JP2020112093A - Mat material - Google Patents

Abstract

To provide a mat material with an excellent winding property having plural mats.SOLUTION: A mat material comprises: a laminate mat 20, on which plural mats including inorganic fibers with a rectangular shape in a plane view are laminated, and which are configured so that longitudinal length of each mat sequentially becomes longer as they are laminated; and an organic sheet 30 wound around the laminate mat. The laminate mat has a first principal plane 23 whose length in a longitudinal direction of the mat is longest, a second principal plane 24 whose length in a longitudinal direction of the mat is shortest on a side opposite to the first principal plane, a first long side plane 25 parallel to the longitudinal direction of the mat, and a second long side plane 26 opposite to the first long side plane. The organic sheet is continuously wound, and in contact with at least a part of the first principal plane 23 of the laminate mat 20 and at least a part of the second principal plane 24.SELECTED DRAWING: Figure 1

Description

The present invention relates to a mat material.

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 been a problem that the PM harms the environment and the human body. .. Moreover, since harmful gas components such as CO, HC and NOx are also contained in the exhaust gas, there is concern about the influence of these harmful gas components on the environment and the human body.

Therefore, as an exhaust gas purifying device for collecting PM in exhaust gas and purifying harmful gas components, an exhaust gas treating body made of a porous ceramic such as silicon carbide or cordierite, and a casing containing the exhaust gas treating body. Various exhaust gas purifying apparatuses have been proposed, which are composed of an exhaust gas treating body and a holding sealing material arranged between the casing and the casing. This holding sealing material prevents the exhaust gas treating body from being damaged due to contact with the casing covering the outer periphery of the exhaust gas treating body due to vibration or impact generated by running of an automobile, or exhaust gas from between the exhaust gas treating body and the casing. Is provided mainly for the purpose of preventing the leakage of oil.

As the holding sealing material used for such an application, a mat material made of inorganic fiber is used. The mat material made of inorganic fibers is also used for heat insulation and soundproofing, which is used by being wound around pipes of automobiles and the like.

Patent Document 1 discloses a holding sealing material in which a plurality of mats made of inorganic fibers are laminated, and the plurality of mats are bound by a band-shaped body having no fixing force.

JP 2012-233433A

In the holding sealing material described in Patent Document 1, since the mat and the band-shaped body are not fixed to each other, the mat may fall off. Therefore, in order to stabilize the relative positions of the plurality of mats, it is necessary to bind the plurality of mats to the belt-shaped body with a strong force. When the binding force of the band-shaped body is increased, the mats on the inside become more difficult to slip when the holding sealing material is wound, so that the inner mat is bent and the winding performance may be insufficient.

The present invention has been made in view of such a problem, and an object of the present invention is to provide a mat member having a plurality of mats and having excellent winding property.

The mat member of the present invention is a laminated mat formed by laminating a plurality of rectangular mats containing inorganic fibers in a plan view, and the length of each mat in the longitudinal direction being sequentially increased as the layers are laminated,
A mat member consisting of an organic sheet wound around the laminated mat,
The laminated mat has a first main surface having the longest length in the longitudinal direction of the mat, a second main surface opposite to the first main surface and having the shortest length in the longitudinal direction of the mat, and the mat. A first long side surface parallel to the longitudinal direction of the first long side surface and a second long side surface opposite to the first long side surface,
The organic sheet is continuously wound around the first main surface, the first long side surface, the second main surface and the second long side surface of the laminated mat,
The organic sheet is bonded to at least a part of the first main surface or at least a part of the second main surface of the laminated mat.

By winding the organic sheet around the laminated mat and adhering the organic sheet to one of the main surfaces of the laminated mat, the relative positions of the plurality of mats can be stabilized to the extent that the mat does not fall off. .. Further, since the mats can be appropriately slipped and can be displaced from each other during winding, the inner mat is prevented from being bent during winding, so that a mat material excellent in winding property can be obtained.

In the mat member of the present invention, the organic sheet is preferably adhered to the second main surface of the laminated mat.
The second main surface of the laminated mat is a surface that becomes an inner side when winding, and it is preferable to use this surface as an adhesive surface of the organic sheet because workability during winding is further improved.

In the mat member of the present invention, on the main surface where the organic sheet is adhered to the laminated mat, there are a winding start portion and a winding end portion of the organic sheet, and the winding start portion and the winding portion of the organic sheet. An end portion is adhered to the laminated mat, and an exposed portion for exposing the main surface of the laminated mat without the organic sheet is formed between the winding start portion and the winding end portion. preferable.
The formation of the exposed portion means that the amount of the organic sheet used is smaller than that in the case where the exposed portion is not provided. It is preferable that the organic sheet is used in a small amount, because it causes a release of an organic gas content when heated when used.

In the mat member of the present invention, on the main surface where the organic sheet is bonded to the laminated mat, there are a winding start portion and a winding end portion of the organic sheet, and the organic sheet at the winding start portion and the winding end. It is preferable that the partial organic sheets are overlapped and bonded.

In the mat member of the present invention, on the main surface where the organic sheet is bonded to the laminated mat, there are a winding start portion and a winding end portion of the organic sheet,
On the main surface where the organic sheet is adhered to the laminated mat, the organic sheet is preferably adhered to the laminated mat over the entire width direction of the laminated mat.

In the mat member of the present invention, the portion where the organic sheet is bonded to the laminated mat preferably extends in the direction along the longitudinal direction of the main surface of the laminated mat.
With such a configuration, a mat member having a better winding property can be obtained.

In the mat member of the present invention, the organic sheet is preferably a nonwoven fabric made of organic fibers. It is also preferable that the organic sheet is made of a resin film.

In the mat member of the present invention, the organic sheet is preferably made of at least one resin selected from the group consisting of polyester, polyethylene and polypropylene.
These materials are preferable because they are excellent in flexibility and elasticity and can be adhered to the laminated mat by heat sealing.

In the mat member of the present invention, the organic sheet is preferably adhered to the laminated mat by heat sealing.
By fusing the organic sheet to the inorganic fibers constituting the laminated mat by heat sealing, the organic sheet can be reliably adhered to the laminated mat.
In addition, it is possible to bond by pressing with a hot plate, and the process of bonding the organic sheet is simple.

In the mat member of the present invention, the organic sheet is preferably adhered to the laminated mat with an adhesive.
The use of an adhesive makes it easier to set the adhesion site.
For example, the central portion of the mat member can be bonded by using a strong adhesive, and the weak adhesive can be used at the end of the mat member.
In this way, at the end portion to which a strong tension is applied at the time of winding, the matte material and the organic sheet are peeled off moderately, so that the organic sheet can be prevented from impairing the winding property.

FIG. 1A is a perspective view schematically showing an example of a mat member, and FIG. 1B is a sectional view taken along the line AA of the mat member shown in FIG. FIG. 2A is a perspective view schematically showing another example of the mat member, and FIG. 2B is a sectional view taken along the line BB of the mat member shown in FIG. 2A. FIG. 3A is a perspective view schematically showing another example of the mat member, and FIG. 3B is a sectional view taken along line CC of the mat member shown in FIG. 3A. FIG. 4 is a perspective view schematically showing the mat member manufactured in Comparative Example 1. 5(a) and 5(b) are photographs showing the winding state of the mat member in the winding test of Example 3 and Comparative Example 1, respectively.

(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 configurations, and can be appropriately modified and applied without departing from the scope of the present invention. Note that a combination of two or more of the respective desirable configurations of the present invention described below is also the present invention.

The mat member of the present invention includes a laminated mat in which a plurality of rectangular mats containing inorganic fibers and having a rectangular shape in a plan view are laminated, and the longitudinal length of each mat is sequentially increased as the layers are laminated. A mat material composed of an organic sheet wound around a mat, wherein the laminated mat has a first main surface having the longest length in the longitudinal direction of the mat and a mat on the side opposite to the first main surface. A second main surface having the shortest length in the longitudinal direction, a first long side surface parallel to the longitudinal direction of the mat, and a second long side surface opposite to the first long side surface; The organic sheet is continuously wound around the first main surface, the first long side surface, the second main surface and the second long side surface of the laminated mat. The laminated mat is bonded to at least a part of the first main surface or at least a part of the second main surface.

FIG. 1A is a perspective view schematically showing an example of a mat member, and FIG. 1B is a sectional view taken along the line AA of the mat member shown in FIG.
The mat member 10 shown in FIG. 1A is composed of a laminated mat 20 in which a plurality of mats are laminated, and an organic sheet 30 wound around the laminated mat 20.

The laminated mat 20 is formed by laminating two sheets of a first mat 21 and a second mat 22.
The first mat 21 is a mat having a long length in the longitudinal direction (the direction indicated by the double-headed arrow L in FIG. 1A), and the second mat 22 is a mat having a short length in the longitudinal direction. ..

The laminated mat 20 has two main surfaces, the main surface having the longest length in the longitudinal direction of the mat is the first main surface 23, and the main surface having the shortest length in the longitudinal direction of the mat is the first. 2 of the main surface 24.
The first main surface 23 is the lower main surface of the first mat 21, and the second main surface 24 is the upper main surface of the second mat 22.

The laminated mat 20 has four side surfaces, and the side surfaces along the longitudinal direction of the mat are the first long side surface 25 and the second long side surface 26. The side faces along the width direction of the mat (the direction indicated by the double-headed arrow W in FIG. 1A) are the first short side face 27 and the second short side face 28.
A concave portion is formed on the first short side surface 27, and a convex portion is formed on the second short side surface 28. The concave portion and the convex portion are shaped so as to fit with each other when the mat member is wound around the exhaust gas purifying device, the exhaust gas treating body, or the exhaust pipe having a cylindrical outer periphery.
In addition, in FIG. 1A, the direction indicated by a double-headed arrow T is the thickness direction of the mat member.

The organic sheet 30 is continuously wound around the laminated mat 20.
The organic sheet 30 has a winding start portion 31 and a winding end portion 32, and the winding start portion 31 and the winding end portion 32 are present on the second main surface 24 of the laminated mat 20.
That is, the organic sheet 30 is the second main surface from the winding start portion 31 of the second main surface 24 of the laminated mat 20 to the first long side surface 25, the first main surface 23, and the second long side surface 26. It is continuously wound up to the winding end portion 32 of 24.

Further, between the winding start portion 31 and the winding end portion 32 of the organic sheet 30, the organic sheet 30 does not exist and the exposed portion 29 exposing the main surface of the laminated mat 20 is formed.
The formation of the exposed portion means that the amount of the organic sheet used is smaller than that in the case where the exposed portion is not provided. It is preferable that the organic sheet is used in a small amount, because it causes a release of an organic gas content when heated when used.

In the mat member of the present invention, the organic sheet is adhered to at least a part of the first main surface or at least a part of the second main surface of the laminated mat.
In the mat member 10 shown in FIGS. 1A and 1B, the organic sheet 30 is bonded to the second main surface 24 of the laminated mat 20. In FIG. 1A and FIG. 1B, hatching is shown by diagonal lines in the portion of the organic sheet 30 where the organic sheet 30 is bonded to the second main surface 24 of the laminated mat 20.
The organic sheet 30 is adhered to the laminated mat 20 only on the second main surface 24, and the organic sheet 30 is attached to the first main surface 23, the first long side surface 25, and the second long side surface 26. Not glued.

Further, when the exposed portion is formed like the mat member 10 shown in FIGS. 1A and 1B, it is preferable that the exposed portion is provided on the second main surface. When the matte material is wound around the exhaust gas treating body, the contact between the exhaust gas treating body and the exposed portion improves the adhesion. Further, when the mat material is wrapped around the exhaust gas treating body and then press-fitted into the casing, the matte material becomes slippery and press-fitted more easily when there is no exposed portion on the casing side and the area where the organic sheet contacts the casing is large. This is because.

The length of the portion where the organic sheet 30 is adhered to the laminated mat 20 is the length shown by the double-headed arrow L ₁ in FIG. 1A, and the width of the portion where the organic sheet 30 is adhered to the laminated mat 20 is This is the sum of the lengths indicated by the double-headed arrow W ₁ and the lengths indicated by the double-headed arrow W ₂ in FIG.
The width of the exposed portion 29 is the length shown by the double-headed arrow W ₃ in FIG.

By wrapping the organic sheet around the laminated mat and adhering the organic sheet to the second main surface, which is one of the main surfaces of the laminated mat, the two mats can be placed relative to each other so that the mat does not fall off. The position can be stabilized. In addition, since the mats can be slipped appropriately during the winding and the mats can be displaced from each other, the second mat, which is the inner mat, is prevented from being bent during the winding. You can

The second main surface 24 of the laminated mat 20 is the main surface having the shortest length in the longitudinal direction of the mat.
The second main surface 24 of the laminated mat 20 is a surface which becomes an inner side at the time of winding, but if this surface is an adhesive surface of the organic sheet 30, workability at the time of winding is further improved.

In the mat member of the present invention, the portion where the organic sheet is bonded to the laminated mat preferably extends in the direction along the longitudinal direction of the main surface of the laminated mat.
In the present specification, the extending direction of the portion where the organic sheet is adhered to the laminated mat is determined by observing the shape of the portion where the organic sheet is adhered to the laminated mat and which of the long sides is the direction.
In the mat member 10 shown in FIGS. 1A and 1B, the portion where the organic sheet 30 is bonded to the laminated mat 20 is shown by rectangular hatching. Since the two long sides of the rectangle are oriented along the longitudinal direction of the second main surface 24 of the laminated mat 20, the organic sheet 30 is adhered to the laminated mat 20 in the mat member 10. It can be determined that the existing portion extends in the direction along the longitudinal direction of the second main surface 24 of the laminated mat 20.
When the portion where the organic sheet is bonded to the laminated mat extends in the direction along the longitudinal direction of the main surface of the laminated mat, the mat member can be made more excellent in winding property.

The organic sheet 30 is preferably adhered to the laminated mat 20 by heat sealing.
By fusing the organic sheet to the inorganic fibers constituting the laminated mat by heat sealing, the organic sheet can be reliably adhered to the laminated mat.
In addition, it is possible to bond by pressing with a hot plate, and the process of bonding the organic sheet is simple.

It is also preferable that the organic sheet 30 is bonded to the laminated mat 20 with an adhesive.
The use of an adhesive makes it easier to set the adhesion site.
For example, the central portion of the mat member can be bonded by using a strong adhesive, and the weak adhesive can be used at the end of the mat member.
In this way, at the end portion to which a strong tension is applied at the time of winding, the matte material and the organic sheet are peeled off moderately, so that the organic sheet can be prevented from impairing the winding property.

The characteristics of the material, dimensions, etc. constituting the mat member of the present invention as described above will be described.
The mat forming the mat member is made of inorganic fiber. The inorganic fiber is not particularly limited, and may be alumina-silica fiber, alumina fiber, silica fiber or the like. Further, it may be glass fiber or biosoluble fiber. It may be changed according to the characteristics required for the mat material such as heat resistance and wind erosion resistance, and it is preferable to use a fiber having a large diameter or a fiber length that can meet the environmental regulations of each country.

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

The number of laminated mat materials in the laminated mat is not particularly limited as long as it is plural. The number of sheets is preferably two or three, and more preferably two.

The preferred range of dimensions for the laminated mat is as follows.
The length of the laminated mat in the longitudinal direction (the length indicated by the double-headed arrow L in FIG. 1A and the length of the mat having the first main surface in the longitudinal direction) is preferably 300 to 1300 mm.
The length of the laminated mat in the width direction (the length indicated by the double-headed arrow W in FIG. 1A) is preferably 40 to 400 mm.
The thickness of the laminated mat (the length indicated by the double-headed arrow T in FIG. 1A) is preferably 2 to 30 mm.
When the thickness of the laminated mat is less than 2 mm, the thickness is too thin, and the heat insulation performance and the sound insulation performance deteriorate. On the other hand, when the thickness of the laminated mat exceeds 30 mm, the flexibility decreases, and the attachability to the member to be attached deteriorates.
The thickness of one mat forming the laminated mat may be the same or different for each of the plurality of mats, but the thickness of one mat is preferably 1 to 15 mm.

The laminated mat has a longitudinal direction which is a winding direction and a lateral direction orthogonal to the longitudinal direction.
In the laminated mat, a convex portion is formed on one end of the laminated mat on the longitudinal direction side, and a convex portion is formed on the other end of the laminated mat. It is preferable that the recess is formed. It is preferable that the convex portion and the concave portion of the laminated mat have such shapes that they are just fitted to each other when the laminated mat is wound around the exhaust gas purifying device, the exhaust gas treating body or the exhaust pipe having a cylindrical outer periphery.
In addition, the laminated mat may have a shape in which the convex portion and the concave portion are not formed.

The bulk density of the mat forming the laminated mat is not particularly limited, but is preferably 0.05 to 0.30 g/cm ³ . When the bulk density of the mat is less than 0.05 g/cm ³ , the entanglement of the inorganic fibers is weak and the inorganic fibers are easily peeled off, so that it becomes difficult to keep the shape of the mat in a predetermined shape. On the other hand, when the bulk density of the mat exceeds 0.30 g/cm ³ , the mat becomes hard, the mountability on the member to be mounted is deteriorated, and the mat is easily cracked.

The mat constituting the laminated mat can be obtained by various methods, for example, it can be produced 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 obtain a mixed liquid. The mixed liquid is poured into a molding machine having a mesh for filtration formed on the bottom surface, and the solvent in the mixed liquid is desolvated to obtain an inorganic fiber aggregate. Then, the mat can be obtained by drying the inorganic fiber aggregate.
In the case of the needling method, for example, it can be manufactured by the following method.
A spinning mixture prepared by using a basic aluminum chloride aqueous solution and silica sol as a raw material 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 prepare a continuous sheet-like article having a predetermined size, and a baking treatment is applied to the mat to obtain a mat. Needle punching treatment is performed before or after this firing treatment to entangle the inorganic fibers.

The protrusions and recesses of the mat that compose the laminated mat must be shaped so that they fit together when the mat material is wound around the exhaust gas purification device, exhaust gas treatment body, or exhaust pipe with a cylindrical outer periphery. Is preferred.
Further, the mat forming the laminated mat may have a shape in which no convex portion and concave portion are formed.

The organic sheet forming the mat member of the present invention is made of an organic material. The organic material is not particularly limited. Examples thereof include paper, resin film, and non-woven fabric made of organic fibers.
It is also preferable that the organic sheet is made of a resin film.
The organic sheet is preferably made of at least one resin selected from the group consisting of polyester, polyethylene and polypropylene.
These materials are preferable because they are excellent in flexibility and elasticity and can be adhered to the laminated mat by heat sealing.

Examples of the nonwoven fabric made of organic fibers include PET (polyethylene terephthalate) fibers fused with PE (polyethylene) powder.
Other usable organic fibers include PP (polypropylene) and rayon.
When the organic sheet is a resin film, examples of the organic material forming the resin film include PET (polyethylene terephthalate), PP (polypropylene), PE (polyethylene) and the like.

The attachment of the organic sheet and the laminated mat may be performed via an adhesive different from the organic sheet, or may be performed by heat-sealing the organic sheet itself without using the adhesive.

When the organic sheet and the laminated mat are attached via an adhesive, an acrylic adhesive, an acrylate latex, a urethane adhesive, an epoxy resin adhesive or the like can be used as the adhesive.

When the organic sheet itself is heat-sealed, the heat-sealing may be performed at an appropriate heating temperature depending on the type of organic material forming the organic sheet.

The basis weight of the organic sheet is not particularly limited, but is preferably 10 g/m ² or more, and preferably 30 g/m ² or less.
When the weight per unit area of the organic sheet is within the above range, the relative positions of the plurality of mats can be stabilized to the extent that the winding property is not hindered and the mats do not fall off.

The thickness of the organic sheet is not particularly limited, but is preferably 0.05 mm or more and 0.3 mm or less.
When the weight per unit area of the organic sheet is within the above range, the relative positions of the plurality of mats can be stabilized to the extent that the winding property is not hindered and the mats do not fall off.

Hereinafter, the mat member of the present invention will be described with reference to an example of a different form from the mat member shown in FIGS. 1(a) and 1(b).
FIG. 2A is a perspective view schematically showing another example of the mat member, and FIG. 2B is a sectional view taken along the line BB of the mat member shown in FIG. 2A.
The mat member 11 shown in FIGS. 2(a) and 2(b) has the same structure as the mat member 10 shown in FIG. 1(a) and the laminated mat 20, and the organic sheet 30 is wound and bonded. different.

In the mat member 11, the winding start portion 31 and the winding end portion 32 of the organic sheet 30 are present on the second main surface 24 to which the organic sheet 30 is bonded to the laminated mat 20, and the organic sheet of the winding start portion 31 is The organic sheets of the winding end portion 32 are overlapped and adhered.
The organic sheet of the winding start portion 31 and the organic sheet of the winding end portion 32 are adhered to each other, and the organic sheet of the winding start portion 31 is further adhered to the second main surface 24 of the laminated mat 20.

In this case, since the main surface of the laminated mat 20 is not exposed between the winding start portion 31 and the winding end portion 32, the exposed portion is not formed.
Further, the portion where the organic sheet 30 is bonded to the laminated mat 20 extends in the direction along the longitudinal direction of the main surface of the laminated mat 20.

In addition, the organic sheet 30 is at a portion hatched in FIG. 2A and FIG. 2B with respect to the second main surface 24 of the laminated mat 20 (where the winding start portion and the winding end portion overlap). Only glued. That is, the organic sheet is bonded to a part of the second main surface of the laminated mat.
The width of the portion where the organic sheet 30 is bonded to the laminated mat 20 is the length shown by the double-headed arrow W ₄ in FIG.

On the main surface where the organic sheet is adhered to the laminated mat, there are a winding start portion and a winding end portion of the organic sheet, and when the organic sheet at the winding start portion and the organic sheet at the winding end portion are overlapped and adhered, , The winding start part and the winding end part are fixed by heat-sealing the part where the organic sheet at the winding start part and the organic sheet at the winding end part overlap, and the organic sheet and the laminated mat are bonded in one step. This is preferable because the work can be performed easily.

Further, when the organic sheet at the winding start portion and the organic sheet at the winding end portion are overlapped and adhered to each other like the mat member 11 shown in FIGS. 2A and 2B, the organic sheets are overlapped and adhered. It is preferable that the portion is on the second main surface side. This is because if the portion where the organic sheets are overlapped and adhered is the inner surface when the mat member is wound, tension is less likely to be applied during winding.

FIG. 3A is a perspective view schematically showing another example of the mat member, and FIG. 3B is a sectional view taken along line CC of the mat member shown in FIG. 3A.
The mat member 12 shown in FIGS. 3A and 3B has the same structure as the mat member 10 shown in FIG. 1A and the laminated mat 20. different.

In the mat member 12, the winding start portion 31 and the winding end portion 32 of the organic sheet 30 exist on the second main surface 24 to which the organic sheet 30 is bonded to the laminated mat 20, and the organic sheet of the winding start portion 31 is The organic sheets of the winding end portion 32 are overlapped and adhered.
Further, on the second main surface 24 of the laminated mat 20, the organic sheet 30 is adhered to the laminated mat 20 over the entire width direction of the laminated mat 20.
Further, the portion where the organic sheet 30 is bonded to the laminated mat 20 extends in the direction along the longitudinal direction of the main surface of the laminated mat 20.
Even in such a form, the effect of the mat member of the present invention can be exhibited.

The mat material of the present invention can be used for a holding sealing material, a heat insulating material, a soundproofing material, etc. by winding the mat material around an exhaust gas purifying device, an exhaust gas treating body or an exhaust pipe.
The shapes of the exhaust gas purifying device, the exhaust gas treating body, and the exhaust pipe are not particularly limited, but may be cylindrical, prismatic, cylindrical, rectangular tubular, or the like.

The exhaust gas treating body is a ceramic honeycomb structure such as a porous ceramic and is used as a catalyst carrier. In the catalyst carrier, the exhaust gas flows into the through holes having both the exhaust gas inflow side end surface and the exhaust gas outflow side end surface opened, and the exhaust gas is purified by the action of the catalyst carried by the partition walls separating the through holes.
Further, the exhaust gas treating body may be a DPF (diesel particulate filter) in which either end of the through hole is alternately sealed.
The material constituting the exhaust gas treating body is not particularly limited, but non-oxides such as silicon carbide and silicon nitride, and oxides such as cordierite and aluminum titanate can be used.

When the mat material of the present invention is wound around an exhaust gas treating body or an exhaust pipe, the second main surface of the laminated mat is arranged on the side (inner side) of the object to be wound and the first main surface of the laminated mat is arranged on the outer side. To do.
At this time, the organic sheet is preferably adhered to the second main surface of the laminated mat. By doing so, workability at the time of winding is improved.
Further, in the mat member of the present invention, since the mats can be appropriately slipped and misaligned between the mats at the time of winding, the SeamGap, which is an index of the winding property, becomes small.
SeamGap is the length of the gap between the convex portion and the concave portion at the position where the convex portion and the concave portion are fitted to each other, and the shorter the gap, the better the winding property.

Next, an example of the method for producing the mat member of the present invention will be described.
First, a mat constituting the laminated mat is prepared, and the mat is laminated to prepare the laminated mat.
The mat can be obtained by various methods. For example, the mat can be obtained by punching a sheet-shaped member obtained by a papermaking method or a needling method into a predetermined shape.

By changing the dimensions at the time of punching, a plurality of mats having different lengths in the longitudinal direction are produced, and the plurality of mats are laminated in the order of increasing length or decreasing length to form a laminated mat. Create.
The number of mats to be laminated may be changed according to the holding power and heat insulation performance required for the mat material.

Next, an organic sheet is wound around the laminated mat. The size of the organic sheet may be adjusted and wound so as to provide an exposed portion as shown in FIG. 1(a), or as shown in FIGS. 2(a) and 2(b). The sheet and the organic sheet at the end of winding may be overlapped on the second main surface side of the laminated mat.

When the laminated mat and the organic sheet are adhered with an adhesive, the adhesive is applied to a part of the laminated mat and/or the organic sheet.
Also, when the organic sheet at the winding start portion and the organic sheet at the winding end portion are bonded with an adhesive, the adhesive is applied to the relevant portion.
If necessary, it is dried to exert the adhesive strength of the adhesive.

When the lamination mat and the organic sheet are adhered by heat sealing, a heat sealer is applied to the portion where the lamination mat and the organic sheet are adhered to perform heat sealing.
The organic sheet at the winding start portion and the organic sheet at the winding end portion may be bonded to the laminated mat by heat sealing once.
The mat member of the present invention can be manufactured by the above steps.

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

(Example 1)
A sheet-like member made of inorganic fibers (mullite fibers) having a basis weight (fiber weight per unit area) of 1050 g/m ² was produced by the papermaking method.
This sheet-shaped member is punched to form a first mat having a length of 673 mm in the longitudinal direction, a width of 98 mm and a thickness of 6.8 mm and a second mat having a length of 630 mm in the longitudinal direction, a width of 98 mm and a thickness of 6.8 mm. A mat was made. The first mat and the second mat have a shape having a concave portion and a convex portion as shown in FIG.
The second mat was laminated on the first mat to form a laminated mat.

As the organic sheet, a nonwoven fabric made of organic fibers having a basis weight of 18 g/m ² and a width of 500 mm was prepared. This is a non-woven fabric in which PE powder is fused to PET fibers.

As shown in FIGS. 1(a) and 1(b), the organic sheet was wound around the laminated mat.
An organic sheet was adhered to the second main surface of the laminated mat by heat sealing.
The condition of heat sealing is heating at 100° C. for 5 seconds.
The length of the portion where the organic sheet is bonded to the laminated mat (the length indicated by the double-headed arrow L ₁ in FIG. 1A) is 500 mm, which is the width of the nonwoven fabric.
The width of the portion where the organic sheet is adhered to the laminated mat (the total length shown by the double-headed arrow W ₁ and the double-headed arrow W ₂ in FIG. 1A) is 60 mm, and the width of the exposed part (see FIG. The length indicated by the double-headed arrow W ₃ in 1(a)) is 38 mm.

(Example 2)
As shown in FIGS. 3A and 3B, the organic sheet was wrapped around the laminated mat.
On the side of the second main surface of the laminated mat, the winding start portion and the winding end portion of the organic sheet were overlapped, and the organic sheet was bonded to the entire second main surface of the laminated mat by heat sealing.
The condition of heat sealing is heating at 100° C. for 5 seconds.
The length of the portion where the organic sheet is bonded to the laminated mat is 500 mm, which is the width of the nonwoven fabric.
The organic sheet and the laminated mat are not adhered to each other on the side of the first main surface of the laminated mat.

(Example 3)
As shown in FIGS. 2A and 2B, the organic sheet was wrapped around the laminated mat.
On the side of the second main surface of the laminated mat, the winding start portion and the winding end portion of the organic sheet were overlapped and bonded together with the laminated mat by heat sealing.
The condition of heat sealing is heating at 100° C. for 5 seconds.
The length of the portion where the organic sheet is bonded to the laminated mat is 500 mm, which is the width of the nonwoven fabric.
The width (the length indicated by the double-headed arrow W ₄ in FIG. 2A) of the portion where the organic sheet is bonded to the laminated mat is 30 mm.

(Example 4)
In Example 2, the main surface for adhering the organic sheet to the laminated mat was changed from the second main surface to the first main surface.
That is, the organic sheet was bonded to the entire first main surface of the laminated mat by heat sealing.
The organic sheet and the laminated mat are not adhered to each other on the second main surface side of the laminated mat.

(Comparative Example 1)
FIG. 4 is a perspective view schematically showing the mat member manufactured in Comparative Example 1.
In Comparative Example 1, the mat member 13 as shown in FIG. 4 was manufactured.
In the mat member 13, the laminated mat 20 is bound by two film bands 130a and 130b. The film bands 130a and 130b are not bonded to the laminated mat 20.
The film band is OPP (biaxially oriented polypropylene film), and the basis weight of the film band is 60 g/m ² .
The length (the length indicated by the double-headed arrows L ₂ and L ₃ in FIG. 4) of the portion where the film band binds the laminated mat is 30 mm, respectively.

(Wrapping test)
The mat member according to each of Examples 1 to 4 and Comparative Example 1 was wrapped around a cylindrical substrate having a diameter of 200 mm.
At the time of winding, the second main surface (second mat) of the laminated mat was on the substrate side, and the first main surface (first mat) was on the outside.
The gap (Seam Gap) between the convex portion and the concave portion at the position where the convex portion and the concave portion are fitted together when wound is determined by the inner mat (second mat) and the outer mat (first mat). Each was measured.
The results are summarized in Table 1.

(Detachment test)
One end of the first mat constituting the mat member was fixed, and the mat member was hung so that the longitudinal direction of the mat member was the vertical direction. Further, at the end portion where the first mat is fixed (upper end portion when the mat member is hung) and the opposite end portion (lower end portion when the mat member is hung), the second mat is formed. The stainless plate was suspended and a downward load was applied to the second mat.
The load was changed by changing the number of stainless steel plates, and in this state, the maximum value of the load that did not cause positional displacement was determined. The larger this value, the more stable the relative positions of the plurality of mats, and the less likely the mats will fall out.
The measurement results are summarized in Table 1.

In each of the winding test and the falling test, three mat materials were used as test samples for each Example and Comparative Example, and measurement was performed, and the average value was calculated.

In Examples 1 to 4, the value of SeamGap is smaller than that in Comparative Example 1, and it can be seen that the winding property is excellent. In Examples 1 to 3, the adhesive surface of the organic sheet is the second main surface of the laminated mat, and the organic sheet is adhered to the surface that is the inner side during winding, so the value of SeamGap is smaller in the outer mat. Has become.
In addition, in Examples 1 to 4, the result of the dropout test is also good, and by adopting the configuration of Examples 1 to 4, it is possible to stabilize the relative positions of a plurality of mats to the extent that the mat does not drop out. Recognize.

(Observation of winding state)
5(a) and 5(b) are photographs showing the winding state of the mat member in the winding test of Example 3 and Comparative Example 1, respectively.
As shown in FIG. 5B, in Comparative Example 1, the inner mat is warped, but in Example 3, as shown in FIG. 5A, the inner mat is not warped. I understand.
From this, it can be said that the mat material of the present invention is a mat material excellent in winding property.

10, 11, 12, 13 Mat member 20 Laminated mat 21 First mat 22 Second mat 23 First main surface 24 of laminated mat Second main surface 25 of laminated mat First long side surface 26 of laminated mat Second long side surface 27 of laminated mat First short side surface 28 of laminated mat Second short side surface 29 of laminated mat Exposed portion 30 Organic sheet 31 Winding start portion 32 Winding end portion 130a, 130b Film band

Claims (11)

A plurality of mats each having a rectangular shape in plan view including inorganic fibers are laminated, and the length of each mat in the longitudinal direction is a laminated mat configured to sequentially become longer as they are laminated,
A mat material comprising an organic sheet wound around the laminated mat,
The laminated mat includes a first main surface having the longest length in the longitudinal direction of the mat, a second main surface opposite to the first main surface and having the shortest length in the longitudinal direction of the mat, and the mat. A first long side surface parallel to the longitudinal direction of the first long side surface, and a second long side surface opposite to the first long side surface,
The organic sheet is continuously wound around the first main surface, the first long side surface, the second main surface and the second long side surface of the laminated mat,
The mat member, wherein the organic sheet is bonded to at least a part of the first main surface or at least a part of the second main surface of the laminated mat. The mat member according to claim 1, wherein the organic sheet is bonded to the second main surface of the laminated mat. On the main surface where the organic sheet is adhered to the laminated mat, there are a winding start portion and a winding end portion of the organic sheet, and the winding start portion and the winding end portion of the organic sheet are adhered to the laminated mat. The mat member according to claim 1 or 2, wherein an exposed portion is formed between the winding start portion and the winding end portion to expose the main surface of the laminated mat without the organic sheet. .. On the main surface where the organic sheet is adhered to the laminated mat, there are a winding start portion and a winding end portion of the organic sheet, and the organic sheet at the winding start portion and the organic sheet at the winding end portion overlap and adhere to each other. The mat member according to claim 1 or 2, which is provided. On the main surface where the organic sheet is bonded to the laminated mat, there are a winding start portion and a winding end portion of the organic sheet,
The mat member according to claim 1 or 2, wherein the organic sheet is bonded to the laminated mat over the entire width direction of the laminated mat on the main surface where the organic sheet is adhered to the laminated mat. The mat member according to any one of claims 1 to 5, wherein the portion where the organic sheet is adhered to the laminated mat extends in a direction along the longitudinal direction of the main surface of the laminated mat. The mat member according to claim 1, wherein the organic sheet is a non-woven fabric made of organic fibers. The mat member according to any one of claims 1 to 6, wherein the organic sheet is made of a resin film. The mat member according to claim 1, wherein the organic sheet is made of at least one resin selected from the group consisting of polyester, polyethylene, and polypropylene. The mat member according to claim 1, wherein the organic sheet is bonded to the laminated mat by heat sealing. The mat member according to claim 1, wherein the organic sheet is bonded to the laminated mat with an adhesive.

Images