, a longitudinally oriented specimen and a laterally oriented specimen were prepared, and the tensile strength was measured.
Table 1 shows a schematic diagram of the longitudinally oriented test piece (longitudinal orientation) and the transversely oriented test piece (shortly oriented), tensile strength, and “longitudinal / shorter ratio” in each example.

From this result, it was found that the tensile strength of the organic sheet can be reduced by providing the slit in a direction perpendicular to the orientation direction of the organic sheet.
Since the tensile strength of the organic sheet is reduced, it is possible to reduce the resistance due to the tensile strength of the organic sheet when performing a winding operation as a mat material.
Although the tensile strength is lowest in Example 1 in which the shape of the slit is linear (line segment), it can be seen that the effect of reducing the tensile strength is exhibited even with other slit shapes.
In addition, since the “long / short ratio” can be reduced, it can be seen that even a mat material that becomes a hard mat material can be a mat material having a good winding property.

(Examples 8 to 10)
Samples for tensile strength tests of Examples 8 to 10 were performed in the same manner as in Example 1 except that the density of the slits formed in the organic sheet was changed as shown in Table 2.
Then, a longitudinally oriented specimen and a laterally oriented specimen were produced, respectively.
The shape of the slit is the same as that of the first embodiment, and the arrangement of the slits is staggered.
The tensile strength of each of the longitudinally oriented test piece and the transversely oriented test piece was measured in the same manner as in Example 1. In addition, the “long / short ratio” was determined.
Table 2 summarizes the results.

From this result, even if the slit density is changed in the range of 25 to 100 places / 100 cm ² , the tensile strength of the organic sheet can be reduced by providing the slit in a direction perpendicular to the orientation direction of the organic sheet. I understood.
In addition, since the “long / short ratio” can be reduced, it can be seen that even a mat material that becomes a hard mat material can be a mat material having a good winding property.

(Example 11)
A large-sized sheet-like member made of inorganic fibers (mullite fibers) having a basis weight (fiber weight per unit area) of 1500 g / m ² was produced by a papermaking method.
Separately, a nonwoven fabric made of organic fibers was prepared as an organic sheet member. This is a nonwoven fabric in which PE powder is fused to PET fiber, and has orientation in the direction in which the length direction of the PET fiber is arranged.
Then, a slit having a length of 5 mm was formed in a direction perpendicular to the orientation direction of the organic sheet member.
The density of the slit is 50 places / 100 cm ² .
The slits are arranged in a staggered manner and have a shape obtained by dividing one straight line into a plurality of line segments.

A bonded body was produced by thermocompression bonding the sheet-like member and the organic sheet member.
Then, the pasted body was punched out in the same manner as the arrangement schematically shown in FIG. 7 to obtain two types of mat members (a first mat member and a second mat member).
The first mat member is a mat member oriented in the transverse direction, and the second mat member is a mat member oriented in the longitudinal direction.
The dimensions of the two types of mat members are both dimensions (length 335 mm in the longitudinal direction, length 70 mm in the transverse direction, thickness 9.7 mm) that can be wound around a cylindrical base having a diameter of 100 mm. The portion is provided with a convex portion and a concave portion as shown in FIGS.

(Winding test)
Two types of mat members (mat members oriented in the longitudinal direction and mat members oriented in the lateral direction) produced in Example 11 were wound around a cylindrical substrate having a diameter of 100 mm.
At the time of winding, the substrate mat was used as the substrate side, and the organic sheet was placed outside.
The gap (Seam Gap) between the convex portion and the concave portion at the position where the convex portion and the concave portion fit when winding was measured.
The length was measured for the two types of mat members, and the difference (length / short difference) was calculated.
Table 3 shows the results.
The smaller the difference between the mat material oriented in the longitudinal direction and the mat material oriented in the transverse direction, the more uniform the mat material is.

(Example 12)
Two types of mat members were prepared and a winding test was performed in the same manner as in Example 11 except that the shape of the slit formed in the organic sheet member was changed to a U-shape. Table 3 shows the results.

(Example 13)
Two types of mat members were prepared and a winding test was performed in the same manner as in Example 11, except that the shape of the slit formed in the organic sheet member was changed to a V-shape. Table 3 shows the results.

(Comparative Example 2)
Except that no slit was formed in the organic sheet member, two types of mat members were prepared and a winding test was performed in the same manner as in Example 11. Table 3 shows the results.

From this result, it can be seen that by providing the slit in a direction inclined (perpendicular to) with respect to the orientation direction of the organic sheet, the (longitudinal / short difference) is reduced. This means that two types of mat materials having similar wrapping properties can be obtained, and that a large number of mat materials having good wrapping properties can be obtained from one large-sized pasted body. Means.

DESCRIPTION OF SYMBOLS 1 1st mat | matte material 2 2nd mat | matte material 20a 1st organic sheet 20b 2nd organic sheet 21a, 21b Convex part 22a, 22b of organic sheet Concave part 25a, 25b Orientation direction 30 of organic sheet Slit ( Line-shaped slit)
110 Sheet-shaped member 120 Organic sheet member 125 Orientation direction 130, 131 of organic sheet member Slit (segment of line segment shape)
130a, 130b, 130c, 130d, 130e, 130f Slits 132 aligned in the same row Slit (cross-shaped slit)
133, 135 slits (U-shaped slits)
134, 136 slits (V-shaped slits)
150 paste

Claims (11)

A base mat made of inorganic fibers, provided on the surface of the base mat, comprising an organic sheet made of an organic material,
A method for manufacturing a mat material, comprising manufacturing two types of mat materials having a longitudinal direction that is a winding direction and a short direction orthogonal to the longitudinal direction,
A step of preparing a sheet-like member made of inorganic fibers,
A step of preparing an organic sheet member made of an organic material and having different tensile strength orientations in the vertical and horizontal directions,
For the organic sheet member, a step of forming a slit extending in a direction inclined with respect to the orientation direction having a high tensile strength,
A step of attaching the organic sheet member to the sheet-shaped member to obtain a pasted body,
A first mat member in which a punching process is performed on the pasted body, a longitudinal direction of the pasted body is a longitudinal direction of the mat member, and a lateral direction of the pasted body is a lateral direction of the mat member; A process of obtaining a second mat member in which the lateral direction of the mat member is the longitudinal direction of the mat member and the longitudinal direction of the pasted body is the short direction of the mat member. The organic sheet member is made of an organic fiber having an orientation, and the orientation direction of the organic fiber is an orientation direction having a high tensile strength,
The method for manufacturing a mat member according to claim 1, wherein in the step of forming the slit, a slit extending in a direction inclined with respect to an orientation direction of the organic fiber is formed. 3. The method according to claim 1, wherein an angle between at least a part of the slit and an orientation direction in which the tensile strength of the organic sheet member is strong exceeds 0 ° and is 90 ° or less. 4. The method for producing a mat member according to any one of claims 1 to 3, wherein an angle between at least a part of the slit and an orientation direction in which the organic sheet member has high tensile strength is 45 degrees or more and 90 degrees or less. . The method for producing a mat member according to any one of claims 1 to 4, wherein the organic sheet member is a nonwoven fabric made of organic fibers. Method for manufacturing a mat member according to claim 1, a density of 25 to 100 sites / 100 cm ² of the slits formed in the step of forming the slit. The length of the slit formed in the step of forming the slit is 10 to 70% of a width of the organic sheet member in a direction orthogonal to an orientation direction in which tensile strength is strong, according to any one of claims 1 to 6. A method for producing the mat material described above. The method for manufacturing a mat member according to any one of claims 1 to 7, wherein a top view shape of the slit is a U shape, a V shape, a straight shape, or a cross shape. The method for producing a mat member according to any one of claims 1 to 8, wherein the slit has a shape obtained by dividing a straight line into a plurality of line segments. The method according to any one of claims 1 to 9, wherein the slits are arranged in a staggered manner. The ratio of the tensile strength at 10% elongation between the first organic sheet provided on the surface of the first mat member and the second organic sheet provided on the surface of the second mat member is as follows: The method for producing a mat material according to any one of claims 1 to 10, wherein (organic sheet having a larger tensile strength / organic sheet having a smaller tensile strength) ≤ 4.

Images