JP6478712B2 - Manufacturing method of holding sealing material - Google Patents

Description

The present invention relates to a holding sealing material, a wound body, and a manufacturing method of the holding sealing material.

Conventionally, in order to purify harmful substances such as harmful gases contained in exhaust gas discharged from an internal combustion engine such as an engine, an exhaust gas purification device has been provided in the exhaust passage (exhaust pipe through which the exhaust gas flows) of the internal combustion engine. ing.
The exhaust gas purification apparatus has a structure in which a casing is provided in an exhaust passage of an internal combustion engine, and an exhaust gas treatment body is disposed in the casing. Examples of the exhaust gas treating body include a catalyst carrier or a diesel particulate filter (DPF).

A holding sealing material is wound around the exhaust gas treating body and disposed in the casing. This holding sealing material prevents the exhaust gas treating body from being damaged by contact with the casing covering the outer periphery due to vibrations or impacts caused by traveling of an automobile or the like, and exhaust gas from between the exhaust gas treating body and the casing. Is disposed mainly for the purpose of preventing leakage.

As the exhaust gas treating body, a cylindrical one is often used, and usually there are many ones having a longer length in the longitudinal direction than the diameter.
However, depending on the purpose, an exhaust gas treatment body having a short length in the longitudinal direction may be used. Patent Document 1 discloses that the exhaust gas treatment body disposed upstream of the exhaust gas purification system is longer than its diameter. A catalyst support having a short directional length is disclosed.

International Publication No. 2008/126321

When wrapping the holding seal material around the exhaust gas treatment body, usually use a holding seal material whose width is shorter than the longitudinal length of the exhaust gas treatment body so that the holding seal material does not protrude from the end face of the exhaust gas treatment body. A wound body is produced. And a wound body is arrange | positioned in a casing by arrangement | positioning methods, such as a press injection method and a sizing method, and an exhaust gas purification apparatus is produced.

Here, when the holding sealing material is wound around the exhaust gas treatment body having a short length in the longitudinal direction as described in Patent Document 1, a holding sealing material having a width shorter than the length in the longitudinal direction of the exhaust gas treatment body is used. Since the width of the portion where the holding sealing material is in contact with the exhaust gas treating body is shortened, the exhaust gas treating body falls down when the wound body is disposed in the casing, and the work of disposing the wound body in the casing becomes difficult. It could be difficult.

The present invention has been made in view of the above-described problems, and when used by wrapping around an exhaust gas treatment body having a short length in the longitudinal direction, the work of disposing the wound body in the casing. An object of the present invention is to provide a holding sealing material capable of improving the properties.

In order to achieve the above object, the holding sealing material of the present invention comprises:
Holding seal material used by winding the longitudinal direction of the holding seal material around the side surface of a columnar exhaust gas treatment body whose length in the longitudinal direction is 10 to 60% of the diameter of the exhaust gas treatment body Because
In the plan view shape, the first long side and the second long side extending in the longitudinal direction of the holding sealing material, and the first long side and the second long side connected to each other and extending in the width direction are connected. A mat having a short side of 1 and a second short side and having a substantially rectangular thickness in plan view;
The first surface of the mat is provided with a raised portion that is thicker than other portions along the first long side and the second long side,
With the first surface of the mat facing the exhaust gas treatment body, the raised portion protrudes outward from the end surface of the exhaust gas treatment body, and the side surface of the raised portion covers the outer periphery of the end surface of the exhaust gas treatment body. It is characterized by being used by being wound around the exhaust gas treatment body so that parts other than the above-mentioned raised portions are in contact with the side surface of the exhaust gas treatment body.

In the holding sealing material of the present invention, the first surface of the mat is provided with a raised portion along the first long side and the second long side.
When the first surface, which is the surface provided with the raised portions, is wound around the exhaust gas treatment body toward the exhaust gas treatment body side, the raised portions protrude outward from the end surface of the exhaust gas treatment body, and the side surfaces of the raised portions are the exhaust gas treatment body. It can be set as the wound body which covered the outer periphery of the end surface of.
In such a wound body, since the raised portion is caught on the end face of the exhaust gas treating body, the exhaust gas treating body is prevented from falling when the wound body is disposed in the casing. Therefore, the workability of the work of arranging the wound body in the casing can be improved.
Further, even after the winding body is disposed in the casing, the exhaust gas treating body is unlikely to fall down in the casing.

In the holding sealing material of the present invention, the raised portion is one step thicker than a portion other than the raised portion in a band-like region having a width along the first long side and the second long side. A stepped shape is preferable.
Further, in the holding sealing material of the present invention, the raised portion is a direction away from the first long side or the second long side, with the first long side and the second long side being the thickest position. It is preferable that it is the inclination shape which becomes thin toward it.
When the shape of the raised portion is stepped or inclined, the exhaust gas treating body can be suitably prevented from falling when the wound body is disposed in the casing.

In the holding sealing material of the present invention, it is preferable that a width of the raised portion provided along each of the first long side and the second long side is 1 to 5 mm.
When the height of the raised portion is less than 1 mm, the raised portion is easily lost when the raised portion is caught on the end face of the exhaust gas treating body, so that the effect of providing the raised portion cannot be obtained.
Further, even if the width of the raised portion exceeds 5 mm, the effect of providing the raised portion does not change, and a useless space is required in the casing. And since the protruding part is not pressed down by the exhaust gas treating body, it easily scatters when the exhaust gas collides. Therefore, when the width of the raised portion is unnecessarily large, the amount of scattered fibers due to the collision of exhaust gas is large, and scattered fibers enter the exhaust gas treatment body, thereby reducing the effect of the exhaust gas treatment body.

In the holding sealing material of the present invention, the holding sealing material preferably has a width of 30 to 100 mm.
The holding sealing material having such a width is suitable for wrapping around an exhaust gas treating body having a shorter length in the longitudinal direction than usual. In addition, when the holding sealing material has a width of less than 30 mm, after being wound around the exhaust gas treatment body, when it is assembled to the exhaust gas treatment device, the frictional resistance between the holding seal material and the exhaust gas treatment device becomes small. The exhaust gas treating body is inclined. And if the width | variety of a holding | maintenance sealing material is larger than 100 mm, since an exhaust gas treatment body will also accompany and a dimension and weight will become large, it will be difficult to obtain the effect of a protruding part.

In the holding sealing material of the present invention, the thickness of the raised portion is preferably 1 to 5 mm thicker than the thickness of a portion other than the raised portion.
If the thickness of the raised portion is less than 1 mm thicker than the portion other than the raised portion, the raised portion is not sufficiently caught on the end face of the exhaust gas treatment body, and the effect of providing the raised portion may be difficult to obtain. is there.
On the other hand, if the thickness of the raised portion is more than 5 mm thicker than the portion other than the raised portion, the raised portion will block the end face of the exhaust gas treatment body, and the exhaust gas near the outer periphery of the exhaust gas treatment body Since processing efficiency falls, it is not preferable.

In the holding sealing material of the present invention, the holding sealing material is preferably made of a mat manufactured by a papermaking method.
A mat manufactured by a papermaking method is preferable because a raised portion is easily formed by punching with a Thomson blade. In general, a mat manufactured by a papermaking method is formed mainly by bonding of fibers by an organic binder, and the smaller the organic binder contained in the mat, the weaker the bonding of fibers. Therefore, it is preferable because it is easily deformed even after molding, and a raised portion is easily formed by punching with a Thomson blade. A mat called a needle mat strengthens the entanglement of fibers by needling treatment of the mat and maintains the moldability, so that a raised portion is hardly formed even by an external force by a Thomson blade.
Moreover, it is preferable that the average fiber diameter of the inorganic fiber which comprises a holding | maintenance sealing material is 6-10 micrometers, and does not contain the fiber of less than 3 micrometers of fiber diameters. Within this fiber diameter range, it is easy to form a holding sealing material while maintaining the strength of the raised portion.
If the average fiber diameter is smaller than 6 μm or contains fibers having a fiber diameter of less than 3 μm, the fiber strength is weak and the fibers are easily cut by impact or the like. On the other hand, if the average fiber diameter is larger than 10 μm, the fiber diameter becomes thick and the Young's modulus of the fiber itself becomes high, so that the raised portion is hardly formed.

The wound body of the present invention is a columnar exhaust gas treatment body in which the length in the longitudinal direction of the exhaust gas treatment body is 10 to 60% of the diameter of the exhaust gas treatment body,
A wound body composed of the holding sealing material of the present invention wound around the side surface of the exhaust gas treating body,
The holding sealing material has the first surface of the mat facing the exhaust gas treating body, the raised portion protrudes outward from the end surface of the exhaust gas treating body, and the side surface of the raised portion is the end surface of the exhaust gas treating body. The outer periphery of the exhaust gas treatment body is covered, and a portion other than the raised portion is wound around the exhaust gas treatment body so as to contact a side surface of the exhaust gas treatment body.

In the wound body of the present invention, since the side surface of the raised portion covers the outer periphery of the end surface of the exhaust gas treatment body, the exhaust gas treatment body is prevented from falling when the wound body is disposed in the casing. Even when it is used by being wound around an exhaust gas treating body having a short length, the workability of the work of arranging the wound body in the casing is improved.

The manufacturing method of the holding sealing material of the present invention is a method of manufacturing the holding sealing material of the present invention by punching a sheet-like inorganic fiber aggregate in the thickness direction with a Thomson blade,
The Thomson blade includes a punching blade and an elastic member arranged along the inner peripheral shape of the punching blade, and a gap through which the inorganic fiber aggregate can enter is provided between the punching blade and the elastic member. It is characterized by being.

In the case of the above method, the inorganic fiber aggregate enters the gap between the punching blade and the elastic member when the inorganic fiber aggregate is punched. And since the inorganic fiber aggregate that has entered the gap is not pressed between the elastic body during punching and does not become thin by punching, it is compared with other parts that are pressed in contact with the elastic member during punching. It becomes a thick part. And this part becomes a raised part and the holding sealing material which has a raised part is manufactured.

In the manufacturing method of the holding sealing material of the present invention, the width of the gap is preferably 2 to 10 mm.
When the width of the gap is 2 to 10 mm, the width of the raised portion formed by punching can be set to a preferable range. Moreover, it is preferable that the said clearance gap is large with respect to the width | variety of the protruding part to form. When the holding sealing material is punched out, the elastic member is deformed so as to reduce the gap. Therefore, if the gap is small, the inorganic fiber aggregate cannot enter the gap and the raised portion may not be formed.
If the width of the gap exceeds 10 mm, the pushing force of the elastic member to the mat is weak, so that the mat is not discharged from the gap between the punching blade and the elastic member after punching.

Fig.1 (a) is a perspective view which shows typically an example of the holding sealing material of this invention, and FIG.1 (b) is the sectional view on the AA line. Fig.2 (a) is a perspective view which shows typically an example of the holding sealing material of this invention from which the form of a protruding part differs, FIG.2 (b) is the BB sectional drawing. FIG. 3 is a top view schematically showing an example of another embodiment of the holding sealing material of the present invention. FIG. 4 is a top view schematically showing an example of another embodiment of the holding sealing material of the present invention. Fig.5 (a) is a perspective view which shows typically an example of the Thomson blade used for the punching of an inorganic fiber aggregate, and FIG.5 (b) is the CC sectional view taken on the line. FIG. 6A is a cross-sectional view schematically showing an example of a state before punching out an inorganic fiber assembly using a Thomson blade, and FIG. 6B shows an amorphous fiber assembly using a Thomson blade. FIG. 6C is a cross-sectional view schematically showing a state after the inorganic fiber aggregate is punched out using a Thomson blade. FIG. 7 is a perspective view schematically showing an example of the wound body of the present invention in which the holding sealing material shown in FIGS. 1A and 1B is wound around the side surface of the exhaust gas treating body. FIG. 8 is a cross-sectional view of the wound body shown in FIG. FIG. 9 is a perspective view schematically showing an example of the exhaust gas treating body constituting the wound body of the present invention. FIG. 10 is a perspective view schematically showing how the wound body of the present invention is press-fitted into the casing. FIG. 11 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus.

(Detailed description of the invention)
Hereinafter, the manufacturing method of the holding sealing material, the wound body, and the holding sealing material of the present invention will be specifically described. However, the present invention is not limited to the following configurations, and can be applied with appropriate modifications without departing from the scope of the present invention. Note that the present invention also includes a combination of two or more desirable configurations of the present invention described below.

First, the holding sealing material of the present invention will be described.
The holding sealing material of the present invention is
Holding seal material used by winding the longitudinal direction of the holding seal material around the side surface of a columnar exhaust gas treatment body whose length in the longitudinal direction is 10 to 60% of the diameter of the exhaust gas treatment body Because
In the plan view shape, the first long side and the second long side extending in the longitudinal direction of the holding sealing material, and the first long side and the second long side connected to each other and extending in the width direction are connected. A mat having a short side of 1 and a second short side and having a substantially rectangular thickness in plan view;
The first surface of the mat is provided with a raised portion that is thicker than other portions along the first long side and the second long side,
With the first surface of the mat facing the exhaust gas treatment body, the raised portion protrudes outward from the end surface of the exhaust gas treatment body, and the side surface of the raised portion covers the outer periphery of the end surface of the exhaust gas treatment body. It is characterized by being used by being wound around the exhaust gas treatment body so that parts other than the above-mentioned raised portions are in contact with the side surface of the exhaust gas treatment body.

Fig.1 (a) is a perspective view which shows typically an example of the holding sealing material of this invention, and FIG.1 (b) is the sectional view on the AA line.
The holding sealing material 1 is a mat having a first surface 11 and a second surface 12, and includes a first long side 21 and a second long side extending in the longitudinal direction (the direction indicated by the double arrow a in FIG. 1A). The mat has a substantially rectangular shape in plan view, which has a long side 22 and a first short side 31 and a second short side 32 that connect the first long side 21 and the second long side 22, respectively.
Both the first long side 21 and the second long side 22 are parallel to the longitudinal direction of the holding sealing material 1.

The first short side 31 is a side connecting the first long side 21 and the second long side 22, but is a side defined as an aggregate of a plurality of sides. Reference numerals 31a, 31b, and 31c Let the connected side be the first short side 31. The second short side 32 is a side connecting the first long side 21 and the second long side 22 and is a side defined as an aggregate of a plurality of sides. Reference numerals 32a, 32b, and The side connecting 32c is defined as a first short side 32.

The holding sealing material 1 has such a shape that the first short side 31 and the second short side 32 are just fitted to each other when the holding sealing material 1 is wound around the exhaust gas treating body.
The holding sealing material of the present invention is a mat having a substantially rectangular shape in plan view, but the “substantially rectangular shape in plan view” includes a portion where the first short side 31 and the second short side 32 are fitted. It is a concept.

On the first surface 11 of the mat, a raised portion 41 is provided along the first long side 21, and a raised portion 42 is provided along the second long side 22.
The raised portion is a portion that is thicker than other portions.
The raised portions shown in FIGS. 1 (a) and 1 (b) are one step thicker than the portions other than the raised portions in the band-like region having a width along the first long side and the second long side. It has a stepped shape.
As shown in FIG. 1B, when the thickness T of the raised portion is set, T> t with respect to the thickness t of a portion other than the raised portion.

Fig.2 (a) is a perspective view which shows typically an example of the holding sealing material of this invention from which the form of a protruding part differs, FIG.2 (b) is the BB sectional drawing.
In the holding sealing material 2 shown in FIG. 2A and FIG. 2B, the raised portions 51 and 52 have the first long side with the first long side 21 or the second long side 22 being the thickest position. 21 or the second long side 22 is inclined so as to become thinner in the direction away from it.
As shown in FIGS. 2A and 2B, the raised portion 51 has an inclined shape that becomes thinner toward the direction away from the first long side 21 with the first long side 21 being the thickest position. The raised portion 52 is inclined so that the second long side 22 becomes the thickest position and becomes thinner in the direction away from the second long side 22.

In the holding sealing material of the present invention, the thickness of the raised portion is preferably 1 to 5 mm thicker than the thickness of the portion other than the raised portion.
If the thickness of the raised portion is less than 1 mm thicker than the portion other than the raised portion, the raised portion is not sufficiently caught on the end face of the exhaust gas treatment body, and the effect of providing the raised portion may be difficult to obtain. is there.
On the other hand, if the thickness of the raised portion is more than 5 mm thicker than the portion other than the raised portion, the raised portion will block the end face of the exhaust gas treatment body, and the exhaust gas near the outer periphery of the exhaust gas treatment body Since processing efficiency falls, it is not preferable.
The thickness of the raised portion is a thickness (a constant value) indicated by a double-headed arrow T in the case of a stepped raised portion as shown in FIG. In the case of an inclined ridge as shown in FIG. 2B, the thickness is defined as the thickness at the first long side or the thickness at the second long side (thickness indicated by a double-headed arrow T).
The thickness of the portion other than the raised portion is the thickness indicated by the double-headed arrow t in FIGS. 1B and 2B, and is a constant value in either case.
That is, it is preferable that the thickness determined by “Tt” in FIGS. 1B and 2B is 1 to 5 mm.
Moreover, as for thickness t of parts other than a protruding part, it is desirable that it is 5-15 mm.

The width of the raised portion is preferably 1 to 5 mm.
The width of the raised portion is a length represented by a double-headed arrow D from the first long side or the second long side toward the inside of the mat in FIGS. 1 (b) and 2 (b).
In the case of an inclined ridge as shown in FIG. 2B, the length from the rising position of the inclination to the first long side or the second long side (indicated by a double-headed arrow D in FIG. 2B). Is defined as the width of the raised portion.
When the height of the raised portion is less than 1 mm, the raised portion is easily lost when the raised portion is caught on the end face of the exhaust gas treating body, so that the effect of providing the raised portion cannot be obtained.
Moreover, even if the width of the raised portion is increased beyond 5 mm, the effect of providing the raised portion does not change, and a useless space is required in the casing. And since the protruding part is not pressed down by the exhaust gas treating body, it easily scatters when the exhaust gas collides. Therefore, when the width of the raised portion is unnecessarily large, the amount of scattered fibers due to the collision of exhaust gas is large, and scattered fibers enter the exhaust gas treatment body, thereby reducing the effect of the exhaust gas treatment body.

It is preferable that the raised portion is formed over the entire length of the holding sealing material along the first long side and along the second long side. If there is a portion where the raised portion is not provided, a strong force may be applied to the boundary with the portion where the raised portion is provided. However, in order to be able to suppress the exhaust gas treating body from falling down, it may have a portion where a raised portion is not provided in a part in the longitudinal direction of the holding sealing material within a range where there is no problem. In this case, since wrinkles are prevented from occurring in the raised portion during winding, the workability of winding is improved.

The holding sealing material preferably has a width of 30 to 100 mm.
The width of the holding sealing material is the width indicated by the double-headed arrow W in FIGS. 1 (a), 1 (b), 2 (a) and 2 (b). This width corresponds to the length in the longitudinal direction of the exhaust gas treatment body to be wound, and is assumed as an object to be wound with the exhaust gas treatment body whose length in the longitudinal direction is shorter than usual.
Further, as described later, when the holding sealing material is wound around the exhaust gas treating body, it is preferable that the raised portion protrudes outside the end surface of the exhaust gas treating body, so that the width of the raised portion ( It is preferable that the width (W−D × 2) excluding the two widths of the raised portion coincides with the length in the longitudinal direction of the exhaust gas treating body to be wound.

The holding sealing material of the present invention is preferably made of a mat containing inorganic fibers. The inorganic fibers constituting the mat are not particularly limited, and may be alumina-silica fibers, alumina fibers, silica fibers, or the like. Moreover, glass fiber and biosoluble fiber may be sufficient. What is necessary is just to change according to the characteristics requested | required of mat | matte, such as heat resistance and wind erosion resistance, and it is preferable to use the thing of the large diameter fiber and fiber length which can be adapted to the environmental regulation 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 compound are more preferable. A highly crystalline alumina material is hard and brittle, so it is not suitable for a mat used as a cushioning material.
Further, since the cushioning property is poor, there is a possibility that the end portion of the exhaust gas treating body is damaged by fibers and is lost.

Further, in the case of an inorganic fiber containing a low crystalline alumina material and a spinel type compound, the crystallization ratio is preferably in the range of 0.1 to 30%, and more preferably in the range of the crystallization rate of 0.4 to 20%. Mats made of inorganic fibers in this range have a high repulsive force and a high restoration surface pressure after a durability test, and have good performance. However, when the crystallization ratio is less than 0.1% or exceeds 30%, the repulsive force and the restoring surface pressure are rapidly decreased. The method for measuring the crystallization rate can be calculated from the integral intensity ratio of the mullite diffraction line (2θ = 26.4 °) and the γ-alumina diffraction line (2θ = 45.4 °).

The mat constituting the holding sealing material can be obtained by various methods. For example, the mat can be produced by a needling method or a papermaking method. In particular, a mat obtained by a papermaking method is preferable.

The average fiber length of the inorganic fibers constituting the mat obtained by the papermaking method is preferably 0.1 to 20 mm, more preferably 0.2 to 10 mm, and more preferably 0.3 to 3.0 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 when the mat-like fiber aggregate is formed, suitable entanglement between the fibers does not occur, and sufficient surface pressure is obtained. It becomes difficult. In addition, 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 fibers in the slurry solution in which the fibers are dispersed in water in the paper making process becomes too strong. When it is set as an aggregate, the fibers are likely to be accumulated unevenly.
The fiber length is measured using tweezers so that the fiber is not broken from the mat, and the fiber length is measured using an optical microscope. Here, the average fiber length is determined by extracting 300 fibers and measuring the fiber length. If the fibers cannot be pulled out without breaking the fibers from the mat, the mat is degreased, the degreased mat is put into water, and the fibers are collected so as not to break while loosening the fibers.

Further, the weight per unit area of the holding sealing material (weight per unit area) is not particularly limited, is preferably a 200~4000g / ^{m 2,} and more desirably 1000 to 3000 g / ^{m 2.} When the basis weight of the holding sealing material is less than 200 g / m ² , the holding force is not sufficient, and when the basis weight of the holding sealing material exceeds 4000 g / m ² , the bulk of the holding sealing material is difficult to decrease. Therefore, when manufacturing an exhaust gas purification apparatus using such a holding sealing material, the exhaust gas treating body is likely to drop off.

FIG. 3 is a top view schematically showing an example of another embodiment of the holding sealing material of the present invention.
The holding sealing material 3 shown in FIG. 3 is provided with a convex portion 13 and a concave portion 14 that are fitted to each other when wound around the exhaust gas treating body.
A raised portion 61 is provided along the first long side 21, and a raised portion 62 is provided along the second long side 22.

FIG. 4 is a top view schematically showing an example of another embodiment of the holding sealing material of the present invention.
In the holding sealing material 4 shown in FIG. 4, in addition to the raised portion 71 along the first long side 21 and the raised portion 72 along the second long side 22, the raised portion along the first short side 31. 73 and the raised portion 74 along the second short side 32 are formed, and the raised portion is provided on the entire outer periphery of the mat constituting the holding sealing material 4. When the raised portion is provided along the short side, the resistance to the exhaust gas treating body increases due to the irregularities on the short side, so that the exhaust gas treating body can be made difficult to fall during the installation work.

Also in the holding sealing material of the form shown in FIGS. 3 and 4, the form of the raised portion may be the step shown in FIGS. 1 (a) and 1 (b), or FIG. 2 (a) and FIG. It may be inclined as shown in 2 (b). Further, the preferable thickness and width of the raised portion can be the same as described above.

Next, the manufacturing method of the holding sealing material of this invention is demonstrated.
The manufacturing method of the holding sealing material of the present invention is a method of manufacturing the holding sealing material of the present invention by punching a sheet-like inorganic fiber aggregate in the thickness direction with a Thomson blade,
The Thomson blade includes a punching blade and an elastic member arranged along the inner peripheral shape of the punching blade, and a gap through which the inorganic fiber aggregate can enter is provided between the punching blade and the elastic member. It is characterized by being.

As the sheet-like inorganic fiber aggregate, a conventionally known inorganic fiber aggregate composed of the above-described inorganic fibers can be preferably used, and an inorganic fiber aggregate obtained by a papermaking method can be preferably used. .

In the case of the paper making method, the inorganic fiber is produced by spinning the spinning solution, firing and fiberizing, and then the inorganic fiber contains the organic binder, water, and the content of the inorganic fiber in the raw material liquid at a predetermined value. And a mixture is prepared by stirring with a stirrer. The mixed solution may contain a colloidal solution made of a polymer compound or a resin as necessary. Then, after pouring a liquid mixture into the molding machine with which the mesh for filtration was formed in the bottom face, the raw material sheet | seat is produced by dehydrating the water in a liquid mixture through a mesh. Then, an inorganic fiber aggregate is produced by heat-compressing and drying the raw material sheet under predetermined conditions.
You may add an inorganic binder etc. to a liquid mixture as needed.
The organic binder is not particularly limited, and is water-soluble organic polymer such as acrylic resin, acrylate latex, rubber latex, carboxymethyl cellulose or polyvinyl alcohol, thermoplastic resin such as styrene resin, thermosetting such as epoxy resin. Examples thereof include resins.
The inorganic binder is not particularly limited, and examples thereof include alumina sol and silica sol.

Fig.5 (a) is a perspective view which shows typically an example of the Thomson blade used for the punching of an inorganic fiber aggregate, and FIG.5 (b) is the CC sectional view taken on the line.
A Thomson blade 200 shown in FIG. 5A includes a punching blade 220 having a shape corresponding to the shape of the holding sealing material manufactured by punching, an outer elastic member 230 disposed along the outer peripheral shape of the punching blade 220, and a punching blade. The inner elastic member 240 is disposed along the inner peripheral shape of 220, and the punching blade 220, the outer elastic member 230, and the inner elastic member 240 are fixed to the substrate 210, respectively.

The height of the punching blade is preferably lower than the height of the elastic member. When the punching is not performed, the cutting edge of the punching blade does not protrude from the elastic member, so that the cutting edge is prevented from being damaged or the operator from being injured by touching the cutting edge.
When punching is performed, the elastic member is compressed and the thickness is reduced, so that the cutting edge pops out to contact and cut the inorganic fiber joined body to be cut.

There is a gap between the punching blade 220 and the inner elastic member 240 on the surface on the side where the cutting edge of the punching blade 220 is in contact with the inorganic fiber assembly (the surface opposite to the substrate 210). In FIG. 5B, this gap is indicated by a double arrow d.
The width of the gap between the punching blade and the elastic member is preferably 2 to 10 mm. When the gap having such a width is provided, a raised portion having a preferable width can be formed by punching.
Here, the width of the gap between the punching blade and the elastic member means the width of the gap between the punching blade and the inner elastic member.

As a member constituting the Thomson blade, the base material is preferably a plate material such as a plywood board. The elastic member is preferably a member having elasticity such as natural rubber, urethane rubber or rubber sponge.
As punching blades, use steels such as carbon steel, stainless steel, molybdenum steel, special steel (alloy steel), alloys such as cobalt alloy (stellite) and titanium alloy, and fine ceramics such as zirconia and alumina. Can do. Further, the Thomson blade is preferably a single blade, and the cut surface of the inorganic fiber aggregate can be made straight compared to the double blade.

FIG. 6A is a cross-sectional view schematically showing an example of a state before punching out an inorganic fiber assembly using a Thomson blade, and FIG. 6B shows an amorphous fiber assembly using a Thomson blade. FIG. 6C is a cross-sectional view schematically showing a state after the inorganic fiber aggregate is punched out using a Thomson blade.

As shown in FIG. 6A, when the lower surface of the Thomson blade 200 (the surface opposite to the substrate 210) is arranged toward the inorganic fiber assembly 80, and the Thomson blade 200 is pressed against the inorganic fiber assembly 80, the elasticity The members (the inner elastic member 240 and the outer elastic member 230) are compressed to reduce the thickness. When the cutting edge of the punching blade 220 comes into contact with the inorganic fiber assembly 80 and further presses the Thomson blade 200, the punching blade 220 penetrates the inorganic fiber assembly 80 as shown in FIG. Cut 80. As a result, the holding sealing material 1 having a predetermined shape is manufactured as shown in FIG.
Here, since there is a gap between the punching blade 220 and the inner elastic member 240, a part of the inorganic fiber aggregate 80 enters the gap during punching.
The inorganic fiber aggregate that has entered the gap is not pressed between the elastic member during punching and does not become thin by punching. Therefore, the inorganic fiber aggregate is thicker than other parts pressed against the elastic member during punching. It becomes a thick part. And this part becomes the raised parts 41 and 42, and the holding sealing material which has a raised part is manufactured.
At this time, the surface roughness Rz of the side surface of the Thomson blade (the surface where the cut surface of the inorganic fiber assembly is in contact with the Thomson blade when the blade edge penetrates the inorganic fiber assembly) is in the range of 10 to 50. desirable. Further, the surface roughness Rz is preferably in the range of 20 to 40, and more preferably in the range of 25 to 35. When the frictional resistance between the inorganic fiber aggregate and the side surface of the Thomson blade is large, the cut surface of the inorganic fiber aggregate is turned up to make it easy to form a raised portion. Here, when Rz is smaller than 10, the frictional resistance with the inorganic fiber aggregate is small, so that the raised portion cannot be easily formed. On the other hand, if Rz is larger than 50, the strength of the Thomson blade itself is reduced, and it is bent and bent. The surface roughness of the Thomson blade can be adjusted by acid treatment or blast treatment.

Next, the wound body of the present invention will be described.
The wound body of the present invention is a columnar exhaust gas treatment body in which the length in the longitudinal direction of the exhaust gas treatment body is 10 to 60% of the diameter of the exhaust gas treatment body,
A wound body composed of the holding sealing material of the present invention wound around the side surface of the exhaust gas treating body,
The holding sealing material has the first surface of the mat facing the exhaust gas treating body, the raised portion protrudes outward from the end surface of the exhaust gas treating body, and the side surface of the raised portion is the end surface of the exhaust gas treating body. The outer periphery of the exhaust gas treatment body is covered, and a portion other than the raised portion is wound around the exhaust gas treatment body so as to contact a side surface of the exhaust gas treatment body.

FIG. 7 is a perspective view schematically showing an example of the wound body of the present invention in which the holding sealing material shown in FIGS. 1A and 1B is wound around the side surface of the exhaust gas treating body.
FIG. 8 is a cross-sectional view of the wound body shown in FIG.
The wound body 140 shown in FIG. 7 is formed by winding the holding sealing material 1 shown in FIGS. 1A and 1B around the side surface of the exhaust gas treatment body 120, and the first holding sealing material 1 is wound. The first short side 31 and the second short side 32 are just fitted to each other.

The raised portions 41 and 42 of the holding sealing material 1 protrude outward from the exhaust gas inflow side end surface 120a and the exhaust gas outflow side end surface 120b of the exhaust gas treatment body 120. The side surface 41a of the raised portion 41 covers the outer periphery of the exhaust gas inflow side end surface 120a of the exhaust gas treatment body 120, and the side surface 42a of the ridge portion 42 covers the outer periphery of the exhaust gas outflow side end surface 120b of the exhaust gas treatment body 120. ing.
And the site | parts other than the protruding parts 41 and 42 of the holding sealing material 1, ie, the 1st surface 11 of the holding sealing material 1, are wound so that the side surface 129 (refer FIG. 9) of the waste gas processing body 120 may contact.

As described above, the side surface 41a of the raised portion 41 of the holding sealing material 1 and the side surface 42a of the raised portion 42 cover the outer periphery of the exhaust gas inflow side end surface 120a and the exhaust gas outflow side end surface 120b of the exhaust gas treating body, respectively. The exhaust gas treatment body 120 is prevented from falling when the wound body 140 is disposed.

Further, when the holding sealing material 1 is manufactured by cutting the inorganic fiber aggregate, the side faces 41b and 42b positioned opposite to the side faces 41a and 42a of the raised portion of the holding sealing material 1 are cut off from the inorganic fiber aggregate. Sometimes the surface of the inorganic fiber aggregate is turned over and the inner part of the surface is exposed.
The surface exposed by the cutting of the inorganic fiber aggregate is partially scraped off the binder (inorganic binder, organic binder) attached to the surface of the inorganic fiber at the time of cutting, so that the amount of binder attached is exposed by cutting. The surface is relatively less than the non-finished surfaces (the first surface and the second surface of the mat), and the surface becomes easy to bend. Therefore, when the holding sealing material is wound so that the raised portion covers the outer periphery of the end surface of the exhaust gas treating body, wrinkles are prevented from occurring in the raised portion.

FIG. 9 is a perspective view schematically showing an example of the exhaust gas treating body constituting the wound body of the present invention.
The exhaust gas treatment body 120 shown in FIG. 9 is a honeycomb structure made of a columnar ceramic material in which a large number of cells 125 are provided side by side with cell walls 126 therebetween. One end of each cell 125 is sealed with a sealing material 128. In addition, an outer peripheral coat layer 127 is provided on the outer periphery of the honeycomb structure for the purpose of reinforcing the outer peripheral portion of the honeycomb structure, adjusting the shape, and improving the heat insulation of the honeycomb structure.
Note that the surface provided with the outer peripheral coat layer 127 is the side surface 129 of the honeycomb structure.

As the dimension of the exhaust gas treatment body, the length in the longitudinal direction of the exhaust gas treatment body (the length indicated by the double arrow b in FIG. 9) is the diameter of the exhaust gas treatment body (the length indicated by the double arrow c in FIG. 9). 10-60%. It is preferably 20 to 50% of the diameter, and more preferably 25 to 45% of the diameter. When the length in the longitudinal direction is less than 10% of the diameter, there is a possibility that the exhaust gas treating body may be destroyed due to buckling when the exhaust gas treating body is disposed in the casing. In addition, when the length in the longitudinal direction is larger than 60% of the diameter, when the exhaust gas treatment body is disposed in the casing, the possibility that the exhaust gas treatment body falls is small, and it is difficult to obtain the effect of providing the raised portion. .

When either end of the cell 125 is sealed, when viewed from one end of the exhaust gas treating body 120, the cells whose end are sealed and the cells that are not sealed are alternately arranged. It is desirable that

The cross-sectional shape obtained by cutting the exhaust gas treatment body in a direction perpendicular to the longitudinal direction is not particularly limited, and may be a substantially circular shape or a substantially oval shape, or a substantially polygonal shape such as a substantially triangular shape, a substantially square shape, a substantially pentagonal shape, or a substantially hexagonal shape. May be.

The cross-sectional shape of the cell 125 constituting the exhaust gas treating body may be a substantially polygonal shape such as a substantially triangular shape, a substantially square shape, a substantially pentagonal shape, or a substantially hexagonal shape, or may be a substantially circular shape or a substantially elliptical shape. Further, the exhaust gas treating body 120 may be a combination of cells having a plurality of cross-sectional shapes.

The material constituting the exhaust gas treating body is not particularly limited, and non-oxides such as silicon carbide and silicon nitride, and oxides such as cordierite and aluminum titanate can be used. Of these, non-oxide porous fired bodies such as silicon carbide or silicon nitride are particularly desirable.
Since these porous fired bodies are brittle materials, they are easily broken by a mechanical impact or the like. However, by wrapping the holding sealing material around the side surface of the exhaust gas treatment body, it becomes easy to absorb the impact, so that it is possible to prevent the exhaust gas treatment body from being cracked by a mechanical impact or thermal shock. .

The exhaust gas treating body may carry a catalyst for purifying exhaust gas. As the catalyst to be carried, for example, a noble metal such as platinum, palladium, rhodium or the like is desirable, and among these, platinum is more desirable. In addition, as other catalysts, for example, alkali metals such as potassium and sodium, and alkaline earth metals such as barium can be used. These catalysts may be used alone or in combination of two or more. When these catalysts are supported, it is easy to burn and remove PM, and toxic exhaust gas can be purified.

The exhaust gas treatment body may be an integrally formed honeycomb structure made of cordierite or the like, or may be made of silicon carbide or the like, and a large number of through holes may be arranged in the longitudinal direction with partition walls therebetween. It may be a collective honeycomb structure formed by binding a plurality of provided columnar honeycomb fired bodies mainly through a paste containing ceramic.

In the exhaust gas treating body, the end portion of the cell may not be sealed without providing the cell with the sealing material. In this case, the exhaust gas treating body functions as a catalyst carrier that purifies harmful gas components such as CO, HC, or NOx contained in the exhaust gas by supporting a catalyst such as platinum.

FIG. 10 is a perspective view schematically showing how the wound body of the present invention is press-fitted into the casing.
FIG. 10 schematically shows a state where the wound body 140 is press-fitted into the casing 130.
When press-fitting the wound body of the present invention into the casing, a press-fitting jig may be used. When using a press-fitting jig, prepare a press-fitting jig whose inside expands in a tapered shape from the short-diameter end to the long-diameter end, and fit the short-diameter end of the press-fitting jig into one end of the casing. And press-fitting can be performed by pushing the wound body from the long-diameter side end of the press-fitting jig.

The material of the casing is not particularly limited as long as it is a metal having heat resistance, and specific examples include metals such as stainless steel, aluminum, and iron.
Moreover, as for the shape of the casing, a clamshell shape, a substantially elliptical shape, a substantially polygonal shape, etc. can be suitably used in addition to the substantially cylindrical shape.

In the wound body of the present invention, since the raised portion is caught on the end face of the exhaust gas treatment body, the exhaust gas treatment body is prevented from falling when the wound body is disposed in the casing. Therefore, the workability of the work of arranging the wound body in the casing can be improved.
Further, even after the winding body is disposed in the casing, the exhaust gas treating body is unlikely to fall down in the casing.

Next, an exhaust gas purification device manufactured using the wound body of the present invention will be described.
FIG. 11 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus.
As shown in FIG. 11, the exhaust gas purifying apparatus 100 includes a metal casing 130, an exhaust gas treatment body 120 accommodated in the metal casing 130, and a holding sealing material 1 disposed between the exhaust gas treatment body 120 and the metal casing 130. And.
In the exhaust gas purification apparatus 100 shown in FIG. 11, the holding sealing material 1 is the holding sealing material of the present invention.
The exhaust gas treatment body 120 has a columnar shape in which a large number of cells 125 are arranged in parallel in the longitudinal direction with a cell wall 126 therebetween. Note that an end of the metal casing 130 is connected to 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 purification device to the outside, if necessary. It will be.

A case where exhaust gas passes through the exhaust gas purifying apparatus 100 having the above-described configuration will be described below with reference to FIG.
As shown in FIG. 11, the exhaust gas discharged from the internal combustion engine and flowing into the exhaust gas purification apparatus 100 (in FIG. 11, the exhaust gas is indicated by G and the flow of the exhaust gas is indicated by an arrow) is an exhaust gas treatment body (honeycomb filter) 120. Flows into one cell 125 opened in the exhaust gas inflow side end face 120 a and passes through the cell wall 126 separating the cells 125. At this time, PM in the exhaust gas is collected by the cell wall 126, and the exhaust gas is purified. The purified exhaust gas flows out from another cell 125 opened in the exhaust gas outflow side end face 120b and is discharged to the outside.

Below, the effect of the manufacturing method of the holding sealing material of this invention, a wound body, and a holding sealing material is demonstrated.

(1) In the holding sealing material of the present invention, a raised portion is provided on the first surface of the mat along the first long side and the second long side.
When the first surface, which is the surface provided with the raised portions, is wound around the exhaust gas treatment body toward the exhaust gas treatment body side, the raised portions protrude outward from the end surface of the exhaust gas treatment body, and the side surfaces of the raised portions are the exhaust gas treatment body. It can be set as the wound body which covered the outer periphery of the end surface of.
In such a wound body, since the raised portion is caught on the end face of the exhaust gas treating body, the exhaust gas treating body is prevented from falling when the wound body is disposed in the casing. Therefore, the workability of the work of arranging the wound body in the casing can be improved.
Further, even after the winding body is disposed in the casing, the exhaust gas treating body is unlikely to fall down in the casing.

(2) In the manufacturing method of the holding sealing material of the present invention, a sheet-like inorganic fiber aggregate is punched in the thickness direction with a Thomson blade. The Thomson blade includes a punching blade and an elastic member arranged along the inner peripheral shape of the punching blade, and a gap through which the inorganic fiber aggregate can enter is provided between the punching blade and the elastic member. Is formed.
In the case of the above method, the inorganic fiber aggregate enters the gap between the punching blade and the elastic member when the inorganic fiber aggregate is punched. And since the inorganic fiber aggregate that has entered the gap is not pressed between the elastic body during punching and does not become thin by punching, it is compared with other parts that are pressed in contact with the elastic member during punching. It becomes a thick part. And this part becomes a raised part and the holding sealing material which has a raised part is manufactured.

(Example)
Examples in which the present invention is disclosed more specifically are shown below. In addition, this invention is not limited only to these Examples.

Example 1
(Inorganic fiber preparation process)
First, an inorganic fiber to be opened in the opening process was produced.
Silica sol is blended with the basic aluminum chloride aqueous solution so that the composition ratio in the inorganic fiber after firing becomes Al ₂ O ₃ : SiO ₂ = 72: 28 (weight ratio), and further an organic polymer (polyvinyl chloride). An appropriate amount of (alcohol) was added to prepare a mixed solution.
The obtained mixed solution was concentrated to obtain a spinning mixture, and the spinning mixture was spun by a blowing method to prepare an inorganic fiber precursor. Subsequently, this inorganic fiber precursor was fired to produce inorganic fibers.

(A) Fiber opening step Next, the inorganic fibers were put into water and stirred using a pulper, whereby the inorganic fibers were stirred and shortened.

(B) Slurry preparation step A generally commercially available acrylic latex solution in which an acrylic resin is dispersed in water is added to the solution of the inorganic fibers obtained in the (a) fiber opening step and stirred. Thus, a slurry was prepared.

(C) the papermaking process □ 500 mm using a Tappi type papermaking machine, by papermaking the slurry, basis weight (weight per unit area) to obtain an inorganic fiber aggregate 1605 g / m ^2.

(D) Drying process The inorganic fiber aggregate was dried to a thickness of 10 mm by heat-treating the resulting inorganic fiber aggregate in a compressed state using a press dryer.

(E) Punching process A Thomson blade having the form shown in FIG. 5A was prepared as a Thomson blade. This is made by attaching an elastic member made of natural rubber to a plywood plate and fixing a punching blade made of carbon steel. A gap of 5 mm is provided between the punching blade and the inner elastic member. Further, the height of the punching blade is 17 mm, and the thickness of the elastic member (both the inner elastic member and the outer elastic member) is 20 mm. Therefore, when the punching is not performed, the cutting edge of the punching blade protrudes from the elastic member. Absent.
Using this Thomson blade, an inorganic fiber aggregate was punched out to produce a holding sealing material. As a result, raised portions having a width of 5 mm were formed along the first long side and the second long side. The raised portion is a stepped raised portion that is one step thicker than the portion other than the raised portion, and the thickness of the raised portion is 1 to 2 mm thicker than the portion other than the raised portion.

1, 2, 3, 4 Holding sealing material 11 1st surface 12 2nd surface 21 1st long side 22 2nd long side 31 1st short side 32 2nd short side 41, 42, 51, 52, 61, 62, 71, 72, 73, 74 Raised portion 80 Inorganic fiber aggregate 120 Exhaust gas treatment body 120a Exhaust gas treatment body exhaust gas inflow side end face 120b Exhaust gas treatment body exhaust gas outflow side end face 129 Exhaust gas treatment body side surface 140 Wound body 200 Thomson blade 220 Punching blade 230 Outer elastic member 240 Inner elastic member

Claims (2)

A method of manufacturing a Riho lifting sealant by the punching of the sheet-shaped inorganic fiber aggregate in the thickness direction by the Thompson blade,
The Thomson blade includes a punching blade and an elastic member disposed along the inner peripheral shape of the punching blade, and a gap through which the inorganic fiber aggregate can enter is provided between the punching blade and the elastic member. A method for producing a holding sealing material, comprising: The method for manufacturing a holding sealing material according to claim 1 , wherein a width of the gap is 2 to 10 mm.

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