JP7115907B2 - Holding seal material, method for manufacturing holding seal material, and exhaust gas purifier - Google Patents

Description

TECHNICAL FIELD The present invention relates to a holding seal material, a method for manufacturing the holding seal material, and an exhaust gas purification apparatus.

The holding sealing material is used to hold a catalyst carrier or an exhaust filter carrier that purifies exhaust gas from automobiles or exhaust gas when coal or heavy oil is burned in an exhaust pipe or to seal the exhaust gas. . The holding sealing material has, for example, the shape of a mat.

In recent years, a design method has also been adopted in which the thickness of the holding seal material is increased in order to improve the heat retention performance at the location where the holding seal material is applied. In such a holding sealing material, in order to secure the repulsive force of the inorganic fibers, which is a factor of the holding force, it is necessary to increase the weight per unit area of the holding sealing material.

As one of techniques for addressing the above, for example, Patent Document 1 discloses a holding seal material that is made heavier by combining a plurality of mats constituting the holding seal material.

JP 2009-264186 A

In a conventional holding sealing material, a plurality of mats are fixed to each other by a binding portion formed by sewing. However, in such a configuration, since the plurality of mats are fixed together by the binding portion, the mats cannot move in the longitudinal direction relative to each other. Therefore, if the positions of the mats are misaligned, it is difficult to finely adjust the relative positions of the mats. There is

Accordingly, the present invention provides a holding sealing material that ensures excellent winding performance even with a holding sealing material in which a plurality of mats are laminated, a method for manufacturing the holding sealing material, and an exhaust gas purifying apparatus.

The holding sealing material of the present invention comprises: a first mat having a first surface and a second surface facing the first surface; and a second mat laminated on the second surface of the first mat. 2 mats, wherein a plurality of cuts are provided from the first surface toward the second surface, and the plurality of cuts extend from the first surface to the A first cut extending toward the second surface and extending halfway through the thickness of the first mat; and a second cut provided to reach an intermediate position.

As one aspect of the holding sealing material of the present invention, for example, the cut is formed so as to draw a convex portion in the main surface of the holding sealing material, and at least part of the convex portion is formed by the first cut. be done.

The exhaust gas purifying apparatus of the present invention comprises a casing, an exhaust gas treating body housed in the casing, and a holding sealing material wound around the exhaust gas treating body and disposed between the exhaust gas treating body and the casing. , and the holding sealing material is wound around the exhaust gas treating body so that the second mat is disposed inside.

In the method for manufacturing a holding sealing material of the present invention, a first sheet and a second sheet are laminated and fixed, and a punched plate having a plate-shaped punching blade projecting in the vertical direction is formed on the first sheet. A holding sealing material manufacturing method for manufacturing a holding sealing material that is a laminate of a first mat punched from the first sheet and a second mat punched from the second sheet by pressing from the side of The punching blade includes a first punching blade, a second punching blade having a height smaller than that of the first punching blade, and a height smaller than that of the first punching blade. A third punching blade having a height greater than that of the second punching blade, wherein the first punching blade penetrates the first sheet and the second sheet to form the outer shape of the holding sealing material. is punched, the second punching blade forms a first cut reaching from the surface of the first sheet to an intermediate position in the thickness of the first sheet, and the third punching blade is A second cut is formed that penetrates the first sheet and reaches an intermediate position in the thickness of the second sheet.

In the holding sealing material of the present invention, since the first mat and the second mat are provided with cuts, when the holding sealing material is wound around the exhaust gas treating body, the cuts are widened to provide excellent winding performance and good workability. can be ensured. In addition, the holding sealing material can be tightly wound around the exhaust gas purifying apparatus of the present invention, so that the exhaust gas can be prevented from leaking while ensuring the productivity of the exhaust gas purifying apparatus. A desired holding seal material with stable quality can be manufactured by the method for manufacturing a holding seal material of the present invention.

1 is a perspective view schematically showing a holding sealing material according to one embodiment of the present invention; FIG. 1 is a perspective view showing an example of a state in which a holding sealing material according to the present invention is wound around an exhaust gas purifying device; FIG. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows an example of a first embodiment of a gap provided in a holding sealing material according to the present invention, (a) a partial cross-sectional view, and (b) a cross-sectional view wound around an exhaust gas treating body. An example of the 2nd Embodiment of the cut|interruption provided in the holding sealing material which concerns on this invention is shown, (a) partial sectional drawing, (b) sectional drawing wound around the exhaust gas processing body. An example of a third embodiment of a cut provided in a holding sealing material according to the present invention is shown, (a) perspective view, (b) AA cross-sectional view of (a), (c) B of (a) -B sectional view. 8A and 8B are perspective views showing the arrangement state of a third embodiment of cuts provided in the holding sealing material according to the present invention, (a) Example 1, (b) Example 2, and (c) Example 3; 1 shows an example of a method for manufacturing a holding sealing material according to the present invention, including (a) a schematic diagram showing a joining state of sheets, (b) a cross-sectional view of a joint by adhesive, and (c) a cross-sectional view of a joint by stitching. An example of a punching plate used for manufacturing a holding sealing material according to the present invention is shown, (a) a perspective view, (b) a perspective view of a punching blade surrounded by part A in (a), (c) a punching plate. The schematic diagram which shows the difference of the height of a extraction blade.

FIG. 1 is a perspective view schematically showing a holding sealing material according to one embodiment of the present invention. The holding sealing material will be described in detail based on FIG.

The holding sealing material 10 according to the present embodiment has a predetermined length in the longitudinal direction X, width in the width direction Y, and thickness. , and a joint portion 40 that joins the first mat 20 and the second mat 30 . The holding sealing material 10 has a laminate structure of the first mat 20 and the second mat 30 .

The first mat 20 has a first surface 21 and a second surface 22 facing the first surface 21 . At least one cut 23 is provided in the first mat 20 from the first surface 21 toward the second surface 22 so as to reach at least halfway through the thickness of the first mat 20. . In this embodiment, two cuts 23 are provided, but the shape, position, number, etc. of the cuts 23 are not limited.

The holding sealing material 10 has a protrusion 11 formed at one of its longitudinal ends, and a recess 12 formed at the other end. The projecting portion 11 and the recessed portion 12 are shaped so that the projecting portion 11 and the recessed portion 12 are fitted to each other when the holding sealing material 10 is wound around the exhaust gas treating body 130 in order to assemble the exhaust gas purifying device 100 described later. It's becoming

In the holding sealing material 10 according to the present embodiment, the mats 20 and 30 constituting the holding sealing material 10 are desirably needle mats obtained by subjecting a base mat made of inorganic fibers to needling treatment. The needling treatment means inserting and withdrawing a fiber entangling means such as a needle from/to the base mat. In the first mat 20 and the second mat 30, inorganic fibers having a relatively long average fiber length are three-dimensionally entangled by needling. The first mat 20 and the second mat 30 are needled in the width direction perpendicular to the longitudinal direction. In order to exhibit an entangled structure, the inorganic fibers have a certain average fiber length. For example, the average fiber length of the inorganic fibers is desirably 50 μm to 100 mm.

In the holding sealing material 10 according to the present embodiment, in order to suppress the bulkiness of the holding sealing material 10 and to improve the workability before assembling the exhaust gas purification device 100, the mat constituting the holding sealing material 10 further includes: A binder such as an organic binder may be included.

The holding sealing material 10 shown in FIG. 1 shows an example in which two mats having a thickness of 1.5 to 15 mm are laminated. There is no particular limitation, and the number of sheets may be three or more.

(exhaust gas purifier)
FIG. 2 is a perspective view schematically showing an example of the exhaust gas purifier 100 according to the present invention. The exhaust gas purifier and the holding sealing material will be described in detail based on FIG.

The exhaust gas purification apparatus 100 includes a columnar exhaust gas treating body 130 in which a large number of cells are arranged side by side in the longitudinal direction with cell walls separated, a casing 120 housing the exhaust gas treating body 130, and the exhaust gas treating body 130 and the casing 120. The holding sealing material 10 is disposed between the holding sealing material 10 and holds the exhaust gas treating body 130 .

An introduction pipe for introducing exhaust gas discharged from the internal combustion engine and a discharge pipe for discharging the exhaust gas that has passed through the exhaust gas purifier 100 are connected to the ends of the casing 120 as required. As the exhaust gas treating body 130, a honeycomb filter in which one of the cells is plugged with a plugging material can be used.

In this embodiment, the inner surface of the second mat 30 is wrapped around the exhaust gas treating body 130, and the second mat 30 is arranged inside. Since the first mat 20 wound around the outside of the second mat 30 is provided with cuts 23, the cuts 23 spread in the winding direction during winding, and the length difference between the inner and outer circumferences (inner and outer circumference length difference) increases. ) can be buried, and the outer periphery of the exhaust gas treating body 130 can be wound without gaps, so that leakage of exhaust gas can be suppressed and workability can be improved. In addition, in the exhaust gas purifying device 100, the protrusion 11 and the recess 12 are fitted to form the fitting portion 13 in the holding sealing material 10, so that the holding sealing material 10 is further prevented from forming a gap. It is possible to suppress exhaust gas leakage. Further, leakage of exhaust gas can be prevented while ensuring the productivity of the exhaust gas purification device 100 .

An embodiment of the cut 23 will be described in detail on the basis of FIGS. 3 to 6. FIG.

FIG. 3 is a conceptual diagram showing a first embodiment of the cut 23. As shown in FIG. As shown in FIG. 3( a ), the cuts 23 of the first embodiment are provided so as to reach halfway through the thickness of the first mat 20 . When the holding sealing material 10 is wound around the exhaust gas treating body 130, the gap 23 widens (see FIG. 3(b)).

In the holding sealing material 10 of the present embodiment, the first mat 20 and the second mat 30 are integrated before being wrapped. The remaining part is torn, and the first mat 20 spreads in the winding direction. As a result, the operation of winding the holding sealing material 10 around the exhaust gas treating body 130 is facilitated.

In addition, since the winding cross section of the exhaust gas treating body 130 is substantially circular, the first mat 30 arranged outside the second mat 30 is in direct contact with the outer periphery of the exhaust gas treating body 130 . Although the mat 20 requires a longer length, the gap 23 spreads in the winding direction, so that the inner and outer circumference length difference between the first mat 20 and the second mat 30 can be filled.

FIG. 4 is a conceptual diagram showing a second embodiment of the cut 23. As shown in FIG. As shown in FIG. 4( a ), the slit 23 of the second embodiment is provided so as to penetrate the first mat 20 and reach halfway through the thickness of the second mat 30 . As in the first embodiment, when the holding sealing material 10 is wound around the exhaust gas treating body 130, the gap 23 widens (see FIG. 4(b)). The gap 23 spreads in the winding direction, and it becomes possible to fill the inner and outer circumference length difference between the first mat 20 and the second mat 30.例文帳に追加

In the first embodiment, handleability such as sagging is improved during transportation of the holding sealing material 10, and in the second embodiment, winding performance is improved. That is, in the first embodiment, the handleability is better than in the second embodiment, and in the second embodiment, the winding property is improved in comparison to the first embodiment.

In the holding sealing material 10 of the present embodiment, in which the first mat 20 and the second mat 30 are fixed at the joint 40, the cut 23 of the present embodiment is formed by winding the two mats 20 and 30 together. This is an effective configuration for complementing the circumference difference.

FIG. 5 is a conceptual diagram showing a third embodiment of the cut 23. As shown in FIG. The cut 23 of the third embodiment is the same as the first cut 23a (see FIG. 5(b)) as in the first embodiment, which is provided so as to reach a midway position in the thickness of the first mat 20. , the same second cut 23b (see FIG. 5(c)) as in the second embodiment, which is provided to penetrate the first mat 20 and reach halfway through the thickness of the second mat 30. types are used together.

The shape of the cut 23 is formed so as to draw a convex portion 50 . The convex portion 50 has a first side 51 serving as a base side of the convex portion 50, a second side 52 perpendicular to the first side 51 and forming a side surface, and a third side connecting the second sides 52. It has sides 53 . That is, it is a combined use of the first embodiment and the second embodiment. It is possible to appropriately arrange the first cut 23a and the second cut 23b for each of the sides 51, 52, 53. FIG. Also, when viewed from the opposite direction, the convex portion 50 is also a concave portion, and it may be interpreted that the convex portion 50 also includes a concave portion.

In the holding sealing material 10 of the present embodiment, when it is wound around the exhaust gas treating body 130, the uncut portion of the first mat 20 to which the first cut 23a has not reached is torn, and the first mat 20 is wound in the winding direction. spread to As a result, the operation of winding the holding sealing material 10 around the exhaust gas treating body 130 is facilitated. In addition, since the winding cross section of the exhaust gas treating body 130 is substantially circular, the first mat 30 arranged outside the second mat 30 is in direct contact with the outer periphery of the exhaust gas treating body 130 . Although the mat 20 requires a longer length, the first cut 23a spreads in the winding direction more than the second cut 23b, and the length difference between the inner and outer circumferences of the first mat 20 and the second mat 30 is reduced. can be filled.

The ratio of the length of the slits 23 to the thickness of the first mat 20 is preferably set in the range of 60% to 99%, more preferably in the range of 70% to 99%, and more preferably in the range of 80% to 99%. A range is more preferred. The ratio of the length of the slits 23 in the second mat 30 to the thickness of the second mat 30 is preferably set in the range of 1% to 60%, more preferably in the range of 20% to 60%. % to 60% range is more preferred.

FIG. 6 is a conceptual diagram showing examples of the third embodiment of FIG. 5, where (a) is Example 1, (b) is Example 2, and (c) is Example 3. FIG. For clarity of explanation, the first cut 23a is indicated by a solid line and the second cut 23b is indicated by a dashed line.

In Example 1, the second cut 23 b is arranged on the first side 51 and the second side 52 , and the first cut 23 a is arranged on the third side 53 . In Example 2, the second cut 23 b is arranged on the first side 51 , and the first cuts 23 a are arranged on the second side 52 and the third side 53 . In Example 3, the second cut 23 b is arranged on the first side 51 and the third side, and the first cut 23 a is arranged on the second side 52 .

By using both the first cut 23a and the second cut 23b and defining the range of each, it is possible to use them properly according to the function and application. That is, Example 1 is a holding sealing material 10 emphasizing good winding properties, and is suitable for a case where the diameter of the exhaust gas treating body 130 is relatively small. In addition, the second embodiment is a holding sealing material 10 in which the handleability of maintaining the shape is emphasized, and is suitable for the case where the diameter of the exhaust gas treating body 130 is relatively large. Example 3 is positioned between Example 1 and Example 2, and balances them.

As a result, the holding sealing material can have both good handleability for maintaining the shape of the first cut 23a of the first embodiment and good workability for winding the second cut 23b of the second embodiment. 10 can be provided.

(Production method)
A method for manufacturing the holding sealing material 10 of the present embodiment will be described with reference to FIGS. 7 and 8. FIG.

A first sheet 60 and a second sheet 61 of inorganic fibers are joined together, and the upper and lower sheets 60 and 61 are completely fixed so as not to move. The joining portion 40 to be joined and fixed is an adhesive 40a (see FIG. 7(b)), a stitch 40b (see FIG. 7(c)), a double-sided tape, or the like, and the fixing means of the joining portion 40 is not limited.

The joined sheets 60 and 61 are cut by a punching plate 71 having a plate-shaped punching blade 70 projecting in the vertical direction shown in FIG. . A first mat 20 is punched from a first sheet 60 and a second mat 30 is punched from a second sheet 61 .

The punching blade 70 has a first punching blade 70a and a second punching blade 70b whose height is smaller than that of the first punching blade 70a (see FIG. 8(c)). In FIG. 8, the first punching blade 70a is indicated by a dashed line, and the second punching blade 70b is indicated by a solid line.

The first punching blade 70 a penetrates the first sheet 60 and the second sheet 61 to punch out the outer shape of the holding sealing material 10 . Also, the second punching blade 70b has a blade height smaller than that of the first punching blade 70a. Further, by adjusting the height of the second punching blade 70b, it is possible to form the first cut 23a reaching from the surface of the first sheet 60 to a midway position in the thickness of the first sheet 60. Yes (embodiment of FIG. 3). Further, by adjusting the height of the second punching blade 70b, it can penetrate the first sheet 60 from the surface of the first sheet 60 and reach a position halfway through the thickness of the second sheet 61. A second cut 23b can also be formed (embodiment of FIG. 4).

In order to manufacture the holding sealing material 10 of the embodiment of FIGS. 5 and 6, a third punching blade 70c as shown in FIG. The third punching blade 70c is smaller in height than the first punching blade 70a and larger in height than the second punching blade 70b. Thereby, the second punching blade 70b forms the first cut 23a reaching from the surface of the first sheet 60 to the midway position in the thickness of the first sheet 60, and the third punching blade 70c , forming a second cut 23b that penetrates the first sheet 60 and reaches an intermediate position in the thickness of the second sheet 61;

For punching the first sheet 60 and the second sheet 61, a punching plate 71 on which a punching blade 70 is erected is used. The punching plate 71 is installed in a press machine, and the laminated body of the first sheet 60 and the second sheet 61 placed on the processing plate is punched by the punching plate 71 to obtain the punched sheet 60. , 61 (that is, the mat) is conveyed to the workbench in that state, and the holding sealing material 10 is collected as a product.

In the punching blades 70 provided on the punching plate 71 of the present embodiment, the first punching blades 70a are arranged on the entire circumference, in each column, and in each row at predetermined intervals, and the second punching blades 70b are arranged between the first punching blades 70a in the row direction. Each holding sealing material 10 is divided by the first punching blade 70a, and cuts 23 are formed by the second punching blade 701b. By changing the height of the second punching blade 70b, the first cut 23a and the second cut 23b can be selected. Further, by adopting the third punching blade 70c in addition to the second punching blade 70b, the first cut 23a and the second cut 23b can be formed simultaneously.

The punching blade 70 is provided so as to form a predetermined shape by bending a strip-shaped punching blade into a predetermined shape and fixing it, or by fixing a plurality of punching blades continuously. . Examples of the material of the punching blade 70 include various metal materials, ceramic materials, and the like. In this embodiment, carbon steel is used from the viewpoint of good workability when bent into a predetermined shape. Further, the shape of the cutting edge of the punching blade 70 includes, for example, a double-edged edge and a single-edged edge. In this embodiment, from the viewpoint of reducing the resistance when punching the inorganic fiber sheets 60 and 61, the punching blade 70 having a double-edged cutting edge is employed. Although the thickness of the punching blade 70 is not particularly limited, it is in the range of about 0.5 to 1.5 mm, and the punching blade 70 with a thickness of 1 mm is adopted in this embodiment.

For details of the punching process, refer to Japanese Patent Application Laid-Open No. 2012-26074 filed by the present applicant.

In this embodiment, the first mat 20 and the second mat 30 are not independently movable in the longitudinal direction, and the first mat 20 or the first mat 20 and the second mat 30 are not moved when the winding is maintained or bent. The slit 23 provided in the edge is enlarged to improve winding performance. In addition, by adjusting the depth of the slit 23, the holding sealing material 10 is excellent in that consideration can be given to winding properties and handling properties for maintaining the shape.

Further, by making the total length of the first mat 20 and the second mat 30 substantially the same, the holding sealing material 10 can be easily designed and manufactured.

Regarding the cuts 23 of the present embodiment, two types of the first cuts 23a and the second cuts 23b have been described, but it is also possible to increase the types of the cuts 23. FIG.

It should be noted that the present invention is not limited to the above-described embodiments, and can be modified, improved, etc. as appropriate. In addition, the material, shape, size, numerical value, form, number, location, etc. of each component in the above-described embodiment are arbitrary and not limited as long as the present invention can be achieved.

INDUSTRIAL APPLICABILITY The holding seal material, the method for manufacturing the holding seal material, and the exhaust gas purifying apparatus of the present invention are applicable to fields requiring excellent winding properties of the holding seal material.

REFERENCE SIGNS LIST 10 holding sealing material 11 protruding portion 12 recessed portion 13 fitting portion 20 first mat 21 first surface 22 second surface 23 cut 23a first cut 23b second cut 30 second mat 40 joining portion 50 Projection 60 First sheet 61 Second sheet 70 Punching blade 70a First punching blade 70b Second punching blade 71 Punching plate 100 Exhaust gas purification device 120 Casing 130 Exhaust gas treating body

Claims (4)

a first mat having a first surface and a second surface opposite the first surface;
a second mat laminated on the second surface of the first mat;
A holding sealing material comprising at least
a plurality of cuts are provided from the first surface to the second surface;
The plurality of cuts are
a first cut extending from the first surface toward the second surface and reaching an intermediate position in the thickness of the first mat;
a second cut penetrating through the first mat and reaching an intermediate position in the thickness of the second mat,
Retaining seal material. The holding sealing material according to claim 1,
the cut is formed so as to draw a convex portion within the main surface of the holding sealing material,
At least part of the convex portion is formed by the first cut,
Retaining seal material. a casing;
an exhaust gas treating body housed in the casing;
and a holding sealing material wound around the exhaust gas treating body and arranged between the exhaust gas treating body and the casing,
The holding sealing material is the holding sealing material according to claim 1 or 2, and is wound around the exhaust gas treating body so that the second mat is disposed inside.
Exhaust gas purifier. Laminating and fixing the first sheet and the second sheet,
A punching plate having a plate-shaped punching blade protruding in the vertical direction is pressed against the first sheet side, and the first mat punched from the first sheet and the second sheet are punched. A method for manufacturing a holding sealing material that is a laminate of the second mats that has been removed, comprising:
The punching blades include a first punching blade, a second punching blade smaller in height than the first punching blade, and a second punching blade smaller in height than the first punching blade. including a third punch blade having a greater height than the punch blade;
the first punching blade penetrates the first sheet and the second sheet to punch out the outer shape of the holding sealing material;
The second punching blade forms a first cut extending from the surface of the first sheet to an intermediate position in the thickness of the first sheet,
The third punching blade penetrates the first sheet and forms a second cut that reaches an intermediate position in the thickness of the second sheet,
A method for manufacturing a holding sealing material.

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