JP2020067033A - Mat material, winding body and insertion method of mat material - Google Patents

Abstract

To provide a mat material which is favorable in handling performance, and excellent in productivity.SOLUTION: In a mat material which is rectangular in a plane view having a first main face, a second main face at a side opposite to the first main face, a first end part, and a second end part at a side opposite to the first end part, the mat material has a first region being a region progressing toward the second end part from the first end part by a prescribed distance, and a second region adjoining the first region. A plurality of penetration holes are formed in the first region, the mat material is wound by at least two windings with the first main face set inside, the first region is located at a first winding in the wound mat material, and the second region is located at a second winding in the wound mat material.SELECTED DRAWING: Figure 1

Description

The present invention relates to a mat member, a wound body, and a mat member inserting method.

BACKGROUND ART Conventionally, engine covers, exhaust manifold covers, silencers, etc., which are arranged around the engine of automobiles, etc., are provided with a sound insulating material to shield and absorb heat and sound emitted from these members. ing.

Patent Document 1 discloses a sound insulation material made of a fiber assembly having grooves or depressions on its surface in order to improve the sound insulation performance. The sound insulation material has a groove or depression as viewed from a direction perpendicular to the surface of the sound insulation material. There is disclosed a sound insulating material, the area of which is 1 to 15% of the total area of the sound insulating material, and the depth of the groove or the depression is 1 to 4 to 3/4 of the thickness of the sound insulating material. This Patent Document 1 describes that the groove or the depression is provided by compression processing, cutting processing, or the like.

Further, in Patent Document 2, in order to have good sound absorption characteristics in a wide frequency range and to enhance the sound absorption characteristics in a desired frequency range according to the purpose, etc., a sound source of a matte porous body is used. A film is provided on the surface on the opposite side, a layer having a through hole that connects the film to the porous body is provided, and a film is provided on the surface on the side facing the sound source, and no through hole is provided. A sound absorbing structure formed by stacking layers is disclosed.

JP-A-11-202873 Japanese Patent No. 3741413

However, in the sound insulation material according to Patent Document 1, since a groove or a depression is formed in one material by cutting or the like, it can be used as a sound insulation material immediately after the cutting processing and the like, and is easy to handle. However, in the above-mentioned sound insulation material, it is necessary to form a bottomed hole having a predetermined depth by cutting or the like, which requires a lot of time and labor for manufacturing, and there is a problem that productivity is not good.

On the other hand, in the sound absorbing structure according to Patent Document 2, since it is sufficient to form the through hole in one of the two porous bodies, each member can be easily manufactured. Since it is necessary to bond the both with an adhesive after the formation, there is a problem that the handleability is not good.
Further, since the adhesive is used, there is a concern that an adhesive layer is formed between the layers and the sound absorbing property is impaired.

The present invention has been made in view of such problems, and an object of the present invention is to provide a mat member having good handleability and excellent productivity.

That is, the mat member of the present invention is
A mat member having a rectangular shape in plan view, having a first main surface, a second main surface opposite to the first main surface, a first end, and a second end opposite to the first end. There
The mat member has a first region that is a region extending from the first end toward the second end by a predetermined distance, and a second region adjacent to the first region.
A plurality of through holes are formed in the first region,
The mat member will be wound at least twice with the first main surface inside.
The first region is located on the first lap of the wound mat member,
The second region is located at the second round in the wound mat member.

The mat member of the present invention has a first region having a through hole and a second region adjacent to the first region.
The mat member of the present invention is wound at least twice with the first main surface inside.
At this time, the first region is located at the first round in the wound mat member, and the second region is located at the second round in the wound mat member.
That is, the first region is wound, and the second region is wound on the outer side (the second main surface side of the first region).
Therefore, the first main surface of the second region is located at the bottom of the through hole on the second main surface side of the first region. That is, in the wound mat member, the bottomed hole including the through hole of the first region and the first main surface of the second region is formed inside the mat member.
By using the mat member of the present invention, a wound mat member having a bottomed hole inside can be easily produced.

In the mat member of the present invention, the first region and the second region are determined by at least two rounds of the mat member of the present invention, and the region wound on the first round is the first region, and the second region is rounded. The area wound around the eyes is the second area.

In the mat member of the present invention, it is desirable that the first region be wound in a circular shape or an elliptical shape when the mat member is viewed from the side.
The mat material wound in a circular shape or an elliptical shape is less likely to be concentrated by external pressure and less likely to be damaged.

In the mat member of the present invention, when the mat member is viewed from the side, the first region is wound in a circular shape, the length of the first region is L _1, and the thickness of the mat member is Letting T be T, the length in the longitudinal direction of the second region is preferably (L ₁ + 2π × T) × 0.95 to (L ₁ + 2π × T) × 1.05.
When the first region is wound in a circular shape, the length of the second region can be easily designed based on the thickness of the mat member and the length of the first region.

It is preferable that the mat member of the present invention is made of inorganic fiber, and an inorganic material layer is formed on the first main surface of the first region.
When the mat member of the present invention on which the inorganic material layer is formed is wound with the first main surface facing inward, the mat member of the present invention exhibits a good sound absorbing function.
When the mat member of the present invention on which the inorganic material layer is formed is wound, the first main surface of the first region of the mat member serves as a surface for receiving sound.
When the first main surface of the first area of the mat member receives a sound, the sound is transmitted to the side wall of the through hole of the first area and the first main surface of the second area located at the bottom of the through hole of the first area. You will reach the surface. The sound is then reflected, attenuated and absorbed in the matte material.
In addition, a part of the sound passes through the inside of the first region of the mat member and tries to go out from the first main surface of the first region where the through hole is not formed. However, since the inorganic material layer is formed on the first main surface of the first region of the mat member, the sound trying to go outside is reflected by the inorganic material layer. As a result, the sound can be prevented from leaking to the outside, and the sound can be efficiently absorbed.

The method of inserting the mat member of the present invention is
A method of inserting a mat member according to the present invention into a tubular body, comprising:
A first area winding step of winding the first area of the mat material such that the first main surface of the mat material is inside
A second area winding step of winding the second area of the mat material around the second main surface of the first area of the mat material after the first area winding step,
After the second region winding step, an inserting step of inserting the mat material into the tubular body with a direction perpendicular to a longitudinal direction of the mat material as an inserting direction is included.

By the method of inserting a mat member according to the present invention, a wound mat member having a bottomed hole inside can be easily produced, and the wound mat member can be easily inserted into the tubular body. .

In the method for inserting a mat member according to the present invention, in the first region winding step and the second region winding step, the mat member is spirally wound so that the mat member on the insertion direction side becomes convex. May be.
When the mat member on the insertion side is convex, the wound mat member can be easily inserted into the tubular body.

In the method of inserting a mat member according to the present invention, in the first region winding step and the second region winding step, the mat member is spirally wound so that the mat member on the insertion direction side becomes concave. Good.
When the wound mat member is inserted into the tubular body, the wound mat member may be displaced in the direction opposite to the inserting direction due to friction between the mat member and the tubular member.
By calculating such a deviation in advance and making the mat member on the insertion direction side concave, the side surfaces of the wound mat member after being inserted into the tubular body can be aligned.

In the method for inserting a mat member according to the present invention, it is preferable that the tubular body is a silencer.
By using the mat member insertion method of the present invention, it is possible to efficiently manufacture a silencer.

The wound body of the present invention has a first main surface, a second main surface opposite to the first main surface, a first end, and a second end opposite to the first end. A wound body comprising a mat material having a rectangular shape in a plan view and a tubular body wound with the mat material such that the first main surface is in contact with the mat material.
The mat member is wrapped around the tubular body at least twice.
The area of the mat member on the first round where the first main surface and the tubular body are in contact is a first area,
The area of the mat material on the second lap is the second area,
A plurality of through holes are formed in the first region,
A tubular body through hole is formed in a side wall of the tubular body.

In the wound body of the present invention, the mat member has a first region having a through hole and a second region adjacent to the first region.
In the wound body of the present invention, the first region is wound around the tubular body with the first main surface of the mat member being the inner side, and the outer side (that is, the second main surface side of the first region) is the second region. It is wrapped around. The first main surface of the second region of the mat member is located at the bottom of the through hole on the second main surface side of the first region of the mat member. Therefore, in the wound body of the present invention, the through hole in the first region of the mat member and the first main surface of the second region of the mat member form a bottomed hole.
Such a wound body can be easily manufactured by using a mat member having a through hole formed in the first region.

In the wound body of the present invention, it is preferable that the tubular body has a circular bottom or elliptical bottom.
When the bottom of the tubular body has a circular or elliptical shape, the mat member is wound around the tubular body in a circular or elliptical shape.
The mat material wound in this manner is less likely to be concentrated by external pressure and less likely to be damaged.

In the wound body of the present invention, the tubular body is preferably made of punching metal.
The punching metal functions as a muffling mechanism in the muffler.
Therefore, the wound body of the present invention can be used as it is as a part of a silencer.

In the wound body of the present invention, it is preferable that the mat member is made of inorganic fiber, and an inorganic material layer is formed on the first main surface of the first region.
The wound body of the present invention is inserted into a cylindrical silencer. At this time, the first main surface of the first region of the mat member becomes a surface that receives the sound that has passed through the tubular body through hole of the tubular body.
When the first main surface of the first area of the mat member receives a sound, the sound is transmitted to the side wall of the through hole of the first area and the first main surface of the second main surface located at the bottom of the through hole of the first area. It will reach the area. The sound is then reflected, attenuated and absorbed in the matte material.
In addition, a part of the sound passes through the inside of the first region of the mat member and tries to go out from the first main surface of the first region where the through hole is not formed. However, since the inorganic material layer is formed on the first main surface of the first region of the mat member, the sound trying to go outside is reflected by the inorganic material layer. As a result, the sound can be prevented from leaking to the outside, and the sound can be efficiently absorbed.

FIG. 1A is a perspective view schematically showing an example of the mat member according to the first embodiment of the present invention. FIG. 1B is a perspective view schematically showing a state in which the mat member shown in FIG. 1A is wound. FIG. 1C is an enlarged view in which the through-hole portion of the mat member shown in FIG. 1B is enlarged. FIG. 2 is a side view schematically showing an example of winding the mat member according to the first embodiment of the present invention in a circular shape. FIG. 3A is a side view schematically showing an example of the mat member according to the first embodiment of the present invention in which the first end portion and the second end portion are obliquely formed. FIG. 3B is a side view showing a state in which the mat member shown in FIG. 3A is wound. 4A and 4B are process diagrams schematically showing an example of the method for producing a mat member according to the present invention. 5A to 5C are process diagrams schematically showing an example of a method of inserting the mat member according to the first embodiment of the present invention in order. FIGS. 6A and 6B are process diagrams showing a modified example of the method for inserting a mat member according to the first embodiment of the present invention. 7A to 7C are process drawings showing another modification of the mat member inserting method according to the first embodiment of the present invention. FIG. 8A is a perspective view schematically showing an example of the mat member according to the second embodiment of the present invention. FIG. 8B is a perspective view schematically showing a state in which the mat member shown in FIG. 8A is wound. FIG. 8C is an enlarged view in which the through-hole portion of the mat member shown in FIG. 8B is enlarged. FIG. 9 is a schematic diagram schematically illustrating the principle of the silencing function of the mat member according to the second embodiment of the present invention. FIG. 10: is a perspective view which shows typically an example of the winding body which concerns on 3rd Embodiment of this invention. FIG. 11A is a perspective view schematically showing an example of a mat member used for the wound body according to the third embodiment of the present invention. FIG. 11B is a perspective view schematically showing a state in which the mat member shown in FIG. 11A is wound. FIG. 12: is a perspective view which shows typically an example of the tubular body used for the winding body which concerns on 3rd Embodiment of this invention.

(Detailed Description of the Invention)
Hereinafter, the mat member of the present invention will be specifically described. However, the present invention is not limited to the following embodiments, and can be appropriately modified and applied within a range not changing the gist of the present invention.

(First embodiment)
Hereinafter, the mat member according to the first embodiment of the present invention will be described with reference to the drawings.
FIG. 1A is a perspective view schematically showing an example of the mat member according to the first embodiment of the present invention. FIG. 1B is a perspective view schematically showing a state in which the mat member shown in FIG. 1A is wound.

As shown in FIG. 1A, the mat member 10 includes a first main surface 11, a second main surface 12 opposite to the first main surface 11, a first end portion 13, and a first end portion 13. It has a rectangular shape in plan view having the second end portion 14 on the opposite side.
The mat member 10 has a first region 15 that is a region extending from the first end 13 toward the second end 14 by a distance L ₁ and a second region 16 that is adjacent to the first region 15.
A plurality of through holes 21 are formed in the first region 15.

As shown in FIG. 1B, the mat member 10 is wound at least twice with the first main surface 11 inside.
In the wound mat member 10, the first region 15 is located on the first round and the second region 16 is located on the second round.
That is, the first region 15 is wound, and the second region 16 is wound on the outer side (on the second main surface 12 side of the first region 15).

Therefore, as shown in FIG. 1C, the first main surface 11 of the second region 16 is located at the bottom portion 21a of the through hole 21 on the second main surface 12 side of the first region 15. That is, in the wound mat member 10, the bottomed hole 22 including the through hole 21 in the first region 15 and the first main surface 11 in the second region 16 is formed inside the mat member 10.
By using the mat member 10, the wound mat member 10 having the bottomed hole 22 inside can be easily manufactured.

In the mat member according to the first embodiment of the present invention, the thickness of the mat member (width indicated by reference numeral “T” in FIG. 1A) is preferably 1.5 to 25 mm, and 5 to 10 mm. Is more desirable.
If the thickness of the mat member is less than 1.5 mm, the strength of the mat member tends to be weakened.
When the thickness of the mat member exceeds 25 mm, it becomes difficult to wind the mat member.

In the mat member according to the first embodiment of the present invention, the mat member is preferably made of inorganic fiber.
Examples of the inorganic fiber include alumina fiber, alumina-silica fiber, silica fiber, glass wool, rock wool and the like. Of these, alumina-silica fibers are preferable.
These inorganic fibers have high heat resistance, and the mat material formed of such inorganic fibers is unlikely to change its shape due to temperature changes.

Furthermore, when alumina-silica fiber is used as the inorganic fiber, the composition ratio of alumina and silica is preferably alumina (Al ₂ O ₃ ): silica (SiO ₂ ) = 60: 40 to 80:20 by weight. , Alumina (Al ₂ O ₃ ): silica (SiO ₂ ) = 70: 30 to 74:26 is more preferable.

The matting material made of inorganic fibers can be obtained by various methods, but it is desirable to manufacture it by a needling method or a papermaking method.

The mat material composed of inorganic fibers obtained by the needling method has an entangled structure. In order to obtain this structure, the inorganic fiber needs to have a certain average fiber length. Therefore, the average fiber length of the inorganic fibers used in the needling method is preferably 1 to 150 mm, more preferably 10 to 80 mm.
If the average fiber length of the inorganic fibers is less than 1 mm, the fiber length of the inorganic fibers is too short, so that the entanglement of the inorganic fibers becomes insufficient, the strength of the mat material becomes difficult to obtain, and the shape retention of the mat material is reduced. It tends to decrease.
When the average fiber length of the fibers exceeds 150 mm, the fiber length of the fibers is too long, so that the number of fibers constituting the mat member decreases, and thus the compactness decreases.

In the mat material composed of inorganic fibers obtained by the papermaking method, the average fiber length of the inorganic fibers is preferably 0.1 to 20 mm.
If the average fiber length of the inorganic fibers is less than 0.1 mm, the fiber length of the inorganic fibers is too short, so that the shape retention as a mat material deteriorates. Further, when the fiber assembly is used as the mat member, suitable entanglement between the inorganic fibers does not occur, and it becomes difficult to obtain a sufficient surface pressure.
When the average fiber length of the inorganic fibers exceeds 20 mm, the fiber length of the inorganic fibers is too long, so that the entanglement of the inorganic fibers in the slurry solution in which the inorganic fibers are dispersed in water becomes too strong in the papermaking process, and thus the mat material When this is done, the inorganic fibers tend to accumulate unevenly and the shear strength also tends to decrease.

To measure the inorganic fiber length, tweezers are used in both the needling method and the papermaking method, and the inorganic fibers are extracted from the mat material so as not to break, and the fiber length is measured using an optical microscope.
In the present specification, the average fiber length means an average length obtained by extracting 300 inorganic fibers from the mat material and measuring the fiber length. If you can not remove the inorganic fiber from the mat material without breaking it, degrease the mat material and put the degreased mat material into water so that the inorganic fibers do not break while untangling the inorganic fibers It is good to collect.

The average fiber diameter of the inorganic fibers forming the mat member is preferably 1 to 20 μm, more preferably 2 to 15 μm, and further preferably 3 to 10 μm.
When the average fiber diameter of the inorganic fibers is less than 1 μm, the strength is low and the inorganic fibers are likely to be cut by impact or the like.
If the average fiber diameter of the inorganic fibers exceeds 20 μm, the fiber diameter becomes too large, and the Young's modulus of the inorganic fibers themselves becomes high, and the flexibility of the mat material tends to become low.

In the mat member according to the first embodiment of the present invention, it is desirable that the through hole be formed in a columnar shape. Examples of the columnar shape include a cylindrical shape, an elliptic cylindrical shape, a triangular pillar shape, a quadrangular pillar shape, a pentagonal pillar shape, a hexagonal pillar shape, and an octagonal pillar shape.
The area of the bottom surface is preferably a 0.20～15Mm ^2, and more preferably a 2.0~7.0mm ^2.

In the mat member according to the first embodiment of the present invention, it is desirable that the through holes be arranged at equal intervals.
Although such an array is not particularly limited, the following array patterns can be mentioned.
That is, the through holes may be arranged such that the center of the through holes is located at the apex of the equilateral triangle on the plane in which the equilateral triangles are continuously arranged vertically and horizontally.
Further, the through holes may be arranged such that the center of the through holes is located at the apex of the square on a plane in which the squares are continuously arranged vertically and horizontally.
Further, the through holes may be arranged such that the center of the through holes is located at the apex of the regular hexagon on a plane in which the regular hexagons are arranged vertically and horizontally.

Further, in the mat member according to the first embodiment of the present invention, the through holes may be formed on the entire surface of the first region or may be formed only on a part of the first region.

In the mat member according to the first embodiment of the present invention, the length L ₁ of the first region is not particularly limited, but is preferably 10 to 60 cm, more preferably 15 to 30 cm.

As described above, the mat member according to the first embodiment of the present invention is wound.
The mat member may be wound in a circular shape, an elliptical shape, a triangular shape, a quadrangular shape, or the like. Of these, a circular shape or an elliptical shape is preferable, and a circular shape is more preferable.

It is desirable that the length of the second region of the mat member according to the first embodiment of the present invention be appropriately determined according to the thickness of the mat member and the shape of the winding.
The length of the second region of the mat member will be described by taking as an example the case where the mat member is wound in a circular shape.

FIG. 2 is a side view schematically showing an example of winding the mat member according to the first embodiment of the present invention in a circular shape.
As shown in FIG. 2, when the mat member 10 is wound in a circular shape, assuming that the length of the first region 15 is L ₁ , the circumference of the circle formed by the first main surface 11 of the first region 15 is It becomes L ₁ and the radius is calculated as L ₁ / 2π.
Further, when the thickness of the mat member 10 is T, the radius of the circle formed by the second major surface 12 of the first region 15 is calculated as T + L ₁ / 2π.
Since the second region 16 of the mat member 10 is wound on the outside, the length of the second region 16 should be calculated as 2π × (T + L ₁ / 2π) = L ₁ + T × 2π. become.

Note that the easiness of winding the mat member 10 differs depending on the elasticity and flexibility of the mat member 10.
Therefore, it is desirable to adjust the length of the second region, which is the second round, based on the stretchability and flexibility of the mat member 10. Considering the stretchability and flexibility of the mat member 10, the length of the second region 16 is preferably (L ₁ + 2π × T) × 0.95 to (L ₁ + 2π × T) × 1.05. .

When the mat member 10 is wound in a circular shape, L ₁ is preferably 100 to 600 mm, more preferably 150 to 300 mm.

When the mat member is wound into an elliptical shape or a polygonal shape, the length of the first region 15 also determines the length of the second region 16.
Also in this case, it is desirable to adjust the length of the second region based on the elasticity and flexibility of the mat member.

In the mat member according to the first embodiment of the present invention, the first end portion and the second end portion may be formed in a shape that does not cause a step on the inner peripheral surface when the mat member is wound.
That is, in the first end portion, the end portion of the first main surface may be formed in a linear shape or a curved shape so as to be arranged outside the end portion of the second main surface.
In addition, the second end portion may be formed in a linear shape or a curved shape so that the end portion of the first main surface is arranged inside the end portion of the second main surface.

The shape of the mat member according to the first embodiment of the present invention in which the first end portion and the second end portion are formed obliquely will be described below in detail with reference to the drawings.
FIG. 3A is a side view schematically showing an example of the mat member according to the first embodiment of the present invention in which the first end portion and the second end portion are obliquely formed. FIG. 3B is a side view showing a state in which the mat member shown in FIG. 3A is wound.

As shown in FIG. 3A, in the mat member 10, the end 11a of the first main surface 11 on the first end 13 side is closer to the end 12a of the second main surface 12 on the first end 13 side. Also, the first end portion 13 may be formed obliquely so as to be arranged outside. In addition, the second end portion is arranged such that the end portion 11b of the first main surface 11 on the second end portion 14 side is located inside the end portion 12b of the second main surface 12 on the second end portion 14 side. 14 may be formed obliquely.

When the first end portion 13 and the second end portion 14 have such a shape, when the mat member 10 is wound so that the first main surface 11 is inside, as shown in FIG. 3B. Therefore, a step is less likely to occur on the inner peripheral surface of the mat member 10.
When the first end portion 13 and the second end portion 14 are formed obliquely, the angle is not particularly limited, and is appropriately determined according to the material, length, thickness, and shape of the mat member 10 to be wound. It is desirable to do.

After being wound, the mat member according to the first embodiment of the present invention may be fixed with an inorganic binder or the like in order to maintain its shape, or may be fixed with a tape or the like.

When fixing with an inorganic binder, apply the inorganic binder to the second main surface of the first region of the mat member, wind the mat member, and then dry the inorganic binder to fix the mat member. May be.
The inorganic binder is not particularly limited, and alumina sol, silica sol or the like can be used.

Next, an example of the method for manufacturing the mat member according to the first embodiment of the present invention will be described.
The method for producing a mat material of the present invention described below includes (1) a fiber layer producing step and (2) a through hole forming step.
4A and 4B are process diagrams schematically showing an example of the method for producing a mat member according to the present invention.

(1) Fiber Layer Manufacturing Step As shown in FIG. 4A, in this step, a fiber layer 10 ′ is prepared. The method for preparing the fiber layer 10 'is not particularly limited. Below, the method of preparing the fiber layer 10 'by the papermaking method which is an example thereof will be described. The papermaking method described below includes a mixed liquid preparation step, a dehydration step, and a heating / pressurizing step.

(Mixed liquid preparation step)
A fiber, an inorganic binder, and water are mixed and stirred with a stirrer to prepare a mixed solution. At this time, inorganic particles and an organic binder may be mixed if necessary. The desirable types of fibers used in this step have already been described, and a description thereof will be omitted here.

(Dehydration step)
The mixed liquid obtained in the mixed liquid adjusting step is poured into a molding machine having a mesh for filtration formed on the bottom surface. Then, water in the mixed solution is dehydrated through a mesh to prepare a raw material sheet.

(Heating and pressing step)
The raw material sheet is heated and pressed to produce a fiber layer. Further, at the time of heating and pressurizing, the raw material sheet may be subjected to a heat treatment in which hot air is aerated and dried, or may be in a wet state without being subjected to the heat treatment.
The fiber layer can be prepared through the above steps.

Note that, as described above, the mat member according to the first embodiment of the present invention is wound at least two turns, and the first turn becomes the first region and the second turn becomes the second region.
In the fiber layer producing step, a region 15 'which becomes the first region and a region 16' which becomes the second region are determined.

(2) Through-hole forming step As shown in FIG. 4 (b), in this step, the through-hole is formed in the area 15 'which is the first area of the fiber layer 10' prepared in the above (1) fiber layer preparing step. 21 is formed. The shape and the like of the through hole 21 have already been described, and thus the description thereof is omitted here.
The method of forming the through holes 21 is not particularly limited, and examples thereof include a method of penetrating the fiber layer 10 ′ using a cutter, a laser, a drill or the like.

Through the above steps, the mat member 10 having the first region 15 and the second region 16 and having the plurality of through holes 21 formed in the first region 15 can be manufactured.

Next, a method of inserting the mat member according to the first embodiment of the present invention, which is a method of using the mat member according to the first embodiment of the present invention, will be described.

The mat member inserting method according to the first embodiment of the present invention is the mat member inserting method of inserting the mat member according to the first embodiment of the present invention into a tubular body.
This insertion method includes (1) first area winding step, (2) second area winding step, and (3) insertion step. Each step will be described below with reference to the drawings.
5A to 5C are process diagrams schematically showing an example of a method of inserting the mat member according to the first embodiment of the present invention in order.

(1) First Area Winding Step In this step, as shown in FIG. 5A, the first area 15 of the mat member 10 is wound so that the first main surface 11 of the mat member 10 is inside. To do.
Although the mat member 10 is wound in a circular shape in FIG. 5A, the mat member 10 may be wound in an elliptical shape, a triangular shape, a quadrangular shape, or the like other than the circular shape.

(2) Second Region Winding Step In this step, as shown in FIG. 5B, the second region 16 of the mat member 10 is rotated once around the second main surface 12 of the first region 15 of the mat member 10. Wind as you would.
As a result, the first main surface 11 of the second region 16 is located at the bottom of the through hole 21 on the second main surface 12 side of the first region 15. That is, in the mat member 10 after the second region winding step, the bottomed hole 22 including the through hole 21 of the first region 15 and the first main surface 11 of the second region 16 is formed inside the mat member 10. It will be.

(3) Inserting Step In this step, as shown in FIG. 5C, the mat member 10 is inserted into the tubular body 40 with the direction perpendicular to the longitudinal direction of the mat member 10 as the inserting direction.

The inner diameter of the tubular body 40 is not particularly limited, but is preferably 90 to 110% of the diameter of the wound mat member 10, and more preferably 95 to 105%.
If the inner diameter of the tubular body is less than 90% of the diameter of the wound mat member, it becomes difficult to insert the wound mat member into the tubular member.
When the inner diameter of the tubular body exceeds 110% of the diameter of the wound mat member, the wound mat member is likely to fall off the tubular member.

Through the above steps, the wound mat member 10 having the bottomed hole 22 inside can be easily manufactured, and the wound mat member 10 can be easily inserted into the tubular body 40. You can

In the first area winding step and the second area winding step, the first area and the second area may be wound as follows.
FIGS. 6A and 6B are process diagrams showing a modified example of the method for inserting a mat member according to the first embodiment of the present invention.
7A to 7C are process drawings showing another modification of the mat member inserting method according to the first embodiment of the present invention.

In the first area winding step and the second area winding step of the mat member inserting method according to the first embodiment of the present invention, as shown in FIG. 6A, the insertion direction side (in FIG. 6A) The mat member 10 may be spirally wound so that the mat member 10 in the direction indicated by the arrow) has a convex shape.
When the mat member 10 on the insertion side is convex, the wound mat member 10 can be easily inserted into the tubular body 40, as shown in FIG. 6B.

In the first region winding process and the second region winding process of the mat member inserting method according to the first embodiment of the present invention, as shown in FIG. 7A, the insertion direction side (in FIG. 7A) The mat member 10 may be spirally wound so that the mat member 10 (in the direction indicated by the arrow) becomes concave.

When the mat member 10 is inserted into the tubular body 40, as shown in FIG. 7B, due to friction between the mat member 10 and the tubular body 40, the portion of the mat member 10 that contacts the tubular body 40 is inserted in the insertion direction. And it will shift in the opposite direction.

By calculating such a shift in advance and making the mat member 10 on the insertion side into a concave shape, as shown in FIG. 7C, the mat member 10 after being wound into the tubular body 40 is wound. The sides can be aligned.

(Second embodiment)
Next, the mat member according to the second embodiment of the present invention will be described.
FIG. 8A is a perspective view schematically showing an example of the mat member according to the second embodiment of the present invention. FIG. 8B is a perspective view schematically showing a state in which the mat member shown in FIG. 8A is wound. FIG. 8C is an enlarged view in which the through-hole portion of the mat member shown in FIG. 8B is enlarged.

As shown in FIG. 8A, the mat member 110 includes a first main surface 111, a second main surface 112 opposite to the first main surface 111, a first end 113, and a first end 113. It has a rectangular shape in a plan view having a second end 114 on the opposite side and is made of an inorganic fiber.
The mat member 110 has a first region 115 that is a region extending from the first end 113 toward the second end 114 by a distance L ₂ and a second region 116 that is adjacent to the first region 115.
The inorganic material layer 131 is formed on the first main surface 111 of the first region 115.

The difference between the mat member 10 according to the first embodiment of the present invention and the mat member 110 according to the second embodiment of the present invention is that the mat member 110 is made of an inorganic fiber and the first region 115 is essential. That is, the inorganic material layer 131 is formed on the first main surface 111. Other configurations may be the same.

As shown in FIG. 8B, the mat member 110 is wound at least twice with the first main surface 111 inside.
In the wound mat member 110, the first region 115 is located on the first round and the second region 116 is located on the second round.
That is, the first region 115 is wound, and the second region 116 is wound on the outer side (on the second main surface 112 side of the first region 115).

Therefore, the first main surface 111 of the second area 116 is located at the bottom 121a of the through hole 121 on the second main surface 112 side of the first area 115. That is, in the wound mat member 110, the bottomed hole 122 including the through hole 121 of the first region 115 and the first main surface 111 of the second region 116 is formed inside the mat member 110.

Further, since the inorganic material layer 131 is formed on the first main surface 111 of the first region 115, the inorganic material layer 131 is formed on the inner peripheral surface of the wound mat member 110. .

The mat member 110 thus wound has a good sound absorbing function.
The principle that the mat member 110 exhibits a good sound absorbing function will be described below with reference to the drawings.
FIG. 9 is a schematic diagram schematically illustrating the principle of the silencing function of the mat member according to the second embodiment of the present invention.
As shown in FIG. 9, when the mat member 110 on which the inorganic material layer 131 is formed is wound, the first main surface 111 of the first region 115 of the mat member 110 is the surface that receives the sound S.
When the first main surface 111 of the first region 115 of the mat member 110 receives a sound, the sound S is transmitted to the side wall of the through hole 121 of the first region 115 and the bottom 121 a of the through hole 121 of the first region 115. The first main surface 111 of the second region 116 located is reached. After that, the sound S is reflected, attenuated, and absorbed in the mat member 110.
Further, a part of the sound S passes through the inside of the first region 115 of the mat member 110 and tries to go outside from the first main surface 111 of the first region 115 where the through hole 121 is not formed. However, since the inorganic material layer 131 is formed on the first main surface 111 of the first region 115 of the mat member 110, the sound S trying to go outside is reflected by the inorganic material layer 131. As a result, the sound S can be prevented from leaking to the outside, and the sound S can be efficiently absorbed.

In the mat member according to the second embodiment of the present invention, the thickness of the inorganic material layer is preferably 0.1 to 5 mm, more preferably 0.5 to 2 mm.
If the thickness of the inorganic material layer is less than 0.1 mm, it becomes difficult to obtain the sound reflection effect due to the presence of the inorganic material layer.
If the thickness of the inorganic material layer exceeds 5 mm, the flexibility of the inorganic material layer may be impaired and cracks may occur when the mat member is brought into contact with a necessary portion, and as a result, the opening shape may not be maintained.

In the mat member according to the second embodiment of the present invention, the inorganic material layer has at least one inorganic material selected from the group consisting of calcium-based materials, silica-based materials, alumina-based materials, carbon-based materials and titanium-based materials. It is desirable to consist of
Further, the inorganic material layer may be made of these single inorganic materials or a plurality of inorganic materials.

Specific examples of such an inorganic material include an inorganic material containing one or more kinds of calcium oxide, aluminum oxide and silicon oxide, and a mixed material containing two or more kinds of aluminum oxide, titanium oxide and silicon oxide.

In the mat member according to the second embodiment of the present invention, the density of the inorganic material layer is preferably 2 to 6 (g / cm ³ ).
Further, the density of the inorganic material layer is preferably 3 times or more the density of the mat material in the portion where the inorganic material layer is not formed, and further, the density of the inorganic material layer is not formed. It is desirable that the density is 3 to 30 times the density of the mat material of the part.

Next, a method of manufacturing the mat member according to the second embodiment of the present invention will be described.
The method for manufacturing a mat member according to the second embodiment of the present invention is performed after performing the (1) fiber layer producing step and (2) through hole forming step in the mat member according to the first embodiment of the present invention, (3) Inorganic material layer forming step is performed.

(3) Inorganic Material Layer Forming Step In this step, the inorganic material layer is formed on the first main surface of the first region of the mat member in which the through holes are formed. The method of forming the inorganic material layer is not particularly limited, and examples thereof include coating and printing.
The method of forming the inorganic material layer by coating will be described below.

(Inorganic material preparation step)
In this step, a powdery inorganic material is prepared. Since the types of inorganic materials have already been described, their description is omitted here.

(Step of applying inorganic material)
In this step, first, a powdery inorganic material is applied to the first main surface of the first region in which the through holes are not formed.
Next, water is applied to the inorganic material to make the inorganic material into a slurry.
In this way, by applying the powdery inorganic material to the first main surface of the first region and then making the inorganic material into a slurry, the formed inorganic material layer is firmly fixed.

(Drying process)
In this step, the inorganic material in slurry form is dried to form an inorganic material layer.
The drying condition is not particularly limited, but is preferably 70 to 100 ° C. and 5 to 15 minutes.

The mat member according to the second embodiment of the present invention can be manufactured through the above steps.

In the method for manufacturing the mat member, the powdery inorganic material is applied to the first main surface of the first region, and then water is applied to the inorganic material to make the inorganic material into a slurry.
However, in the method for manufacturing a mat member according to the second embodiment of the present invention, the slurry-like inorganic material may be directly applied to the first main surface of the first region.

The mat member according to the second embodiment of the present invention is wound in the same manner as the mat member according to the first embodiment of the present invention and then inserted into the tubular body.
As the insertion method, the same method as the mat member according to the first embodiment can be applied.

It is desirable that the cylindrical body be a silencer.
As described above, the mat member according to the second embodiment of the present invention exhibits a good sound absorbing function. Therefore, the silencer in which the mat member according to the second embodiment of the present invention is inserted also exhibits an excellent sound absorbing function.
Moreover, the silencer can be efficiently manufactured by such a method of inserting the mat member.

Examples of the muffler include an automobile muffler and a motorcycle muffler.

(Third Embodiment)
Next, a wound body that is a third embodiment of the present invention will be described.
FIG. 10: is a perspective view which shows typically an example of the winding body which concerns on 3rd Embodiment of this invention.
FIG. 11A is a perspective view schematically showing an example of a mat member used for the wound body according to the third embodiment of the present invention. FIG. 11B is a perspective view schematically showing a state in which the mat member shown in FIG. 11A is wound.
FIG. 12: is a perspective view which shows typically an example of the tubular body used for the winding body which concerns on 3rd Embodiment of this invention.

As shown in FIG. 10, the wound body 250 includes a mat member 210 and a tubular member 260 wound with the mat member 210.

As shown in FIG. 11A, the mat member 210 before being wound around the tubular body 260 includes a first main surface 211, a second main surface 212 opposite to the first main surface 211, and a first end portion. It has a rectangular shape in plan view having 213 and a second end 214 on the side opposite to the first end 213.
Further, as shown in FIG. 11B, the mat member 210 is wound twice.

In the mat member 210, a region of the mat member 210 in the first round where the first main surface 211 and the tubular body 260 are in contact is a first region 215. The area of the mat member 210 in the second round is the second area 216.
Further, a plurality of through holes 221 are formed in the first region 215.

As shown in FIG. 12, a tubular body through hole 261 is formed in the side wall of the tubular body 260.

In the wound body 250, the mat member 210 has a first region 215 having a through hole 221 and a second region 216 adjacent to the first region 215.
Further, in the wound body 250, the first region 215 is wound around the tubular body 260 with the first main surface 211 of the mat member 210 inside, and the outside thereof (that is, the second main surface 212 side of the first region 215 side). ) Is wrapped around the second region 216.
The first main surface 211 of the second region 216 of the mat member 210 is located at the bottom of the through hole 221 on the second main surface 212 side of the first region 215 of the mat member 210. Therefore, in the wound body 250, the through hole 221 in the first region 215 of the mat member 210 and the first main surface 211 of the second region 216 of the mat member 210 form a bottomed hole.
Such a wound body 250 can be easily manufactured by using the mat member 210 having the through holes 221 formed in the first region 215.

The mat member in the wound body according to the third embodiment of the present invention is preferably the mat member according to the first embodiment or the second embodiment.
The desirable material and shape of the mat material are the same as the desirable material and shape of the mat material according to the first embodiment and the mat material according to the second embodiment.

In particular, it is preferable that the mat member is made of inorganic fiber and that the inorganic material layer is formed on the first main surface (that is, the mat member according to the second embodiment).
In this case, the muffling function can be improved by inserting the winding body according to the third embodiment of the present invention into the cylindrical muffler. The principle will be described below.
When the wound body according to the third embodiment of the present invention is inserted into a cylindrical silencer, the first main surface of the first region of the mat member is a surface that receives sound passing through the tubular body through hole of the tubular body. become.
When the first main surface of the first area of the mat member receives a sound, the sound is transmitted to the side wall of the through hole of the first area and the first main surface of the second main surface located at the bottom of the through hole of the first area. It will reach the area. The sound is then reflected, attenuated and absorbed in the matte material.
In addition, a part of the sound passes through the inside of the first region of the mat member and tries to go out from the first main surface of the first region where the through hole is not formed. However, since the inorganic material layer is formed on the first main surface of the first region of the mat member, the sound trying to go outside is reflected by the inorganic material layer. As a result, the sound can be prevented from leaking to the outside, and the sound can be efficiently absorbed.

In the wound body according to the third embodiment of the present invention, the shape of the tubular body is not particularly limited, but the shape of the bottom is circular, elliptical, triangular, quadrangular, pentagonal, hexagonal, octagonal, etc. May be Among these, it is desirable that the shape is circular or elliptical.
When the bottom of the tubular body has a circular or elliptical shape, the mat member is wound around the tubular body in a circular or elliptical shape.
The mat material wound in this manner is less likely to be concentrated by external pressure and less likely to be damaged.

In the wound body according to the third embodiment of the present invention, the tubular body is preferably made of punching metal.
The punching metal functions as a muffling mechanism in the muffler.
Therefore, the wound body according to the third embodiment of the present invention can be used as it is as a part of a silencer.
The material of the punching metal may be stainless steel, aluminum, steel, titanium, Inconel or the like.

The thickness of the tubular body is not particularly limited, but is preferably 0.3 to 3 mm, more preferably 1 to 2 mm.

When the bottom surface of the tubular body is circular, its radius is preferably 15 to 100 mm, more preferably 20 to 50 mm.

As the method for manufacturing a wound body according to the third embodiment of the present invention, a tubular body and the mat member according to the first embodiment or the mat member according to the second embodiment are prepared, and It can be manufactured by winding the mat member around the tubular body so that the first main surface of one region is in contact with the tubular body.

The method for fixing the mat member is not particularly limited, but may be fixed using, for example, an inorganic binder or the like, or may be fixed with a tape or the like.
The inorganic binder is not particularly limited, and alumina sol, silica sol or the like can be used.

The wound body according to the third embodiment of the present invention is used by being inserted into a tubular body.
It is desirable that the cylindrical body be a silencer.
By using the wound body according to the third embodiment of the present invention, the silencing function of the silencer can be improved.

(Other embodiments)
The mat member according to the first to third embodiments of the present invention is a mat member having such a length that it can be wound exactly twice.
However, the mat member of the present invention may be longer than the length that can be wound exactly twice as long as the length can be wound at least twice.
Further, the length of the mat member does not have to be a length that allows the mat to be exactly rotated, and may be a length that can be two and a half rounds, or a length that can be two and three quarters rounds, for example.

Further, even when the mat material of the present invention has a length capable of being wound two or more times, the first region and the second region are determined by winding the mat material of the present invention at least twice, and the first area The region wound around is the first region, and the region wound on the second turn is the second region.

10, 110, 210 Matte material 10 'Fiber layers 11, 111, 211 First main surfaces 11a, 11b Ends 12, 112, 212 of the first main surface Second main surfaces 12a, 12b Ends 13 of the second main surface , 113, 213 1st end part 14, 114, 214 2nd end part 15, 115, 215 1st area | region 15 '1st area | region 16, 116, 216 2nd area | region 16' 2nd area | region 21 , 121, 221 through holes 21a, 121a bottom portions 22, 122, 222 of the through holes bottomed holes 40 tubular body 131 inorganic material layer 250 wound body 260 tubular body 261 tubular body through hole

Claims (12)

A mat member having a rectangular shape in plan view, having a first main surface, a second main surface opposite to the first main surface, a first end, and a second end opposite to the first end. There
The mat member has a first region that is a region extending from the first end toward the second end by a predetermined distance, and a second region adjacent to the first region.
A plurality of through holes are formed in the first region,
The mat member will be wound at least two turns with the first main surface inside.
The first region is located on the first lap of the wound mat member,
The mat member, wherein the second region is located at the second round in the wound mat member. The mat member according to claim 1, wherein the first region is wound in a circular shape or an elliptical shape when the mat member is viewed from the side. When the mat member is viewed from the side, the first region is wound in a circular shape,
When the length of the first region is L ₁ and the thickness of the mat member is T,
The mat member according to claim 2, wherein the length of the second region in the longitudinal direction is (L ₁ + 2π × T) × 0.95 to (L ₁ + 2π × T) × 1.05. The mat member according to claim 1, wherein the mat member is made of inorganic fiber, and an inorganic material layer is formed on the first main surface of the first region. A method of inserting a mat member according to any one of claims 1 to 4 into a tubular body, wherein the first mat member is placed so that the first main surface of the mat member faces inside. A first region winding step of winding the region,
A second area winding step of winding the second area of the mat material around the second main surface of the first area of the mat material after the first area winding step,
After the second region winding step, an inserting step of inserting the mat material into the tubular body with a direction perpendicular to a longitudinal direction of the mat material as an inserting direction is included. . The mat member according to claim 5, wherein in the first region winding process and the second region winding process, the mat member is spirally wound so that the mat member on the insertion direction side has a convex shape. Insertion method. Inserting the mat member according to claim 5, wherein in the first region winding process and the second region winding process, the mat member is spirally wound so that the mat member on the insertion direction side has a concave shape. Method. The said cylindrical body is a silencer, The insertion method of the mat | matte material in any one of Claims 5-7. A mat material having a rectangular shape in plan view, which has a first main surface, a second main surface opposite to the first main surface, a first end, and a second end opposite to the first end. A winding body comprising a tubular body around which the mat member is wrapped so that the first main surface is in contact with,
The mat member is wound around the tubular body at least twice.
The region of the mat member on the first round where the first main surface and the tubular body are in contact is a first region,
The area of the mat member on the second lap is the second area,
A plurality of through holes are formed in the first region,
A wound body, wherein a tubular body through hole is formed in a side wall of the tubular body. The wound body according to claim 9, wherein the tubular body has a bottom portion having a circular shape or an elliptical shape. The wound body according to claim 9 or 10, wherein the tubular body is made of punched metal. The wound body according to claim 9, wherein the mat member is made of inorganic fiber, and an inorganic material layer is formed on the first main surface of the first region.

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