JP2021105379A - Mat material and exhaust emission control device - Google Patents

Abstract

To secure ease of winding around an exhaust gas treatment body and suppress deformation during insertion into a casing even when a mat material has through holes formed therein.SOLUTION: A mat material 10A comprises at least an inorganic fiber, and the mat material 10A includes through holes 14a penetrating in a thickness direction T1. In plan view, the mat material 10A includes: normal regions 16; and reinforcement regions 15a each formed continuously from at least part of a peripheral edge 14a1 of the through hole 14a over at least part of an outer edge 18 of the mat material 10A and having strength higher than that of the normal region 16.SELECTED DRAWING: Figure 1

Description

The present invention relates to a mat material and an exhaust gas purification device.

Conventionally, in order to purify harmful substances such as harmful gas contained in exhaust gas discharged from an internal combustion engine such as an engine, an exhaust gas purification device is provided in an exhaust passage (exhaust pipe or the like through which exhaust gas flows) of the internal combustion engine. ing. The exhaust gas purification device has a structure in which a casing is provided in the exhaust passage of the internal combustion engine and an exhaust gas treatment body is arranged in the casing. Examples of the exhaust gas treatment body include a catalyst carrier or a diesel particulate filter (DPF). In order to improve the purification efficiency of harmful substances by the exhaust gas purification device in which the catalyst is carried on the exhaust gas treatment body, the temperature of the exhaust passage of the internal combustion engine and the exhaust gas is set to a temperature suitable for catalyst activation (hereinafter, "catalyst activation temperature"). It is also necessary to maintain it.

As described above, the exhaust gas purification device in which the catalyst is supported on the exhaust gas treatment body cannot exert a sufficient catalytic action unless the temperature is raised until the temperature reaches a predetermined catalyst activation temperature. Therefore, in the exhaust gas purification device immediately after starting the engine, there is a problem that it takes a certain amount of time for the exhaust gas purification performance to reach a sufficient level.

To solve such a problem, an electric heating catalyst converter (EHC; Electrical Heated Catalyst) that rapidly heats a catalyst has been proposed for the purpose of reducing harmful substances emitted immediately after starting an engine.

For example, in Patent Document 1, an exhaust gas treatment body around which a holding seal material is wound is provided in a casing, and an exhaust gas purification device provided so that an electrode member or the like passes through a hole in the casing and a penetrating portion of the holding seal material. Is disclosed.

Further, in Patent Document 2, when applied to an exhaust gas purification device used in a urea SCR system, it has a mat-like shape as a holding sealing material capable of maintaining a high holding power even after long-term use, and adsorbs urea. It is composed of a suction part for holding the exhaust gas holder and a holding part for holding the exhaust gas holding body. The long side surface of the suction part and the long side surface of the holding part face each other with a space, and the suction part and the holding part are opposed to each other. It is disclosed that the portions are connected via a connecting portion and the width of the suction portion is smaller than the width of the holding portion.

Japanese Unexamined Patent Publication No. 2012-149604 International Publication No. 2010/004637

In Patent Document 1, a through hole as a penetrating portion is formed in a mat material which is a holding sealing material, and an electrode member for heating an exhaust gas treatment body is arranged so as to pass through the through hole. In the manufacture of the exhaust gas purification device, there is a step of inserting the exhaust gas treatment body and the mat material into the casing, but at the time of insertion, a part of the main body of the mat material adjacent to the through hole is easily deformed and is directed toward the through hole. This part may be deformed and the smooth insertion into the casing may be hindered.
Further, in Patent Document 2, similarly, since the penetrating portion is formed in the mat material which is the holding sealing material, it has the same problem as the mat material of Patent Document 1.

The present invention provides a mat material having through holes formed in it, which can be easily wound around an exhaust gas treatment body and can suppress deformation when inserted into a casing. ..

The mat material of the present invention is a mat material composed of at least inorganic fibers, and the mat material has through holes penetrating in the thickness direction, and the mat material has a normal region and the penetrating in a plan view. It includes a reinforcing region that is continuously formed from at least a part of the peripheral edge of the hole to at least a part of the outer edge of the mat material and has a higher strength than the normal region.

The mat material of the present invention is, for example, a substantially rectangular shape in a plan view having a longitudinal direction and a width direction perpendicular to the longitudinal direction in a plan view, and the reinforcing region covers at least the entire length of the peripheral edge along the longitudinal direction. Formed across.

In the mat material of the present invention, for example, at least two of the reinforcing regions are formed on both sides of the through hole in the width direction.

In the mat material of the present invention, for example, the reinforcing region and the normal region are formed of an integral mat that is not a separate member from each other.

In the mat material of the present invention, for example, the mat material contains an organic binder or an inorganic binder in the normal region and the reinforcing region, and the content of the organic binder or the inorganic binder in the reinforcing region is the normal region. The content of the organic binder or the inorganic binder is higher than that of the above.

In the mat material of the present invention, for example, the normal region and the reinforcing region are subjected to needle punching treatment, and the density of the needle punching treatment in the reinforcing region is higher than the density of the needle punching treatment in the normal region.

In the mat material of the present invention, for example, a reinforcing material having a higher strength than the material constituting the normal region is embedded in the reinforcing region.

In the mat material of the present invention, for example, the reinforcing material comprises at least one of an organic material, an inorganic material, and a metal material.

In the mat material of the present invention, for example, in a plan view, the area of the normal region is larger than the area of the reinforcing region.

The mat material of the present invention is applied to one of devices selected from, for example, a water heater, a microwave oven, a gas stove, a burner tester, a heating tester, an internal combustion engine, and a firing furnace.

The exhaust gas purification device of the present invention is arranged between the exhaust gas treatment body, the casing accommodating the exhaust gas treatment body, and the exhaust gas treatment body and the casing, and any of the above-mentioned mats holding the exhaust gas treatment body. It is equipped with materials.

According to the present invention, a reinforcing region having a higher strength than the normal region is formed at a specific position, so that the ease of winding around the exhaust gas treatment body can be ensured and the deformation when inserted into the casing can be suppressed. It is possible.

FIG. 1 is a perspective view schematically showing an example of a mat material according to the first embodiment of the present invention. FIG. 2 is a plan view of the mat material shown in FIG. FIG. 3A is a partially cutaway perspective sectional view schematically showing an example of an exhaust gas purification device according to the first embodiment of the present invention, and FIG. 3B is shown in FIG. 3A. FIG. 5 is a cross-sectional view taken along the line AA of the exhaust gas purification device. FIG. 4 is a perspective view schematically showing an example of an exhaust gas treatment body constituting the exhaust gas purification device according to the first embodiment of the present invention. FIG. 5 is a perspective view schematically showing an example of a casing constituting the exhaust gas purification device according to the first embodiment of the present invention. 6 (a), 6 (b), 6 (c) and 6 (d) are perspective views schematically showing an example of a method for manufacturing an exhaust gas purification device according to the first embodiment of the present invention. be. FIG. 7 is a perspective view schematically showing an example of a mat material according to a second embodiment of the present invention. FIG. 8 is a perspective view schematically showing an example of a mat material according to a third embodiment of the present invention.

Hereinafter, embodiments 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 without changing the gist of the present invention.

(First Embodiment)
Hereinafter, the mat material of the present invention, the exhaust gas purification device, and the first embodiment, which is an embodiment of the method for manufacturing the exhaust gas purification device, will be described with reference to the drawings.

First, the mat material according to the first embodiment of the present invention will be described. FIG. 1 is a perspective view schematically showing an example of a mat material according to the first embodiment of the present invention. The mat material 10A shown in FIG. 1 is made of at least inorganic fibers such as alumina-silica fibers and has a mat-like shape. More specifically, the mat member 10A is predetermined length (in FIG. 1, indicated by the arrow _{L 1),} the width (in FIG. 1, indicated by arrow _{W 1),} and, in thickness (Fig. 1, the arrow T _It has a flat plate shape having a substantially rectangular shape in a plan view (shown in 1). Further, the mat material 10A has a _{first end surface 11 (11a, 11b and 11c) parallel to the width W 1} direction of the mat material 10A, and a second end surface 12 (12a, 12b and 12c). .. Further, the mat material 10A has a through hole 14a.
In the present specification, the "length in the longitudinal direction of the mat material" means the distance between the first end face and the second end face in the length direction of the mat material. The "longitudinal length of the mat material" is also simply referred to as the "length of the mat material". Further, in the plan view of the mat material 10A, the longitudinal direction L ₁ (direction of arrow L ₁ ), the width direction W ₁ (direction of arrow W ₁ ), and the thickness direction T ₁ (direction of arrow T ₁ ) are defined, respectively. NS.

In the mat material of the present embodiment, the first end face and the second end face are each provided with a step consisting of at least one protruding portion. In the mat material 10A shown in FIG. 1, two protrusions 13a and 13c are formed on the first end face 11, and one protrusion 13b is formed on the second end face 12. When the first end surface 11 and the second end surface 12 of the mat material 10A are brought into contact with each other, the convex portion formed by the protruding portion 13b and the concave portion formed by the protruding portions 13a and 13c are fitted to each other. .. As described above, the mat material 10A shown in FIG. 1 is provided with three steps on the first end surface 11 and the second end surface 12, respectively. FIG. 2 is a plan view of the mat material shown in FIG. FIG. 2 shows the specific positions of the protrusions 13a, 13b and 13c formed on the mat material 10A.
In the mat material of the present embodiment, a so-called uneven shape is adopted as the shape of the protruding portion 13a, the protruding portion 13b and 13c to be fitted, but the mat material has an L-shaped fitting portion having a known shape. It may be in shape.

As used herein, the term "protruding portion" refers to the following areas. In the end face of the mat material (first end face or second end face), the portion of the mat material existing in the region between the end face to which the start point of each step belongs and the end face to which the end point of the step belongs is called a "protruding portion". I will do it. Therefore, the protruding portions of the mat material are present on the first end face side and the second end face side of the mat material, respectively.

In the mat material of the present embodiment, it is preferable that the lengths of the protruding portions are substantially equal in the length direction of the mat material. That is, it is preferable that the distance between the first end face and the second end face is substantially equal in any part of the mat material. In the mat member 10A shown in FIG. 1, the length _{L 1} direction of the mat material 10A, the length of the protruding portion 13a (in FIG. 1, indicated by the arrow _{X 1),} the length of the projecting portion 13b (in FIG. 1, arrows indicated by X _2), and, in the length of the protruding portion 13c (Fig. 1, are substantially equal either indicated by the arrow _{X 3)} it is. Thus, the mat material 10A shown in Figure 1, has a fixed length L _1. In addition, "substantially equal" allows that the lengths are not exactly the same, and includes the case where they can be equated with substantially the same length.

At least one through hole is formed in the mat material of the present embodiment. Further, one through hole is formed so as to penetrate the mat material in the thickness direction of the mat material.

In the mat material of the present embodiment, the position where the through hole is formed is not particularly limited, but it is preferably formed in a portion other than the protruding portion.

In the mat material of the present embodiment, the shape of the through hole of the mat material is, for example, a substantially columnar shape, a substantially square columnar shape, a substantially elliptical columnar shape, a substantially conical trapezoidal shape, a columnar shape having a bottom surface surrounded by a substantially straight line and a substantially arc. Examples of the cross-sectional shape of the through hole include a substantially circular shape, a substantially polygonal shape such as a substantially quadrangular shape, a substantially elliptical shape, a substantially oval shape (approximately a race track shape), and the like. When the exhaust gas purification device is manufactured using the mat material of the present embodiment, the cross-sectional shape of the through hole of the mat material can be matched with the cross-sectional shape of the electrode member or the like. The cross section of the through hole means a cross section in a direction parallel to the main surface of the mat material. Further, in the present specification, terms such as "substantially columnar", "substantially circular shape", "substantially vertical", and "substantially parallel" allow that the shape is not mathematically exact, and "circle". Includes shapes that can be substantially equated with shapes such as "columnar", "circular", "vertical", and "parallel".

In the mat material of the present embodiment, the diameter of the cross section of the through hole of the mat material is preferably 1 to 100 mm, more preferably 20 to 40 mm. If the diameter of the cross section of the through hole of the mat material is less than 1 mm, the cross-sectional area of the through hole of the mat material is too small. Therefore, when the mat material is used for the exhaust gas purification device, an electrode member or the like is formed in the through hole of the mat material. Is difficult to place. On the other hand, if the diameter of the cross section of the through hole of the mat material exceeds 100 mm, the area of the mat material becomes too small, so that the holding power of the mat material as the holding sealing material is lowered. Further, if the diameter of the cross section of the through hole of the mat material exceeds 100 mm, the area of the mat material occupying the width direction of the mat material decreases, so that the tensile strength of the mat material decreases.

Moreover, in the mat member of the present embodiment, the area of the cross section of the through-hole of the mat member is preferably 1～10000Mm ^2, more preferably 400~1600mm ^2. If the cross-sectional area of the through hole of ^{the mat material is less than 1 mm 2} , it is not possible to secure a sufficient area for arranging the electrode member and / or the sensor when the mat material is used in the exhaust gas purification device. On the other hand, if the cross-sectional area of the through hole of ^{the mat material exceeds 10000 mm 2} , the area of the mat material becomes too small, and the holding power of the mat material decreases.

The diameter of the cross section of the through hole is the diameter of the portion perpendicular to the thickness direction of the mat material, and when the cross-sectional shape of the through hole is other than the circular shape, the maximum length passing through the center of the cross section. Say that. The diameter of the cross section of the through hole is, for example, the diameter of the cross section when the through hole is substantially cylindrical, the major axis of the cross section when the through hole is substantially elliptical, and the case where it is approximately square or polygonal. Refers to the length of the longest part of the cross section. When the through hole has a substantially truncated cone shape, it means the diameter of the larger circle.

In the mat material 10A shown in FIG. 1, the shape of the through hole 14a is substantially prismatic, and the shape of the cross section of the through hole 14a is substantially quadrangular.

Further, the mat material 10A of the present embodiment is continuously formed from at least a part of the normal region 16 and the peripheral edge 14a1 of the through hole 14a to at least a part of the outer edge 18 of the mat material 10A in the plan view. It is configured to include a reinforcing region 15a having a higher strength than the normal region 16. Here, the normal region 16 refers to a region other than the reinforcing region 15a of the mat material 10A. Then, a reinforcing region 15a is formed at a specific position of the mat material 10A, and its strength is set to be higher than that of the normal region 16. In this embodiment, the protrusions 13a, 13b and 13c may also be included in the normal region 16.

Generally, a binder such as an organic binder or an inorganic binder can be applied to the mat material. The binder provided to the mat material allows the inorganic fibers that make up the mat material to be fixed to each other, reducing the bulk of the mat material when the mat material is press-fitted into the casing, and preventing the inorganic fibers from scattering. Can be done. Further, the strength of the mat material can be improved by increasing the content of the organic binder or the inorganic binder.
The mat material 10A of the present embodiment contains an organic binder or an inorganic binder in both the normal region 16 and the reinforcing region 15a, and the content of the organic binder or the inorganic binder in the reinforcing region 15a is the organic binder or the inorganic binder in the normal region 16. It is higher than the binder content. The content of the organic binder or the inorganic binder in the normal region 16 may be zero (that is, the normal region 16 does not contain the organic binder or the inorganic binder).

The organic binder to be added is not particularly limited, and examples thereof include epoxy resin, acrylic resin, rubber resin, and styrene resin. Among the above organic binders, a rubber resin (latex) or the like is preferable. As the organic binder-containing liquid containing an organic binder, for example, a solution in which a water-soluble organic polymer such as carboxymethyl cellulose or polyvinyl alcohol is dissolved, acrylic rubber, acrylonitrile-butadiene rubber or styrene-butadiene rubber is dispersed in water. Examples include latex.

The inorganic binder to be added is also not particularly limited, and for example, silica, alumina, titania, yttria, ceria, zinc, magnesia, zirconia, colloidal sol selected from these, or a combination thereof, etc. Can be mentioned.

An example of the method for manufacturing the mat material of the present embodiment will be described. For example, a mat material is manufactured by a method of punching a base mat produced by entwining inorganic fibers into a desired shape by a spinning method, and then the manufactured mat material is punched into a predetermined shape using a punching blade or the like. A method of forming a through hole, a method of punching the through hole together when punching the base mat, and the like can be considered. The mat material of the present embodiment can be manufactured by the above method.
Further, the mat material of the present embodiment may be manufactured by papermaking or three-dimensional molding.

Next, the exhaust gas purification device according to the first embodiment of the present invention will be described. FIG. 3A is a partially cutaway perspective sectional view schematically showing an example of an exhaust gas purification device according to the first embodiment of the present invention. FIG. 3B is a cross-sectional view taken along the line AA of the exhaust gas purification device shown in FIG. 3A. The exhaust gas purification device 100 shown in FIGS. 3A and 3B is a mat arranged between the casing 120, the exhaust gas treatment body 130 housed in the casing 120, and the exhaust gas treatment body 130 and the casing 120. It is provided with a material 110. The exhaust gas purification device 100 further includes a sensor 140a that is connected to the exhaust gas treatment body 130, passes through the mat material 110, and penetrates the casing 120. The mat material 110 is wound around the exhaust gas treatment body 130, and the exhaust gas treatment body 130 is held by the mat material 110. That is, the mat material 110 holds the exhaust gas treated body 130 with a predetermined holding force, and also functions as a holding sealing material for sealing the exhaust gas treated body 130 and the casing 120. If necessary, an introduction pipe for introducing the exhaust gas discharged from the internal combustion engine and an exhaust pipe for discharging the exhaust gas that has passed through the exhaust gas treatment body to the outside are connected to the end portion of the casing 120.

The mat material constituting the exhaust gas purification device of the present embodiment will be described. In the exhaust gas purification device of the present embodiment, the mat material of the present embodiment is used. In the exhaust gas purification device 100 shown in FIGS. 3 (a) and 3 (b), an example is shown in which the mat material 10A shown in FIG. 1 is used as the mat material 110. As shown in FIGS. 3A and 3B, a through hole 114a is formed in the mat material 110 wound around the exhaust gas treatment body 130. A sensor 140a is arranged in the through hole 114a. An electrode member or the like may be arranged instead of the sensor 140a.

In the exhaust gas purification device of the present embodiment, the first end face and the second end face of the mat material may be in contact with each other without a gap, or a predetermined gap may be formed. When a gap is formed between the first end face and the second end face at the contact portion of the mat material, the electrode member and / or the sensor can be arranged in the gap. When a gap is formed between the first end face and the second end face of the mat material, the distance between the first end face and the second end face of the mat material is preferably 100 mm or less. It is more preferably 20 to 100 mm, and even more preferably 20 to 40 mm. If the distance between the first end face and the second end face of the mat material exceeds 100 mm, the area of the mat material in contact with the exhaust gas treated body is reduced, so that the mat material does not easily hold the exhaust gas treated body. .. If the distance between the first end face and the second end face at the contact portion of the mat material is less than 20 mm, the size of the gap is too small, so the electrode member and / or the sensor is arranged in the gap. It becomes difficult.

The exhaust gas treatment body constituting the exhaust gas purification device of the present embodiment will be described. FIG. 4 is a perspective view schematically showing an example of an exhaust gas treatment body constituting the exhaust gas purification device according to the first embodiment of the present invention. FIG. 4 shows an example of a catalyst carrier as an example of an exhaust gas treated body.

The exhaust gas treatment body 130 shown in FIG. 4 is mainly made of a porous ceramic, and its shape is substantially cylindrical. Further, a coat layer 133 is provided on the outer periphery of the exhaust gas treated body 130 for the purpose of reinforcing the outer peripheral portion of the exhaust gas treated body 130, adjusting the shape, and improving the heat insulating property of the exhaust gas treated body 130. There is. The coat layer may be provided as needed.

The exhaust gas treatment body 130 shown in FIG. 4 is a honeycomb structure in which a large number of through holes 131 are arranged side by side in the longitudinal direction (in the direction indicated by the double-headed arrow a in FIG. 4) across the partition wall 132. In the exhaust gas treatment body 130, a catalyst for purifying harmful gas components such as CO, HC, and NOx contained in the exhaust gas is supported on the partition wall 132 of the honeycomb structure. Examples of the catalyst include platinum and the like.

The casing constituting the exhaust gas purification device of the present embodiment will be described. FIG. 5 is a perspective view schematically showing an example of a casing constituting the exhaust gas purification device according to the first embodiment of the present invention. The casing 120 shown in FIG. 5 is mainly made of a metal such as stainless steel, and its shape is substantially cylindrical. The casing 120 is provided with a hole 121a for allowing the sensor to pass through. The inner diameter of the casing 120 is slightly shorter than the total length of the diameter of the end face of the exhaust gas treatment body 130 shown in FIG. 4 and the thickness of the mat material wound around the exhaust gas treatment body 130. The length of the casing may be slightly longer than the length in the longitudinal direction of the exhaust gas treatment body, or may be substantially the same as the length in the longitudinal direction of the exhaust gas treatment body.

In the exhaust gas purification device 100 shown in FIGS. 3A and 3B, the position of the through hole 114a of the mat material 110 coincides with the position of the hole 121a of the casing 120. The sensor 140a is arranged in the through hole 114a of the mat material 110 and the hole 121a of the casing 120.

The sensor constituting the exhaust gas purification device of the present embodiment will be described. In the exhaust gas purification device of the present embodiment, the type of sensor is not particularly limited, and examples thereof include an exhaust gas purification device, a temperature sensor for measuring the temperature of an atmosphere, an oxygen sensor, and the like. These sensors may be used alone or in combination of a plurality of sensors as long as they are arranged in the through holes of the mat material.

Hereinafter, a method for manufacturing an exhaust gas purification device according to the first embodiment of the present invention will be described with reference to the drawings. 6 (a), 6 (b), 6 (c) and 6 (d) are perspective views schematically showing an example of a method for manufacturing an exhaust gas purification device according to the first embodiment of the present invention. be. 6 (a), 6 (b), 6 (c) and 6 (d) show FIG. 3 (a) and FIG. 6 (a) as an example of the method for manufacturing the exhaust gas purification device according to the first embodiment of the present invention. The manufacturing method of the exhaust gas purification apparatus 100 shown in FIG. 3B will be described.

First, as shown in FIG. 6A, a winding step of winding the mat material 110 around the exhaust gas treatment body 130 to produce a winding body (exhaust gas treatment body around which the mat material is wound) 160 is performed. As the mat material 110, the mat material 10A shown in FIG. 1 is used. In FIG. 6A, the mat material 110 is formed with a through hole 114a.

Next, as shown in FIG. 6B, an accommodating step of accommodating the produced winding body 160 in a substantially cylindrical casing 120 is performed. Examples of the method of accommodating the wound body in the casing include a press-fitting method (stuffing method), a sizing method (swazing method), and a clamshell method. In the press-fitting method (stuffing method), the wound body is press-fitted to a predetermined position inside the casing by using a press-fitting jig or the like. In the sizing method (swazing method), after the winding body is inserted into the inside of the casing, it is compressed from the outer peripheral side so as to reduce the inner diameter of the casing. In the clamshell method, the casing is formed into a shape that can be separated into two parts, the first casing and the second casing, and the winding body is placed on the first casing and then covered with the second casing. Seal. Among the methods for accommodating the wound body in the casing, a press-fitting method (stuffing method) or a sizing method (swazing method) is preferable. This is because in the press-fitting method (stuffing method) or the sizing method (swazing method), it is not necessary to use two parts as the casing, so that the number of manufacturing steps can be reduced.

FIG. 6B shows a method of press-fitting the winding body 160 into the casing 120 by using the press-fitting jig 170. The press-fitting jig 170 has a substantially cylindrical shape as a whole, and the inside thereof extends in a tapered shape from one end to the other end. One end of the press-fitting jig 170 is a minor diameter side end portion 171 having an inner diameter corresponding to a diameter slightly smaller than the inner diameter of the casing 120. Further, the other end of the press-fitting jig 170 is a major axis side end portion 172 having an inner diameter corresponding to at least the outer diameter of the winding body 160. By using the press-fitting jig 170, the winding body 160 can be easily press-fitted into the casing 120. The method of press-fitting the wound body into the casing is not particularly limited, and for example, a method of press-fitting the wound body into the casing by pushing the wound body by hand may be used.

However, when the winding body 160 including the exhaust gas treatment body 130 and the mat material 110 is press-fitted into the casing, the portion adjacent to the through hole 114a of the mat material 110 (the portion corresponding to the reinforcing region 15a in this figure) is formed. , Contacting the inner circumference of the press-fitting jig 170 or the casing 120, the portion is deformed in the direction toward the through hole 114a (the direction opposite to the arrow in FIG. 6B), which hinders smooth insertion into the casing. There is a risk of being damaged.

In the mat material 10A of the present embodiment, as described above, a reinforcing region 15a having a higher strength than the normal region 16 is provided adjacent to the through hole 14a in the press-fitting direction. The high-strength reinforcing region 15a has high resistance even if it comes into contact with the inner circumference of the press-fitting jig 170 or the casing 120 during press-fitting, and deformation is suppressed. Therefore, smooth press-fitting and thus smooth production of the exhaust gas purification device can be realized. Further, since the reinforcing region 15a is formed only in a part thereof, the rigidity of the mat material 10A does not become excessively large, and the work of winding the mat material 130 around the exhaust gas treatment body 130 can be easily performed.

As shown in FIGS. 1 and 2, the reinforcing region 15a is continuously formed over the peripheral edge 14a1 that defines the shape of the cross section of the through hole 14a and the outer edge 18 that defines the shape of the matte material 10A. “Continuously” means that the reinforcing region 15a exists seamlessly between the peripheral edge 14a1 and the outer edge 18. In the present embodiment, the reinforcement region 15a is at least the total length of the peripheral edge 14a1 in the longitudinal direction L ₁ is formed over the (L ₂ length of FIG. ₂₎ so as to ensure a predetermined strength. With such a configuration, sufficient strength can be ensured. However, if the necessary strength can be secured, the length of the reinforcement region 15a may be shorter than the length L ₂ in the longitudinal direction L _1. Further, as long as the winding operation to the surroundings of the exhaust gas treating body 130 of the mat member 10A it does not become difficult, the length of the reinforcement region 15a may be longer than the length L ₂ in the longitudinal direction L _1.

In the present embodiment, at least two reinforcing areas are formed on both sides of the through hole 14a in the width direction W _1, and FIG. 6 (b) press-fitting shown in FIG. 6 (b) shows the mat member 10A Can be easily performed from the opposite direction.

The reinforcing region 15a and the normal region 16 can be formed from an integral mat (base mat) that is not a separate member from each other. That is, by adjusting the amount of the organic binder added to the produced base mat, it is possible to generate the reinforcing region 15a and the normal region 16 from the one base mat. The mat material 10A can be easily manufactured as compared with the case where the parts constituting the reinforcing region 15a and the parts constituting the normal region 16 are separately prepared and assembled.

Subsequently, as shown in FIG. 6C, a position adjusting step is performed in which the position of the through hole 114a formed in the mat material 110 is aligned with the position of the hole 121a in the casing 120. Examples of the method of adjusting the position of the through hole to the position of the hole of the casing include a method of rotating the winding body housed in the casing. In the above-mentioned accommodating step, when the wound body is accommodated in the casing so that the position of the through hole and the position of the casing coincide with each other, the accommodating step and the position adjusting step can be performed at the same time.

After that, an arrangement step (first arrangement step) of connecting to the exhaust gas treatment body, passing through the mat material, and arranging the sensor so as to penetrate the casing is performed. As shown in FIG. 6D, in the arrangement step (first arrangement step), a sensor 140a such as a temperature sensor is passed through a through hole 114a formed in the mat material 110 and a hole 121a in the casing 120, and the sensor is passed through the hole 121a. The 140a is connected to the exhaust gas treatment body 130. By going through the above steps, the exhaust gas purification device 100 shown in FIGS. 3 (a) and 3 (b) can be manufactured.

(Second Embodiment)
In the mat material, a needle punching treatment can be applied to a base mat composed of inorganic fibers. The needle punching process is a process of inserting and removing a fiber entanglement means such as a needle from a base mat. In the matte material subjected to the needle punching treatment, inorganic fibers having a relatively long fiber length are three-dimensionally entangled. Therefore, the strength of the mat material is improved.

FIG. 7 is a perspective view schematically showing an example of a mat material according to a second embodiment of the present invention. The mat material 10B shown in FIG. 7 has basically the same configuration as the mat material 10A according to the first embodiment, but both the normal region 16 and the reinforcing region 15b are subjected to needle punching treatment, and the reinforcing region 15b is formed. The density of the needle punching process is set higher than the density of the needle punching process in the normal region 16. By such a process, the reinforcing region 15b and the normal region 16 can be generated. The needle punching process in the normal region 16 may be omitted.

(Third Embodiment)
FIG. 8 is a perspective view schematically showing an example of a mat material according to a third embodiment of the present invention. The mat material 10C shown in FIG. 8 has basically the same structure as the mat material 10A according to the first embodiment, but the reinforcing region 15c has higher strength than the material (inorganic fiber or the like) constituting the normal region 16. Reinforcing material 15d is embedded. By such a process, the reinforcing region 15c and the normal region 16 can be generated.
The reinforcing material 15d can be made of various materials such as an organic material, an inorganic material, and a metal material, and the type thereof is not particularly limited. The material of the reinforcing material 15d is not particularly limited as long as it can secure a certain strength such as an organic substance (resin, rubber), ceramic, or metal.
Examples of more specific materials for forming the reinforcing material 15d include, for example, ABS resin, polyethylene, polypropylene, polystyrene, vinyl chloride resin, methacrylic resin, polyamide, polycarbonate, polyacetal, polyester, polyurethane, polyphenylene ether, elastomer, polyphenylene sulfide. , Acrylonitrile styrene, acrylonitrile butadiene styrene, resins such as fluororesin, nitrile rubber, hydride nitrile rubber, fluorine rubber, silicone rubber, ethylene propylene rubber, chloroprene rubber, acrylic rubber, butyl rubber, urethane rubber, chlorosulphonized polyethylene rubber, epichlorohydrin Examples thereof include rubber such as rubber, aluminum, iron, copper, nickel, titanium, and alloys thereof. Further, the shape and number of the reinforcing members 15d are not particularly limited.

In the above-described embodiment, the shape of the through hole 14a is substantially prismatic, and the shape of the cross section of the through hole 14a is substantially quadrangular. Then, the two through holes 14a are arranged along the longitudinal direction of the mat material. However, the shape, number, position, etc. of the through holes 14a are not particularly limited, and the reinforcing region 15c may be appropriately provided according to the specific aspect of the through holes 14a.

In the plan view of the mat material, for example, the area of the normal region is set to be larger than the area of the reinforcing region. As a result, it is possible to suppress an excessive increase in the rigidity of the mat material and ensure the ease of winding around the exhaust gas treated body.

Further, the mat material of the present invention can be applied to various devices, but not only internal combustion engines such as jet engines and automobile engines, but also water heaters, microwave ovens, gas stoves, burner testers, hot surface pressure measuring machines. It can be applied to heating testers, baking furnaces, etc. that require heating.

The present invention is not limited to the above-described embodiment, and can be appropriately modified, improved, and the like. In addition, the material, shape, size, numerical value, form, number, arrangement location, etc. of each component in the above-described embodiment are arbitrary and are not limited as long as the present invention can be achieved.

10A, 10B, 10C, 110 Matte materials 11, 11a, 11b, 11c First end faces 12, 12a, 12b, 12c Second end faces 13a, 13b, 13c Protruding parts 14a, 114a Through holes 14a1 Peripheral edges 15a, 15b, 15c Reinforcement area 15d Reinforcement material 16 Normal area 18 Outer edge 100 Exhaust gas purification device 120 Casing 121a Hole 130 Exhaust gas treatment body 131 Through hole 132 Partition wall 133 Coat layer 140a Sensor 160 Winding body 170 Press-fitting jig 171 Short diameter side end 172 Long diameter side end Department

Claims (11)

A matte material composed of at least inorganic fibers
The mat material has a through hole penetrating in the thickness direction and has a through hole.
In a plan view, the mat material is continuously formed from at least a part of the peripheral edge of the through hole to at least a part of the outer edge of the mat material, and is reinforced with higher strength than the normal region. Including the area,
Mat material. The mat material is a substantially rectangular shape in a plan view having a longitudinal direction and a width direction perpendicular to the longitudinal direction in a plan view.
The reinforcing region is formed over at least the entire length of the peripheral edge along the longitudinal direction.
The mat material according to claim 1. At least two of the reinforcing regions are formed on both sides of the through hole in the width direction.
The mat material according to claim 2. The reinforcing area and the normal area are formed of an integral mat that is not a separate member from each other.
The mat material according to any one of claims 1 to 3. The mat material contains an organic binder or an inorganic binder in the normal region and the reinforcing region.
The content of the organic binder or the inorganic binder in the reinforcing region is higher than the content of the organic binder or the inorganic binder in the normal region.
The mat material according to any one of claims 1 to 4. The mat material is subjected to needle punching treatment in the normal region and the reinforcing region.
The density of the needle punching treatment in the reinforcing region is higher than the density of the needle punching treatment in the normal region.
The mat material according to any one of claims 1 to 4. A reinforcing material having a higher strength than the material constituting the normal region is embedded in the reinforcing region.
The mat material according to any one of claims 1 to 4. The reinforcing material comprises at least one of an organic material, an inorganic material and a metallic material.
The mat material according to claim 7. The mat material according to any one of claims 1 to 8, wherein the mat material has an area of the normal region larger than the area of the reinforcing region in a plan view. The mat material is applied to one of devices selected from water heaters, microwave ovens, gas stoves, burner testers, heating testers, internal combustion engines and firing furnaces.
The mat material according to any one of claims 1 to 9. Exhaust gas treatment body and
A casing that houses the exhaust gas treatment body and
An exhaust gas purification device including a mat material arranged between the exhaust gas treatment body and the casing and holding the exhaust gas treatment body.
The mat material is the mat material according to any one of claims 1 to 9.
Exhaust gas purification device.

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