KR20150014848A - Holding seal material and exhaust gas purifying apparatus - Google Patents

Abstract

Provided is a holding sealing material capable of reducing scattering of inorganic fibers, and preventing a film from being peeled off from a holding sealing material by preventing the holding sealing material from protruding from the end of a metal casing as the holding sealing material is dislocated from an exhaust gas processing body when the exhaust gas processing body in which the holding sealing material is wound is inserted into the metal casing. The holding sealing material consists of a rectangular mat when viewed from a plane comprising inorganic fibers having a first principal plane, and a second principal plane opposite to the first principal plane. The first principal plane and the second principal plane are coated by a film. The film is bonded to wind the mat continuously. A winding starting part and a winding closing part of the film are placed on the second principal plane. The film is not placed between the winding starting part and the winding closing part, thereby an exposed part where the second principal plane is exposed is formed. At least one side between a side consisting of the winding starting part and a side consisting of the winding closing part is not parallel with the longitudinal direction of the mat with respect to the entire part.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a holding sealer and an exhaust gas purifying device,

The present invention relates to a holding sealer and an exhaust gas purifier.

Particulate matter (hereinafter also referred to as PM) is included in the exhaust gas discharged from an internal combustion engine such as a diesel engine. Recently, it has become a problem that the PM causes harm to the environment or human body. Further, since harmful gas components such as CO, HC, and NOx are also contained in the exhaust gas, there is also a concern about the influence of the harmful gas component on the environment and the human body.

Therefore, as an exhaust gas purifying apparatus for collecting PM in the exhaust gas or purifying harmful gas components, an exhaust gas purifying apparatus composed of porous ceramics such as silicon carbide or cordierite, and a metal casing And a holding seal member made of inorganic fibers disposed between the exhaust gas treating body and the metal casing, have been proposed variously. The holding sealer is used to prevent the exhaust gas treating body from being damaged by contact with the metal casing covering the outer periphery thereof due to vibrations or impacts caused by running of the automobile or the like, To prevent gas from leaking, and the like.

Since the holding sealer is made of inorganic fibers, it contains a large amount of fine inorganic fibers having irritation (for example, fibers having a diameter of about 3 to 8 mu m). When an exhaust gas processing body is manufactured using such a holding sealer, there is a problem that when the operator handles the holding sealer, the inorganic fibers scatter around the holding sealer and the working environment deteriorates.

Further, when the holding sealer is wound around the exhaust gas treating body, cracks or the like may be generated on the outer surface of the holding sealer. The fine inorganic fibers may scatter even from such cracks.

Patent Document 1 discloses a holding sealer having a two-layer structure composed of a mat made of ceramic fibers arranged on the exhaust gas treating body side and a mat made of ceramic fibers arranged on the metal casing side.

In the holding seal member disclosed in Patent Document 1, a mat having excellent heat resistance is disposed on the side of the exhaust gas processing body which becomes a high temperature, and a mat having excellent flexibility is disposed on the side of the metal casing to prevent deterioration of the holding sealer and degradation of quality, And adhesion between the processing body and the metal casing is improved.

Further, in the holding sealer of Patent Document 1, the holding sealer is sealed by the airtight sheet, thereby preventing the ceramic fibers from being damaged, and facilitating the mounting to the metal casing.

Patent Document 2 discloses a holding sealer accommodated in an inner space of a packaging material in order to reduce the scattering of inorganic fibers from the holding sealer.

Patent Document 1: JP-A-2003-129832 Patent Document 2: JP-A-2010-101308

When the holding sealer having the structure described in Patent Document 1 is wound around the exhaust gas processing body, there is a gas-tight sheet between the holding sealer and the exhaust gas processing body, so that the holding sealer and the exhaust gas processing body The adhesion is lowered. That is, the holding sealer and the exhaust gas treating body are easily displaced. In Patent Document 1, the holding sealer is wound around the exhaust gas treating body, the exhaust gas treating body wound with the holding sealer is sandwiched from above and below by two separate metal casings, the upper and lower portions are pressed, , And the outer peripheral portion of the metal casing is fixed by a clinching process or the like to manufacture an exhaust gas purifying apparatus. When the exhaust gas purifying apparatus is manufactured by such a method, adhesion between the holding sealer and the exhaust gas treating body is hardly a problem. However, for example, in the exhaust gas purifying apparatus having the structure described in Patent Document 1 There has been a problem that the holding sealer is displaced from the exhaust gas treating body and protrudes from the end of the metal casing when the body is pressed into the metal casing. That is, the holding sealer having the constitution described in Patent Document 1 has a problem that it is not suitable for the pressure-applying method. There has been the same problem in the holding sealer having the constitution described in Patent Document 2.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described problems, and it is an object of the present invention to provide an exhaust gas purifying apparatus and an exhaust gas purifying method, And it is an object of the present invention to provide a holding sealer which can prevent the film from being peeled off from the holding sealer, and an exhaust gas purifying device using the holding sealer.

That is, the holding sealer of the present invention is a holding seal material comprising a rectangular mat as viewed from a plane including inorganic fibers having a first main surface and a second main surface opposite to the first main surface, wherein the first main surface, Wherein the second major surface is covered with a film, the film is continuously joined to wind the mat, and the second main surface has a winding start portion and a winding end portion of the film, And at least one side of the side constituting the winding start portion and the side constituting the winding end portion are formed as a whole Is not parallel to the longitudinal direction of the mat.

The holding sealer according to the present invention is generally applied to an exhaust gas purifying apparatus composed of an exhaust gas processing body, a metal casing accommodating the exhaust gas processing body, and a holding sealer disposed between the exhaust gas processing body and the metal casing . The holding sealer of the present invention is wound around the exhaust gas processing body such that the first main surface is the metal casing side and the second main surface is the exhaust gas processing body. The exhaust gas processing body of the present invention in which the holding sealer is wound is housed in the metal casing by press fitting. The holding sealer of the present invention is characterized in that the sides constituting the winding start portion of the film bonded to the holding sealer of the present invention at the time of press fitting and the sides constituting the winding end portion are parallel to the longitudinal direction of the mat constituting the holding sealer Are wound on the exhaust gas processing body so that the non-exposed side is first pressed into the metal casing.

In the holding sealer of the present invention, the first main surface and the second main surface are covered with a film, and the film is continuously joined to wind the mat.

Usually inorganic fibers scatter from the surface of the mat. However, if the film is covered with the holding sealer of the present invention, scattering of such inorganic fibers can be reduced.

In the holding sealer of the present invention, the winding start portion and the winding end portion of the film exist on the second main surface.

That is, the film covers the first main surface and the side surface of the mat and is folded back from the side surface to the second main surface.

Thus, when the holding sealer of the present invention is handled, peeling of the film by impact, friction, or the like can be prevented.

In the holding sealer of the present invention, the film is not present between the winding start portion and the winding end portion, and an exposure portion exposing the second main surface is formed.

If such an exposed portion is not present and the space between the main surface of the mat and the exhaust gas processing body is completely blocked by the film, the adhesion between the mat and the exhaust gas processing body becomes low. This makes it easier for the holding sealer and the exhaust gas treating body to be displaced when the exhaust gas treating body with the holding sealer is pressed into the metal casing, and the holding sealer is liable to protrude from the end portion of the metal casing. However, in the holding sealer of the present invention, there is a portion where no film exists between the mat and the exhaust gas processing body because of the exposed portion. In this portion, the inorganic fibers contained in the mat come into direct contact with the exhaust gas treating body. This improves the adhesion between the mat and the exhaust gas treating body. Further, when the exhaust gas processing body with the holding sealer of the present invention is press-fitted into the metal casing due to the friction between the inorganic fibers and the exhaust gas processing body, the holding sealer and the exhaust gas processing body are difficult to be displaced. Therefore, the holding sealer can be prevented from protruding from the end portion of the metal casing.

In the holding sealer of the present invention, at least one side of the side constituting the winding start portion and the side constituting the winding end portion are not parallel to the longitudinal direction of the mat in the whole portion.

When the exhaust gas processing body with the holding sealer is pressed into the metal casing, a force in the press-fitting direction is applied to the exhaust gas processing body so as to push the exhaust gas processing body into the metal casing.

At this time, the main surface of the holding sealer on the side in contact with the exhaust gas processing body is pulled in the press-in direction by the frictional force. Further, the main surface of the holding sealer on the side in contact with the metal casing is pulled in the direction opposite to the press-in direction by the frictional force with the metal casing.

The same thing can be said for the film bonded to the mat. That is, the surface of the film that is in direct contact with the exhaust gas treating body is pulled in the press-in direction. Further, the surface of the film directly contacting the second main surface of the mat is stretched in the direction opposite to the press-in direction. When the force for pulling the surface of the film in direct contact with the exhaust gas treating body exceeds the maximum static frictional force between the main surface of the mat and the surface of the film in direct contact with the main surface of the mat, the film is dried from the mat.

Here, the force applied to the winding start portion existing on the second main surface of the mat will be described.

In the following description, a case where the winding start portion is pressed into the metal casing before the winding end portion will be described for convenience. However, by rotating the holding sealer 180 DEG around the axis perpendicular to the longitudinal direction of the exhaust gas processing body, the positions of the starting portion of the winding and the end of winding can be changed. Therefore, the same logic can be applied even if the start of winding and the end of winding are opposite.

When the holding sealer is wound around the exhaust gas processing body, the side constituting the winding start portion becomes perpendicular to the press-in direction if the longitudinal direction of the variation mat constituting the winding start portion is parallel. As a result, the force for pulling the film in the press-in direction is directly applied to the winding start portion. Therefore, the film tends to be dried from the start of winding.

However, when the holding sealing material is wound around the exhaust gas treating body, the side constituting the winding start portion does not become perpendicular to the press-fitting direction unless the variation constituting the winding starting portion is parallel to the longitudinal direction of the mat. As a result, a force for pulling the film in the press-in direction is dispersed and applied to the winding start portion. Therefore, it is possible to prevent the film from drying from the winding start portion.

That is, the holding sealer having the structure of the present invention can prevent the film from being dried from the holding sealer when press fitting.

In the holding sealer of the present invention, it is preferable that the side not parallel to the longitudinal direction of the mat is a straight line.

The film used in the holding sealer of the present invention is usually produced by manufacturing a large sheet and cutting the film from the sheet.

When cutting the film from the sheet, the film can be produced by merely cutting the sheet into a straight line if the non-parallel sides of the mat are straight lines. Thus, the holding sealer of the present invention can be manufactured efficiently.

In the holding sealer of the present invention, it is preferable that an angle formed by a side not parallel to the longitudinal direction of the mat and a straight line parallel to the longitudinal direction of the mat is 3 to 30 degrees.

When an angle formed by a side not parallel to the longitudinal direction of the mat and a straight line formed by a straight line parallel to the longitudinal direction of the mat is less than 3 DEG, when the exhaust gas processing body with the holding sealer is pressed into the metal casing, It is not possible to sufficiently disperse the force for pulling in the press-in direction, and the film tends to dry.

When the angle formed by the side not parallel to the longitudinal direction of the mat and the angle formed by the straight line parallel to the longitudinal direction of the mat exceeds 30 degrees, the exposed portion is not formed in the width direction of the mat on the second main surface of the mat , The proportion of the portion of the mat entirely covered with the film in the width direction increases. The direction perpendicular to the longitudinal direction of the mat coincides with the press-in direction when the holding sealer is wound around the exhaust gas processing body and press-fitted into the metal casing. This makes it difficult to obtain the effect of preventing the holding sealer and the exhaust gas treating body from being displaced in a portion of the second main surface of the mat where the exposed portion is not formed in the width direction of the mat. Thus, the holding sealer and the exhaust gas treating body are liable to be displaced.

In the holding sealer of the present invention, it is preferable that a curve which is not parallel to the longitudinal direction of the mat is curved.

In the case where the end face perpendicular to the longitudinal direction of the exhaust gas processing body is an elliptical or racetrack type, when the exhaust gas processing body with the holding sealer is press-fitted into the metal casing, in the portion with a high curvature, It is more influenced, so that more force is required to press-fit the exhaust gas processing body.

Therefore, the force for pulling the film in the press-in direction is different depending on the position. That is, in the portion of the mat disposed in the portion of the exhaust gas processing body having a high curvature, the force applied to the side not parallel to the longitudinal direction of the mat becomes strong. Therefore, in this portion, the film is liable to be dried. However, it is also possible to disperse the force applied to the side not parallel to the longitudinal direction of the mat by adjusting the curvature of the curved line, which is not parallel to the longitudinal direction of the mat, as a curved line in accordance with the shape of the exhaust gas processing body have. Thereby, it is possible to prevent the film from drying.

In the holding sealer of the present invention, it is preferable that the area of the exposed portion is 20 to 80% of the area of the second main surface.

If the area of the exposed portion is less than 20% of the area of the second main surface, the portion of the inorganic fibers included in the mat directly contacting the exhaust gas processing body is too small, so that the exhaust gas processing body, The holding sealer and the exhaust gas treating body are liable to be displaced.

When the area of the exposed portion exceeds 80% of the area of the second main surface, the folded portion of the film on the second main surface becomes too small, and the film is easily peeled off.

In the holding sealer of the present invention, the constituent material of the film is preferably at least one selected from the group consisting of polyester, high-density polyethylene and polypropylene.

As described above, the holding sealer of the present invention is usually wound around an exhaust gas processing body and pressed into a metal casing. At this time, the first main surface of the mat comes into contact with the metal casing through the film.

When the constituent material of the film is composed of at least one kind selected from the group consisting of polyester, high-density polyethylene and polypropylene, the frictional force between the first main surface of the mat and the metal casing is reduced. Thus, the exhaust gas processing body with the holding sealer of the present invention can be smoothly press-fitted into the metal casing.

In the holding sealer of the present invention, it is preferable that the film is fixed to the mat by an adhesive material or thermocompression bonding.

By using an adhesive material or a thermocompression bonding, the film can be firmly fixed to the mat.

An exhaust gas purifying apparatus of the present invention comprises an exhaust gas processing body, a metal casing accommodating the exhaust gas processing body, and a holding seal member disposed between the exhaust gas processing body and the metal casing Wherein the holding sealer is made of a rectangular mat in a plane including inorganic fibers having a first major surface and a second major surface opposite to the first major surface, Wherein the first major surface and the second major surface are covered by a film, the film is continuously joined to wind the mat, and on the second main surface, the winding start portion and the winding end portion of the film are present , An exposed portion where the film is not present and the second main surface is exposed is formed between the winding start portion and the winding end portion, At least one side of the side constituting the turn starting portion and at least one side constituting the end of the winding is not parallel to the longitudinal direction of the mat in the whole portion, And a distance from a side not parallel to the longitudinal direction of the mat to the pressure inlet is longer than a distance from the other side to the pressure inlet.

In the exhaust gas purifying apparatus of the present invention, since the holding sealer of the present invention is used, the above effect is exhibited.

1 is a cross-sectional view schematically showing an example of an exhaust gas purifying apparatus of the present invention.
2 is a perspective view schematically showing an example of the holding sealer of the present invention.
3 (a) to 3 (c) schematically show one example of a step of accommodating the exhaust gas processing body with the holding sealer of the present invention in a metal casing. Fig. 3 (a) is a schematic diagram schematically showing a state before the exhaust gas treating body wound around the holding sealer is received in the metal casing. Fig. Fig. 3 (b) is a schematic diagram schematically showing a state in which the exhaust gas processing body with the holding sealant is pressed into the metal casing. Fig. Fig. 3 (c) is a sectional view taken along line AA in Fig. 3 (b).
4A is a view showing a state in which, when the mutual mat constituting the winding start portion is in parallel with the longitudinal direction of the mutual mat, the holding sealer is applied to the winding start portion when the exhaust gas processing body is press- This diagram schematically shows the force. Fig. 4 (b) is a cross-sectional view showing a state in which when the exhaust gas treating body with the holding sealer is pressed into the metal casing, Fig. 5 schematically shows the force applied.
Fig. 5 is a plan view of a holding seal showing a relationship between a side not parallel to the longitudinal direction of the mat constituting the winding start portion and a straight line parallel to the longitudinal direction of the mat, schematically showing from the second main surface side of the mat.
6 is a perspective view schematically showing an example of an exhaust gas treating body constituting the exhaust gas purifying apparatus of the present invention.

Hereinafter, the present invention will be described in detail. However, the present invention is not limited to the following description, and can be suitably modified and applied without departing from the gist of the present invention. It is also the present invention that a combination of two or more preferred embodiments of the present invention described below.

1 is a cross-sectional view schematically showing an example of an exhaust gas purifying apparatus of the present invention.

1, an exhaust gas purifying apparatus 1, which is an example of an exhaust gas purifying apparatus of the present invention, includes an exhaust gas processing body 10, a metal casing 20 covering the outside of the exhaust gas processing body 10 And a holding sealer 30 disposed between the exhaust gas processing body 10 and the metal casing 20. An end portion of the metal casing 20 on the side where the exhaust gas is introduced And an exhaust pipe 22 connected to the outside is connected to the other end of the metal casing 20. The exhaust pipe 22 is connected to the exhaust pipe 22 connected to the outside.

The holding sealer 30 has a mat 31 and a film 40. The mat 31 has a first main surface 32 on the side of the metal casing 20 and a second main surface 33 on the side of the exhaust gas processing body 10. The film 40 covers the first major surface 32 and the second major surface 33. In the part of the second main surface 33, the film 40 is not present, and the exposed portion 38 in which the exhaust gas processing body 10 is in direct contact is formed.

In the exhaust gas purifying apparatus 1 shown in Fig. 1, an exhaust gas filter (honeycomb filter) sealed in any one of the cells by the sealing material 13 is used as the exhaust gas processing body 10 .

The case where the exhaust gas passes through the exhaust gas purifying apparatus 1 having the above-described configuration will be described below with reference to Fig.

1, the exhaust gas discharged from the internal combustion engine and flowing into the exhaust gas purifying apparatus 1 (indicated by an arrow G in FIG. 1 and the flow of the exhaust gas is indicated by an arrow) Flows into one cell 11 opened in the exhaust gas inlet side end face 10a of the processing body 10 and passes through the cell wall 12 from which the cell 11 is separated. At this time, PM in the exhaust gas is collected in the cell wall 12, and the exhaust gas is purified. The purified exhaust gas flows out from the other cells 11 opened to the exhaust gas outlet side end face 10b and is discharged to the outside.

Next, the holding sealer 30 of the present invention will be described.

2 is a perspective view schematically showing an example of the holding sealer of the present invention. The holding sealer 30 of the present invention shown in Fig. 2 has a length in a predetermined longitudinal direction (hereinafter, simply referred to as an entire length, indicated by an arrow L in Fig. 2) and a width And an inorganic fiber having a thickness (indicated by an arrow T in Fig. 2).

The mat 31 has a first main surface 32 and a second main surface 33 which is a major surface opposite to the first major surface 32. [ The mat 31 has a cross section 34 in which the convex section 34a is formed, a cross section 35 in which the concave section 35a is formed, a first side face 36 as a longitudinal side face, And a second side surface 37 which is a side surface opposite to the second side surface 36. The longitudinal side surface is a surface located at a portion where a long side of a rectangle is formed when the mat 31 is viewed from a plane. The convex portion 34a and the concave portion 35a are shaped to exactly fit together when the holding sealer 30 is wound around the exhaust gas processing body 10 in order to manufacture the exhaust gas purifying apparatus 1 .

The first major surface 32 and the second major surface 33 of the mat 31 are covered by the film 40 and the film 40 is formed in a direction perpendicular to the longitudinal direction of the mat 31 So that the mat 31 is wound by one-turn winding. Therefore, the first side surface 36 and the second side surface 37 are also covered with the film 40. [

The winding start portion 41 and the winding end portion 42 of the film 40 are present on the second main surface 33 and the film 40 is provided between the winding start portion 41 and the winding end portion 42. [ The second main surface 33 is exposed and the exposed portion 38 is formed.

The sides 43 constituting the winding start portion 41 are not parallel to the longitudinal direction of the mat 31 in the whole portion.

The side 44 constituting the winding end portion 42 is substantially parallel to the side 43. [

If the winding direction of the film 40 is reversed, the winding end portion 42 is a place where the winding end is started. Therefore, the winding end portion and the winding start portion may be opposite to each other. However, Treat it like this.

In the holding sealer 30 of the present invention, the side 44 constituting the winding end portion 42 may not be parallel to the side 43 constituting the winding start portion 41, Or may be parallel to the longitudinal direction of the base 31.

The holding sealer 30 of the present invention is configured such that the first main surface 32 of the mat 31 is the metal casing 20 side and the second main surface 33 is the exhaust gas processing body 10 side, And is wound on the gas processing body 10. The exhaust gas processing body 10 in which the holding sealer 30 of the present invention is wound is housed in the metal casing 20 by press fitting. At this time, in the exhaust gas processing body 10 in which the holding sealer 30 of the present invention is wound, the side 43 constituting the winding start portion 41 is first press-fitted into the metal casing 20.

The mat 31 is a needle mat obtained by subjecting a base mat made of inorganic fibers to a needling process. In addition, the needling treatment means that the fiber entanglement means such as a needle is inserted and removed from the base mat. In the mat 31, inorganic fibers having a relatively long average fiber length are entangled three-dimensionally by needling treatment. This mat is needled in the width direction perpendicular to the longitudinal direction.

In order to exhibit the interlocking structure, the inorganic fibers have an average fiber length of a predetermined degree. For example, the average fiber length of the inorganic fibers may be about 50 to 100 mm.

The average fiber diameter of the inorganic fibers constituting the mat 31 is preferably 1 to 20 占 퐉, more preferably 3 to 10 占 퐉.

When the average fiber diameter of the inorganic fibers is 1 to 20 占 퐉, the strength and flexibility of the inorganic fibers are sufficiently high, and the shear strength of the mat 31 can be improved.

If the average fiber diameter of the inorganic fibers is less than 1 占 퐉, the inorganic fibers tend to be tapered, so that the tensile strength of the inorganic fibers becomes insufficient. On the other hand, if the average fiber diameter of the inorganic fibers exceeds 20 탆, the inorganic fibers are less likely to bend, resulting in insufficient flexibility.

A weight per unit area of the mat 31 (weight per unit area) is not particularly limited, and preferably in the 200 ~ 4000g / m ^2, more preferably 1000 ~ 3000g / m ^2. If the unit weight of the mat 31 is less than 200 g / m ² , the holding force is not sufficient, and if the unit weight of the mat 31 exceeds 4000 g / m ² , the volume of the mat 31 hardly decreases. Therefore, when the exhaust gas purifying apparatus 1 is manufactured by using the mat 31, the exhaust gas processing body 10 is likely to fall off.

The bulk density (volume density of the mat before winding) of the mat 31 is not particularly limited, but is preferably 0.10 to 0.30 g / cm ³ . If the bulk density of the mat 31 is less than 0.10 g / cm ³ , the entanglement of the inorganic fibers is weak and the inorganic fibers are easily peeled off, so that it becomes difficult to maintain the shape of the mat 31 in a predetermined shape.

If the bulk density exceeds 0.30 g / cm ³ , the mat 31 becomes hard, and the rolled property to the exhaust gas treating body 10 is lowered and is easily separated.

The mat 31 may further include a binder such as an organic binder in order to suppress an increase in volume or to improve the workability before assembly of the exhaust gas treating apparatus 1. [

The thickness of the mat 31 is preferably 1.5 to 15 mm.

Usually, the inorganic fibers scatter from the surface of the mat. In the holding sealer 30 of the present invention, however, the film 40 is sandwiched between the first major surface 32, the second major surface 33, the first side surface 36, and the second side surface 37 ), It is possible to prevent scattering of the inorganic fibers in the covered portion of the film 40. Further,

The mat 31 may be a single-layer mat or a laminated mat.

2, in the holding sealer 30 of the present invention, the winding start portion 41 of the film 40 and the winding end portion 42 are present on the second main surface 33. As shown in Fig.

That is, the film 40 covers the first main surface 32, the first side surface 36 and the second side surface 37 of the mat 31 and has a structure folded back from each side to the second major surface 33 .

Thus, when the holding sealer 30 of the present invention is handled, the film 40 can be prevented from being peeled off by impact, friction, or the like.

The holding sealer 30 of the present invention does not include the film 40 between the winding start portion 41 and the winding end portion 42 so that the exposed portion 38 in which the second main surface 33 is exposed, Respectively.

If such an exposed portion is not present and the space between the main surface of the mat and the exhaust gas processing body is completely blocked by the film, the adhesion between the mat and the exhaust gas processing body becomes low. This makes it easier for the holding sealer and the exhaust gas treating body to be displaced when the exhaust gas treating body with the holding sealer is pressed into the metal casing, and the holding sealer is liable to protrude from the end portion of the metal casing. However, since the holding sealer 30 of the present invention has the exposed portion 38, a portion where the film 40 is not present between the mat 31 and the exhaust gas processing body 10 is generated. In this portion, the inorganic fibers contained in the mat 31 come into direct contact with the exhaust gas processing body 10. As a result, the adhesion between the mat 31 and the exhaust gas processing body 10 is improved. When the exhaust gas processing body 10 in which the holding sealer 30 of the present invention is wound is pressed into the metal casing 20 due to the frictional force between the inorganic fibers and the exhaust gas processing body 10, (30) and the exhaust gas processing body (10). Therefore, it is possible to prevent the holding sealer 30 from protruding from the end portion of the metal casing 20.

The reason why the holding sealer 30 and the exhaust gas processing body 10 are difficult to be displaced at the time of press fitting will be described below with reference to the drawings.

Figs. 3 (a) to 3 (c) schematically illustrate an example of a step of accommodating the exhaust gas treating body with the holding sealer of the present invention in a metal casing. Fig. Fig. 3 (a) is a schematic diagram schematically showing a state before the exhaust gas treating body wound around the holding sealer is received in the metal casing. Fig. Fig. 3 (b) is a schematic diagram schematically showing a state in which the exhaust gas processing body with the holding sealant is pressed into the metal casing. Fig. 3 (c) is a sectional view taken along the line A-A in Fig. 3 (b).

3 (a), the holding sealer 30 of the present invention is configured such that the second main surface 33 of the mat 31 contacts the exhaust gas processing body 10, and the exhaust gas processing body 10 ). The exhaust gas processing body 10 in which the holding sealer 30 of the present invention is wound is housed in the metal casing 20 such that the winding start portion 41 of the film 40 is first pressed into the pressurizing opening 23. [ Arrows in Fig. 3 (a) indicate the direction of press-fitting.

The inner diameter of the metal casing 20 is mainly made of stainless steel or the like and the inner diameter of the metal casing 20 is larger than the diameter of the end face of the exhaust gas processing body 10 and the diameter of the exhaust gas processing body 10 And the thickness of the holding sealer 30 in a state of being wound around the holding sealer 30.

The end portion (exhaust gas inlet side end face) 10a on the rear side in the press-in direction of the exhaust gas processing body 10 is pressed against the metal casing 20 by receiving the pressure P ₁ as shown in Fig. 3 (b) .

The force exerted by the holding sealer 30 at this time will be described with reference to Fig. 3 (c).

When the end portion 10a on the rear side in the pressure direction of the exhaust gas processing body 10 receives the pressure P ₁ , the exposed portion of the holding sealer 30 of the present invention in direct contact with the exhaust gas processing body 10 38 and the film 40 are pulled in the press-in direction. This force is denoted by F ₁ .

When the exhaust gas processing body 10 in which the holding sealer 30 is wound is pressed into the metal casing 20, the first main surface 32 comes into contact with the metal casing 20, A frictional force is generated between the holding sealer 30 and the sealing material 30, and a force in a direction opposite to the pushing-in direction acts on the holding sealer 30. [ When the frictional resistance generated between the metal casing 20 and the holding sealer 30 is increased, a larger P ₁ is required for press-fitting. When P ₁ is increased, F _{1 is} also increased. The holding sealer 30 is displaced from the exhaust gas processing body 10 when F ₁ exceeds the maximum static friction force between the holding sealer 30 and the exhaust gas processing body 10.

The holding sealer 30 of the present invention is provided with the exposed portion 38 and the exposed portion 38 is in direct contact with the exhaust gas treating body 10. [ As described above, in the exposed portion 38, the inorganic fibers included in the mat 31 directly come into contact with the exhaust gas processing body 10. As compared with the case where the film 40 completely blocks the gap between the second main surface 33 of the mat 31 and the exhaust gas processing body 10, the holding sealer 30, The maximum static frictional force with the processing body 10 becomes large. Therefore, it is difficult for the holding sealer 30 and the exhaust gas processing body 10 to be displaced from each other.

In the holding sealer 30 of the present invention, the sides 43 constituting the winding start portion 41 are not parallel to the longitudinal direction of the mat 31 in the whole portion.

The film 40 bonded to the mat 31 may sometimes be dried from the winding start portion 41 when the exhaust gas processing body 10 in which the holding sealer 30 is wound is pressed into the metal casing 20. [

This cause is the same as the cause that the holding sealer 30 is displaced from the exhaust gas processing body 10 at the time of the press-fitting.

The reason why the film 40 is dried from the winding start portion 41 will be described with reference to Fig. 3 (c).

The surface 40a of the film 40 which is in direct contact with the exhaust gas processing body 10 is pulled in the press-in direction. Let this force be F ₂ . The surface 40b of the film 40 which is in direct contact with the second main surface 33 of the mat 31 is pulled in the opposite direction to the press-in direction. F ₂ exceeds the maximum static frictional force between the second main surface 33 of the mat 31 and the surface 40b of the film 40, 33).

In addition, the film 40 is hardly dried at a portion other than the winding start portion 41, for example, from the winding end portion 42. As described above, the surface 40a of the film 40 is pulled in the press-in direction. The portion of the film 40 other than the winding start portion 41 is continuous in the direction opposite to the press-in direction. The film 40 is more likely to be dried than the winding start portion 41 because the continuous film 40 is affected by the frictional force caused by the contact between the mat 31 and the continuous film 40 at portions other than the winding start portion 41 have. In other words, when the film 40 is curled at the time of press-fitting, most of the film 40 is dried from the winding start portion 41.

Here, the force applied to the winding start portion 41 existing on the second main surface 33 of the mat 31 will be described below with reference to the drawings.

Fig. 4 (a) schematically shows a force applied to the winding start portion when the exhaust gas processing body wound around the holding sealer is press-fitted into the metal casing, when the mutual mat constituting the winding starting portion is parallel to the longitudinal direction Fig.

Fig. 4 (b) is a cross-sectional view showing a state in which when the exhaust gas treating body with the holding sealer is pressed into the metal casing, Fig. 5 schematically shows the force applied.

In Fig. 4 (a), the sides 43 'constituting the winding start portion 41 are parallel to the longitudinal direction of the mat 31. Fig. As a result, the side 43 'is perpendicular to the press-in direction. Therefore, the force F ₂ for pulling the film 40 in the press-in direction is directly applied to the winding start portion 41.

4 (b), the sides 43 constituting the winding start portion 41 are not parallel to the longitudinal direction of the mat 31 in the whole portion. Force to tension the film 40 in a press-in direction (F ₂₎ is, the two sides 43 and perpendicular to the direction of the force (F _2a), sides (43) parallel to the direction of the force (F _2b) Synthesis It can be expressed as force. The force causing the film 40 to dry is the force F _2a in the direction perpendicular to the side 43. F _2a is a force less than F ₂ .

It is assumed from the above that the sides 43 constituting the winding start portion 41 are not parallel to the longitudinal direction of the mat 31 in the entire portion is the side 43 'constituting the winding start portion 41, The film 40 becomes harder to dry than when it is parallel to the longitudinal direction of the mat 31.

That is, in the holding sealer 30 having the constitution of the present invention, it is possible to prevent the film 40 from being dried from the holding sealer 30 when press fitting.

In the holding sealer 30 of the present invention, the side 43, which is not parallel to the longitudinal direction of the mat 31, is a straight line.

The film 40 used in the holding sealer 30 of the present invention is usually manufactured by manufacturing a large sheet and cutting the film 40 from the sheet.

In the holding sealer 30 of the present invention, since the side 43, which is not parallel to the longitudinal direction of the mat 31, is a straight line, when cutting the film 40 from the sheet, It is possible to manufacture the holding sealer 30 of the present invention efficiently.

In the holding sealer 30 of the present invention, the side 43, which is not parallel to the longitudinal direction of the mat, and the angle formed by the straight line? Parallel to the longitudinal direction of the mat are 3 to 30 .

Fig. 5 is a plan view of a holding seal showing a relationship between a side not parallel to the longitudinal direction of the mat constituting the winding start portion and a straight line parallel to the longitudinal direction of the mat, schematically showing from the second main surface side of the mat.

5, a straight line parallel to the longitudinal direction of the mat 31 is indicated by a straight line, and a straight line perpendicular to the longitudinal direction of the mat 31 is indicated by beta. In the present invention, the angle formed by the side not parallel to the longitudinal direction of the mat and the straight line parallel to the longitudinal direction of the mat is a side 43 that is not parallel to the longitudinal direction of the mat 31, Of the angle formed by the side 43 and the straight line a of the triangle formed by the straight line alpha and the straight line beta.

If the angle formed by the side 43 not parallel to the longitudinal direction of the mat 31 and the straight line? Parallel to the longitudinal direction of the mat is less than 3 占 the holding sealer 30 is wound The force F ₂ for pulling the film 40 in the press-in direction can not be sufficiently dispersed when the exhaust gas processing body 10 is press-fitted into the metal casing 20, so that the film 40 is easily dried.

When the angle formed by the side 43 which is not parallel to the longitudinal direction of the mat 31 and the straight line alpha parallel to the longitudinal direction of the mat 31 exceeds 30 degrees, The exposed portion 38 is not formed on the second major surface 33 in the width direction of the mat and the proportion of the portion of the mat 31 entirely covered with the film 40 increases. The direction perpendicular to the longitudinal direction of the mat 31 coincides with the press-in direction. The holding sealer 30 and the exhaust gas processing body 10 (see FIG. 10) are formed in the portion of the second main surface 33 of the mat 31 where the exposed portion 38 is not formed in the width direction of the mat 31, It is difficult to obtain an effect of preventing deviations from occurring.

It is preferable that the side 43 not parallel to the longitudinal direction is a straight line. However, in the holding sealer 30 of the present invention, the side 43 not parallel to the longitudinal direction of the mat 31 may be curved do. When the end face perpendicular to the longitudinal direction of the exhaust gas processing body 10 is an oval or racetrack type and when the exhaust gas processing body 10 in which the holding sealer 30 is wound is pressed into the metal casing 20, In the high portion, the exhaust gas processing body 10 is more affected by the peripheral frictional resistance, so that more force is required to press the exhaust gas processing body 10 into.

Due to this, the force F ₂ for pulling the film 40 in the press-in direction is different depending on the position. That is, in the portion of the mat 31 disposed in the portion of the exhaust gas processing body 10 having a high curvature, the force applied to the side 43 becomes strong. Therefore, at this portion, the film 40 becomes easy to dry. However, the side 43 can be curved and the force applied to the side 43 can be dispersed by adjusting the curvature of the side 43 in accordance with the shape of the exhaust gas processing body 10. Thereby, it is possible to prevent the film 40 from being dried.

In the holding sealer 30 of the present invention, the area of the exposed portion 38 is preferably 20 to 80% of the area of the second main surface 33. [

If the area of the exposed portion 38 is less than 20% of the area of the second main surface 33, the portion of the inorganic fibers included in the mat 31 directly contacting the exhaust gas processing body 10 is too small, The holding sealer 30 and the exhaust gas processing body 10 are easily displaced when the exhaust gas processing body 10 in which the holding sealer 30 is wound is pressed into the metal casing 20. [

When the area of the exposed portion 38 exceeds 80% of the area of the second main surface 33, the portion of the second main surface 33 where the film 40 is folded again becomes too small, It becomes easy to peel off.

In the holding sealer 30 of the present invention, the constituent material of the film 40 is preferably at least one selected from the group consisting of polyester, high-density polyethylene and polypropylene.

As described above, the holding sealer 30 of the present invention is normally wound around the exhaust gas processing body 10 and press-fitted into the metal casing 20. As described above, At this time, the first main surface 32 of the mat 31 comes into contact with the metal casing 20 through the film 40.

When the constituent material of the film 40 is at least one selected from the group consisting of polyester, high-density polyethylene and polypropylene, the distance between the first main surface 32 of the mat 31 and the metal casing 20 . Thus, the exhaust gas processing body 10 in which the holding sealer 30 of the present invention is wound can be smoothly press-fitted into the metal casing 20.

In the holding sealer 30 of the present invention, it is preferable that the film 40 is fixed to the mat 31 by adhesive material or thermocompression bonding.

By using the adhesive material or the thermocompression bonding, the film 40 can be securely fixed to the mat 31.

Next, the exhaust gas processing body 10 constituting the exhaust gas purifying apparatus 1 of the present invention will be described.

6 is a perspective view schematically showing an example of an exhaust gas treating body constituting the exhaust gas purifying apparatus of the present invention.

As shown in Fig. 6, the exhaust gas processing body 10 is mainly made of porous ceramics and has a substantially cylindrical shape. For the purpose of reinforcing the outer periphery of the exhaust gas processing body 10, shaping it, or improving the heat insulating property of the exhaust gas processing body 10, the outer periphery of the exhaust gas processing body 10, A layer 14 is formed.

The internal structure of the exhaust gas processing body 10 is the same as already described in the description of the exhaust gas purifying apparatus 1 of the present invention (see Fig. 1).

The exhaust gas processing body 10 is a filter in which one end of the cell is sealed, but the end portion of the cell may not be sealed in the exhaust gas processing body constituting the exhaust gas purifying apparatus of the present invention. Such an exhaust gas treating body can be suitably used as a catalyst carrier.

The exhaust gas processing body 10 constituting the exhaust gas purifying apparatus of the present invention is an integrated exhaust gas processing body. The exhaust gas processing body of the present invention is an exhaust gas processing body of an exhaust gas purifying apparatus of the present invention, It may be a treating body.

The shape of the exhaust gas processing body 10 is a columnar shape, but the exhaust gas processing body constituting the exhaust gas purifying device of the present invention may have any shape such as an elliptical columnar shape, a horny columnar shape, or the like.

The exhaust gas treating body 10 may be a non-oxidized porous ceramic such as silicon carbide or silicon nitride, or an oxidized porous ceramic such as sialon, alumina, cordierite, or mullite. Among these, silicon carbide is preferable.

When the exhaust gas treating body 10 is a silicon carbide porous ceramic, the porosity of the porous ceramic is not particularly limited, but is preferably 35 to 60%.

If the porosity is less than 35%, the exhaust gas treating body may immediately be clogged. On the other hand, when the porosity exceeds 60%, the strength of the exhaust gas treating body is lowered and may be easily broken.

The average pore diameter of the porous ceramic is preferably 5 to 30 占 퐉.

If the average pore diameter is less than 5 占 퐉, the PM may easily clog. On the other hand, if the average pore diameter exceeds 30 占 퐉, the PM will escape from the pore and can not collect PM, This is because there is no case.

The porosity and the pore diameter can be measured by a conventionally known method for measurement by a scanning electron microscope (SEM).

The cell density on the cross section of the exhaust gas processing body 10 is not particularly limited, but a preferable lower limit is 31.0 cells / cm ² (200 cells / inch ² ) and a preferable upper limit is 93.0 cells / cm ² / inch ² ), a more preferable lower limit is 38.8 / cm ² (250 / inch ² ), and a more preferable upper limit is 77.5 / cm ² (500 / inch ² ).

A catalyst for purifying the exhaust gas may be carried on the exhaust gas processing body 10, and a noble metal such as platinum, palladium or rhodium is preferable as the catalyst for supporting the exhaust gas. Among them, platinum is more preferable Do. As other catalysts, for example, alkali metals such as potassium and sodium, and alkaline earth metals such as barium may be used. These catalysts may be used alone or in combination of two or more.

If these catalysts are supported, PM can be easily removed by burning, and toxic exhaust gas can be purified.

Next, the exhaust gas purifying apparatus 1 of the present invention using the holding sealer 30 of the present invention will be described.

An exhaust gas purifying apparatus (1) of the present invention includes an exhaust gas processing body (10), a metal casing (20) for accommodating the exhaust gas processing body (10), an exhaust gas processing body And a holding sealer 30 disposed between the holding sealer 30 and the holding sealer 30. The metal casing 20 has a pressurizing port 23 and the holding sealer 30 has a pressure- And a second major surface 33 opposite to the first main surface 32. The first major surface 32 and the second major surface 33 are formed of a rectangular mat 31 as viewed from a plane including the main surface 32 and the second main surface 33 opposite to the first major surface 32, The second major surface 33 is covered with the film 40 and the film 40 is continuously joined to wind the mat 31. On the second main surface 33, The film 40 is not present between the winding start portion 41 and the winding end portion 42 so that the second main surface 33 is exposed, (38) is formed, At least one side of the side 43 constituting the winding start portion 41 and the side 44 constituting the winding end portion 42 is formed so as to be parallel to the longitudinal direction of the mat 31 The holding sealer 30 is arranged so that the exposed portion 38 is in contact with the exhaust gas processing body 10 and the distance from the side not parallel to the longitudinal direction of the mat 31 to the pressure inlet 23 Is longer than the distance from the other side to the pressure inlet (23).

Since the holding sealer 30 of the present invention is used in the exhaust gas purifying apparatus 1 of the present invention, the above-described effect is exhibited.

Next, an example of the holding sealer 30 of the present invention and the manufacturing method of the exhaust gas purifying apparatus 1 of the present invention will be described.

(a) Mat preparation process

First, a step of preparing a mat made of inorganic fibers subjected to a needle punching treatment is performed.

The mat can be obtained by various methods, but can be produced, for example, by the following method. That is, first, for example, an inorganic fiber precursor having an average fiber diameter of 3 to 10 μm is prepared by spinning a spinning mixture containing a basic aqueous aluminum chloride solution and silica sol as raw materials by a blowing method. Subsequently, the inorganic fiber precursor is compressed to produce a continuous sheet material having a predetermined size, and a needle punching process is performed on the continuous sheet material, followed by a firing process. Through this process, the mat 31 can be manufactured, and the mat 31 can be prepared.

(b) Film adhesion process

Next, a step of adhering the film 40 to the mat 31 is performed.

First, the film 40 is cut. At this time, the sides (43) constituting the winding start portion (41) are not parallel to each other in the longitudinal direction and the entire portion of the mat (31).

Subsequently, the film 40 is continuously made in the direction perpendicular to the longitudinal direction of the mat 31 from the winding start portion 41 of the second main surface 33 of the mat 31 to the winding end portion 42 The wheels are wound and glued. At this time, the winding start portion 41 and the winding end portion 42 are separated to form an exposed portion 38 in which a part of the second main surface 33 of the mat 31 is exposed.

The film 40 may be adhered to the film 40 and the mat 31 may be adhered to the film 40 at the same time as the film 40 is covered with the film 40. After the mat 40 is covered with the film 40, It may be bonded by pressing.

The mat 31 that has undergone the above steps becomes the holding sealer 30 which is an example of the holding sealer of the present invention.

The mat preparing step (a) may include a step of attaching the organic binder and the inorganic binder to the inorganic fibers.

The method and order of adhering the organic binder and the inorganic binder to the inorganic fibers are not particularly limited. For example, the mat may be impregnated with a binder by immersing the mat in the binder-containing solution after the firing process, The binder may be impregnated into the mat by dropping the binder onto the mat. Thereafter, the adhesion amount of the binder can be adjusted by sucking and dewatering the mat with the binder.

Next, an example of a method for manufacturing the exhaust gas purifying apparatus 1, which is an example of the exhaust gas purifying apparatus of the present invention, will be described using the holding sealer 30.

A manufacturing method of an exhaust gas purifying apparatus (1) of the present invention comprises an exhaust gas processing body (10), a metal casing (20) for accommodating the exhaust gas processing body (10) The holding sealer 30 is a method of manufacturing the exhaust gas purifier 1 composed of the holding sealer 30 disposed between the holding sealer 30 and the metallic casing 20, The holding sealer is a holding sealer manufactured by the holding sealer so that the first main surface 32 of the mat 31 becomes the metal casing 20 side and the second main surface 33 becomes the exhaust gas processing body 10 side, A step of winding the ash material 30 on the exhaust gas processing body 10 and a step of disposing the exhaust gas processing body 10 wrapped with the holding sealer 30 in the metal casing 20 so that the winding start portion 41 is first pressed, And a step of press-fitting into the inside of the mold.

(c) Winding process

A step of winding the holding sealer 30 of the present invention around the exhaust gas processing body 10 is performed.

In this step, the holding sealer 30 is wound around the outer circumference of the substantially cylindrical exhaust gas processing body 10 manufactured by a conventionally known method such that the second main surface 33 of the mat 31 is in contact with the outer circumference of the exhaust gas processing body 10 . At this time, the convex portion 34a of the mat 31 and the concave portion 35a are engaged with each other.

(d)

3 (a), the exhaust gas processing body 10 in which the holding sealer 30 is wound is pressed into the pressurizing opening 23 first by the winding start portion 41 of the film 40 The metal casing 20 is press-fitted into the metal casing 20 by a press-fitting method (stuffing method).

The exhaust gas purifying apparatus 1, which is an example of the exhaust gas purifying apparatus of the present invention, is manufactured through the above processes.

Hereinafter, the functions and effects of the holding sealer and the exhaust gas purifying apparatus of the present invention are listed.

The holding sealer of the present invention is used in the exhaust gas purifying apparatus of the present invention as described above. Thus, the following effects are exhibited.

(1) In the holding sealer of the present invention, the first main surface and the second main surface are covered with a film, and the film is continuously joined to wind the mat.

As a result, scattering of inorganic fibers can be reduced.

(2) In the holding sealer of the present invention, the winding start portion and the winding end portion of the film exist on the second main surface. That is, the film covers the first main surface and the side surface of the mat and is folded back from the side surface to the second main surface. Thus, when the holding sealer of the present invention is handled, peeling of the film by impact, friction, or the like can be prevented.

(3) In the holding sealer of the present invention, there is no film between the winding start portion and the winding end portion, and an exposed portion where the second main surface is exposed is formed. This improves the adhesion between the mat and the exhaust gas treating body. Further, when the exhaust gas processing body with the holding sealer of the present invention is press-fitted into the metal casing due to the friction between the inorganic fibers and the exhaust gas processing body, the holding sealer and the exhaust gas processing body are difficult to be displaced. Therefore, the holding sealer can be prevented from protruding from the end portion of the metal casing.

(4) In the holding sealer of the present invention, at least one side of the side constituting the winding start portion and the side constituting the winding end portion is not parallel to the longitudinal direction of the mat in the whole portion. Further, the exhaust gas processing body with the holding sealer is press-fitted into the metal casing so that the non-parallel side of the mat is pressed first.

As a result, a force for tensioning the film in the press-in direction is dispersed and applied to the side not parallel to the longitudinal direction of the mat. Therefore, it is possible to prevent the film from being dried from the side not parallel to the longitudinal direction of the mat. That is, it is possible to prevent the film from being dried from the holding sealer when press fitting.

(Example)

The following examples illustrate the present invention in more detail. However, the present invention is not limited to this embodiment.

(Example 1)

(a) Mat preparation process

(a-1) Spinning process

Al ₂ O _3: SiO ₂ = 72: 28 (weight ratio) in the inorganic fiber after sintering with respect to the basic aluminum chloride aqueous solution prepared so that the Al content was 70 g / l and the Al: Cl ratio was _1: (Weight ratio), and an organic polymer (polyvinyl alcohol) was added in an appropriate amount to prepare a mixed solution.

The obtained mixed solution was concentrated to prepare a spinning mixture. This spinning mixture was spinned by a blowing method to produce an inorganic fiber precursor having an average fiber diameter of 100 mm and an average fiber length of 5.1 m.

(a-2) Compression process

The inorganic fiber precursor obtained in the above step (a-1) was compressed to produce a continuous sheet material.

(a-3) Needle punching process

The sheet material obtained in the above step (a-2) was continuously subjected to needle punching treatment using the following conditions to produce a needle punching body.

First, we prepared a needle board with a needle at a density of 21 / cm ² . Next, the needle board was placed above one surface of the sheet material, and the needle board was moved up and down once along the thickness direction of the sheet material to perform needle punching processing, thereby producing a needle punching processing body. At this time, the needle was passed through until the barb formed at the tip portion of the needle completely penetrated the surface opposite to the sheet-like article.

(a-4) Firing process

The needle punching treatment body obtained in the above step (a-3) was continuously fired at a maximum temperature of 1250 占 폚 to produce a fired sheet shaped article made of inorganic fibers containing alumina and silica. The average fiber diameter of the inorganic fibers was 5.1 mu m, and the minimum value of the inorganic fiber diameter was 3.2 mu m. The alumina fiber holding sealer thus obtained had a bulk density of 0.15 g / cm ³ and a unit weight of 1400 g / m ² .

(a-5) Cutting step

The fired sheet material obtained in the above step (a-4) was cut to produce a cut sheet material.

(a-6) Impregnation process

An organic binder solution (acrylic latex) containing an acrylic resin as an organic binder was flow-coated on the cut sheet material obtained in the above step (a-5) and impregnated with an organic binder to prepare an impregnated sheet shaped article .

(a-7) Drying process

After the excess organic binder solution was sucked and removed from the impregnated sheet form obtained in the above step (a-6), the resultant was compression dried to reduce its thickness to produce a needle punching mat having a thickness of 6.8 mm.

(a-8) Cutting process

The mat obtained in the above step (a-7) has a total length of 1089 mm in width and 371 mm in width when viewed in plan, a convex portion 34a having a length of 24.5 mm and a width of 100 mm is formed at one end, The mat 31 is formed by cutting the concave portion 35a to be fitted with the convex portion 34a.

(b) Film adhesion process

A polyester adhesive film (thickness: 40 mu m; manufactured by Kato Seiko Co., Ltd.) was cut into a substantially rectangular shape having a total length of 1050 mm and a width of 589 mm. Thereafter, the film was cut from the vertex of the substantially rectangular shape so that the angle 43 formed by the straight line parallel to the longitudinal direction of the film was 5 degrees, . The sides 43 and 44 are formed so that the angle 44 formed by the straight line parallel to the longitudinal direction of the film is 5 degrees, The film was cut from the apex of the substantially rectangular shape. The film thus cut is a parallelogram having an acute angle of 85 °, an obtuse angle of 95 °, a short side of 497mm, and a long side of 1054mm.

Next, the winding start portion 41 of the film was disposed on the second main surface 33 of the mat 31. Then, The positional relationship between the mat 31 and the winding start portion 41 is as follows. The ends of the sides 43 forming the acute angle of the parallelogram were disposed at a distance of 102 mm from the first side 36 of the mat 31 in the direction of the second side 37. [ At the same time, the end of the side 43 forming the obtuse angle of the parallelogram was disposed at a position 10 mm from the first side 36 of the mat 31 in the direction of the second side 37.

Thereafter, the winding start portion 41 of the second main surface 33 of the mat 31 is set as a winding start portion, and the film is wound around the second main surface 33, the first side surface 36, The first main surface 32, the second side surface 37 and the second main surface 33 to the winding end portion 42 of the second main surface 33 of the mat 31 by continuous winding.

The holding sealer thus manufactured becomes the holding sealer 30 according to the first embodiment.

(c) Winding process

(c-1) Production of a molded article of an exhaust gas treating body

52.8% by weight of a coarse powder of silicon carbide having an average particle diameter of 22 占 퐉 and 22.6% by weight of silicon carbide fine powder having an average particle diameter of 0.5 占 퐉 were mixed and the resulting mixture was mixed with 2.1% by weight of an acrylic resin, 2.8% by weight of a lubricant (UniLube manufactured by Nichiyu Corporation), 1.3% by weight of glycerin, and 13.8% by weight of water were added and kneaded to obtain a wet mixture, followed by extrusion molding, A molded body of the gas processing body 10 was produced.

(c-2) Drying process

The molded body of the exhaust gas processing body 10 obtained in the above step (c-1) was dried by using a microwave drier to obtain a dried body of the exhaust gas processing body 10 .

(c-3) Degreasing process

The dried body of the exhaust gas treating body 10 obtained in the above step (c-2) was degreased at 400 캜 to obtain a degreasing body of the exhaust gas treating body 10.

(c-4) Firing process

The degreased body of the exhaust gas treating body 10 obtained in the above step (c-3) was subjected to a sintering process under the conditions of 2200 캜 for 3 hours under atmospheric pressure argon atmosphere to obtain a sintered body having a porosity of 45%, an average pore diameter of 15 탆, A silicon carbide sintered body having a number of cells (cell density) of 300 pieces / inch ² and a cell wall thickness of 0.25 mm (10 mils) was produced.

(c-5) Catalyst carrying step

The silicon carbide sintered body of the exhaust gas treating body 10 obtained in the above step (c-4) was immersed in a platinum nitrate solution and maintained at 600 占 폚 for 1 hour to obtain a silicon carbide sintered body of the exhaust gas treating body 10 A platinum catalyst was supported on the cell walls 12.

The silicon carbide sintered body thus produced becomes the exhaust gas processing body 10 in which the holding sealer 30 of the first embodiment is wound. The exhaust gas processing body 10 had an approximately cylindrical shape with an overall length of 350 mm and an outer diameter of 326 mm.

(c-6) Holding seal re-winding process

The holding sealer 30 of the present embodiment was wound around the exhaust gas processing body 10 obtained in the above step (c-5). At this time, the holding sealer 30 of this embodiment was wound so that the second main surface 33 of the mat 31 came into contact with the exhaust gas processing body 10. In addition, the protrusion 34a of the mat 31 and the recess 35a are fitted.

(d)

The exhaust gas processing body 10 in which the holding sealer 30 is wound is press-fitted into the metal casing 20 by the press fitting method (stuffing method) so that the winding start portion 41 is pressed first. The gap volume density GBH of the holding sealer 30 was 0.4 g / cm < ³ >.

The thus constructed exhaust gas purifying apparatus becomes the exhaust gas purifying apparatus according to the first embodiment.

(Comparative Example 1)

In the film adhering step, an exhaust gas purifying apparatus according to Comparative Example 1 was produced in the same manner as in Example 1, except that the cutting and bonding of the film were changed as follows.

The polyester adhesive film was cut into a substantially rectangular shape having a total length of 1050 mm and a width of 497 mm.

Subsequently, the winding start portion 41 of the second main surface 33 of the mat 31 is set as the starting portion of the winding, and the film is wound around the second main surface 33, the first side surface 36, The first main surface 32, the second side surface 37 and the second main surface 33 to the winding end portion 42 of the second main surface 33 of the mat 31 by continuous winding. The winding start portion 41 is positioned at a position 56 mm from the first side 36 of the mat 31 in the direction of the second side 37 and the winding end portion 42 is positioned at a position And 56 mm in the direction of the first side 36 from the second side 37.

(evaluation)

Five exhaust gas purifying apparatuses according to Example 1 and Comparative Example 1 were respectively manufactured and visually confirmed whether or not the holding sealer protruded from the end of the metal casing.

In Example 1, the holding sealer did not protrude from the metal casing in all of the exhaust gas purifying apparatuses. On the other hand, in Comparative Example 1, in the three of the five exhaust gas purifying apparatuses, the holding sealer protruded from the metal casing.

Further, the holding sealer was taken out from each exhaust gas purifying device, and the state of the film was visually confirmed. In Example 1, the film was not curled from the holding sealer in all the holding sealants. On the other hand, in Comparative Example 1, for three of the five holding sealers, the film was curled from the holding sealer.

The holding sealer of the present invention is a holding seal material composed of a rectangular mat as seen from a plane including inorganic fibers having a first main surface and a second main surface opposite to the first main surface, Wherein the main surface is covered with a film and the film is continuously joined to wind the mat, and on the second main surface, there is a winding start portion and a winding end portion of the film, At least one side of the side constituting the winding start portion and the side constituting the winding end portion are formed in the entire portion So that it is not necessary to be parallel to the longitudinal direction of the mat.

In these essential components, various components described in the detailed description of the present invention (for example, shapes of sides that are not parallel to the longitudinal direction of the mat, sides that are not parallel to the longitudinal direction of the mat, The angle of the angle formed by the straight line, the area of the exposed portion, the constituent material of the film, the fixing method of the film, etc.) are appropriately combined.

1 Exhaust gas purifier
10 Exhaust gas treatment body
11 cells
12 cell wall
13 Sealant
14 Outer coat layer
20 Metal casing
21 introduction pipe
22 outlet pipe
23 pressure inlet
30 Holding seal material
31 mat
32 first main surface
33 2nd week
34, 35 section
34a convex portion
35a concave portion
36 First aspect
37 Second Side
38 Exposure
40 film
41 Start of the tour
42 winding end portion
43 Sides constituting the beginning of the tournament
44 Sides constituting the end of winding

Claims (8)

A holding seal material comprising a rectangular mat as viewed from a plane including inorganic fibers having a first major surface and a second major surface opposite to the first major surface,
Wherein the first main surface and the second main surface are covered with a film,
Wherein the film is continuously joined to wind the mat,
And a winding start portion and a winding end portion of the film are present on the second main surface,
An exposed portion where the film is not present and the second main surface is exposed is formed between the winding start portion and the winding end portion,
At least one side of the side constituting the winding start portion and the side constituting the winding end portion are not parallel to the longitudinal direction of the mat in the whole portion. The method according to claim 1,
Wherein the non-parallel sides of the mat are straight lines. The method of claim 2,
Wherein an angle formed by a side not parallel to the longitudinal direction of the mat and a straight line parallel to the longitudinal direction of the mat is 3 to 30 degrees. The method according to claim 1,
Wherein the holding sealer has a curve that is not parallel to the longitudinal direction of the mat. The method according to any one of claims 1 to 4,
Wherein an area of the exposed portion is 20 to 80% of an area of the second main surface. The method according to any one of claims 1 to 4,
Wherein the constituent material of the film is at least one member selected from the group consisting of polyester, high-density polyethylene, and polypropylene. The method according to any one of claims 1 to 4,
Wherein the film is fixed to the mat by an adhesive material or thermocompression bonding. An exhaust gas purifying apparatus comprising an exhaust gas processing body, a metal casing accommodating the exhaust gas processing body, and a holding seal member disposed between the exhaust gas processing body and the metal casing,
The metal casing has a pressure inlet,
Wherein the holding sealer is made of a rectangular mat in a plane including inorganic fibers having a first main surface and a second main surface opposite to the first major surface,
Wherein the first main surface and the second main surface are covered with a film,
Wherein the film is continuously joined to wind the mat,
And a winding start portion and a winding end portion of the film are present on the second main surface,
An exposed portion where the film is not present and the second main surface is exposed is formed between the winding start portion and the winding end portion,
At least one side of the side constituting the winding start portion and the side constituting the winding end portion is not parallel to the longitudinal direction of the mat,
Wherein the holding sealer is disposed so that the exposed portion contacts the exhaust gas processing body,
Wherein the distance from the side not parallel to the longitudinal direction of the mat to the pressure inlet is longer than the distance from the other side to the pressure inlet.

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