WO2020129475A1

WO2020129475A1 - Method of producing exhaust treatment device

Info

Publication number: WO2020129475A1
Application number: PCT/JP2019/044521
Authority: WO
Inventors: 辰長屋
Original assignee: 株式会社三五
Priority date: 2018-12-20
Filing date: 2019-11-13
Publication date: 2020-06-25
Also published as: JP6968301B2; JPWO2020129475A1

Abstract

Provided is a method of producing an exhaust treatment device, including: wrapping a cushioning mat around a side surface of a column so that side surfaces at two ends in the axial direction of the column are exposed, causing two end edges in the direction of wrapping of the cushioning mat to face one another and fitting together a recess and a projection formed at the two end edges to form a fitted part; affixing adhesive tape to an affixation region, which is a region composed of a part of a first end surface that is one bottom surface out of two bottom surfaces of the column, at least a part of the fitted part, and a side surface of the column interposed between the first end surface and the fitted part, thus obtaining a column unit; and press-fitting or inserting the column unit into the interior of a tubular member, leading with the first end surface. Provided thereby is an exhaust treatment device including a tubular member, a column, and a cushioning mat, wherein misalignment, turning up, and/or deformation of the cushioning mat is reduced when the column unit is being press-fitted or inserted into the interior of the tubular member, without causing excessive increase in the amount of adhesive tape used.

Description

Exhaust treatment device manufacturing method

The present invention relates to a method for manufacturing an exhaust treatment device. More specifically, the present invention relates to a method for manufacturing an exhaust treatment device that holds a columnar body inside a tubular member via a cushioning mat.

Exhaust gas emitted from internal combustion engines such as gasoline engines and diesel engines includes particulate matter (PM) such as soot, carbon monoxide (CO), unburned hydrocarbons (HC: HydroCarbon), and nitrogen oxides ( Substances such as NOx) are included. Therefore, from the viewpoint of protecting the global environment, for example, a filter such as a gasoline particulate filter (GPF: Gasoline Particulate Filter) and a diesel particulate filter (DPF: Diesel Particulate Filter) that collect PM and an oxidation catalyst (OC: Oxidation Catalyst). ) And an exhaust treatment unit including an exhaust treatment unit such as an exhaust purification catalyst such as a selective catalytic reduction denitration unit (SCR: Selective Catalytic Reduction), and these substances can be removed by interposing them in an exhaust passage of an internal combustion engine. It is widely practiced.

The exhaust treatment unit as described above is composed of, for example, a ceramic or metal carrier on which a catalytic metal is supported and a ceramic or metal filter having a honeycomb structure. For example, a buffer is provided inside a metal casing. It is generally held through a mat. Since the casing generally has a cylindrical shape, the exhaust treatment unit held inside such a casing generally has a columnar shape. Therefore, in the present specification, the casing of the exhaust treatment device is hereinafter referred to as a “cylindrical member”, and the columnar exhaust treatment unit held inside the tubular member is hereinafter generically referred to as a “column”.

As a method of manufacturing the exhaust treatment device having the above-described structure (a method of holding the columnar body inside the tubular member), a sheet shape or a tape shape for the purpose of cushioning and sealing (including inorganic fiber etc.) A so-called "stuffing method" is generally used in which a cushioning mat, which is a member of, is wound around the outer circumference (side surface) of a pillar to form a pillar unit, and the pillar unit is press-fitted into the cylindrical member. Target. At the time of press-fitting, as shown in FIG. 14, for example, a guide jig (not shown) is fitted to one end (one opening) of the tubular member 10 so that the pillar 21 is provided on the side opposite to the tubular member 10. While pressing the end face, the cushioning mat 22 is slid against the funnel-shaped tapered surface of the guide jig to compress it, and the columnar unit 20 is pressed into a predetermined position inside the tubular member 10. The compressed cushioning mat 22 generates a desired surface pressure (mat surface pressure, holding surface pressure) due to the restoring force, and resists vibration and/or exhaust pressure when the exhaust treatment device is used and the tubular member 10 The column body 21 is continuously held at a predetermined position inside.

In the press-fitting method, as shown by the hatched portions in FIG. 14, two end edges facing each other in the winding direction around the side surface of the pillar body 21 of the cushioning mat 22 and/or each of these two end edges are joined to each other. It is general that the adhesive tape 23 is attached and fixed (temporarily fixed) to the formed fitting portion between the concave portion and the convex portion (for example, see Patent Document 1). As a result, it is possible to maintain the state in which the cushioning mat 22 is wound around the column body 21 (the wound state) until the column body unit 20 is pressed into the tubular member 10.

The above-mentioned “temporary fixing” is also useful from the viewpoint of maintaining the winding state during transportation before reaching the press-fitting process in the actual manufacturing line. A flammable adhesive tape is used. As a result, the adhesive tape is burned off by the heat of the exhaust gas in the initial stage of use of the exhaust gas treatment device, so that the adhesive tape does not affect the restoring force of the cushioning mat and thus the holding force of the column. In addition, the frictional force obtained by the product of the vertical reaction force from the inner wall of the tubular member and the friction coefficient between the inner wall and the cushioning mat due to the matting surface pressure (holding surface pressure) generated by the restoring force of the cushioning mat is It becomes the holding power of the pillar. Since the coefficient of friction is predetermined, the mat surface pressure substantially determines the holding force of the column.

Depending on the configuration of the column body, such as the mechanical strength of the material forming the column body and/or the structure of the column body, it is not possible to withstand the stress acting at the time of press-fitting into the inside of the tubular member. It may cause problems such as buckling. In such a case, the so-called "sizing method" can be adopted instead of the press-fitting method described above. The sizing method is a method in which at least a part of the region of the side wall of the tubular member facing the cushioning mat is inserted to a predetermined diameter after the pillar unit is inserted into the tubular member without substantially compressing the cushioning mat. This is a construction method in which a columnar holding force is generated by a diameter reduction process for reducing the diameter (for example, refer to Patent Document 2). In the sizing method, since the dimensions of the column body unit and the tubular member can be designed so that the column body is not stressed when the column body unit is inserted, the possibility of leading to the damage of the column body as described above is low, Further, the holding surface pressure can be adjusted by the diameter reduction process with higher accuracy than the press-fitting method.

However, in both the press-fitting method and the sizing method, for example, when the taper surface of the guide jig and/or the inner wall of the tubular member slides on the buffer mat, the abutting portion and/or the fitting of the buffer mat described above are fitted. The parts may be displaced from each other or the ends of the cushioning mat may be turned over. Therefore, in both the press-fitting method and the sizing method, it is necessary to attach (temporarily fix) the adhesive tape to the abutting portion and/or the fitting portion of the cushioning mat as described above.

By the way, these days, it is required to accelerate the arrival of the exhaust purification catalyst at the activation temperature (early increase of the catalyst bed temperature) in order to further improve the exhaust treatment performance. In order to meet such a demand, by increasing the cross-sectional area of the columnar body, pressure loss in the exhaust passage is reduced to facilitate an increase in the exhaust flow rate, and at the same time, the columnar body is made thin ( It has been proposed to reduce the heat capacity (heat mass) of the column by reducing the dimension of the column in the flow direction of. In the case of such a pillar body, the dimension (width) of the cushioning mat in the axial direction of the pillar body becomes shorter than before and the contact area between the cushioning mat and the tubular member becomes smaller, so that a sufficient holding force is maintained. Therefore, it is necessary to increase the mat surface pressure (holding surface pressure) generated by the restoring force of the cushioning mat.

As described above, in order to increase the mat surface pressure (holding surface pressure), the compression margin (compression ratio) of the cushioning mat is increased at the time of press fitting in the press fitting method or when the diameter of the tubular member is reduced in the sizing method. It is necessary to increase the bulk density of the cushioning mat inside the member. Increasing the compression ratio in this way leads to increasing the thickness (dimension in the radial direction of the column) of the cushioning mat at the time before the press-fitting or insertion into the tubular member. That is, the outer diameter of the cushioning mat wound around the side surface of the columnar body becomes larger than before before press-fitting or inserting into the tubular member. As a result, there is a high possibility that the abutting portion and/or the fitting portion of the cushioning mat will be displaced from each other or the end portion of the cushioning mat will be flipped over when it is press-fitted or inserted into the tubular member. Becomes more difficult to press fit or insert into. For example, FIG. 15 shows a state in which the end portion of the abutting portion of the cushioning mat 22 is turned up as the columnar unit 20 is press-fitted into the tubular member even though the adhesive tape 23 is used for temporary fixing. FIG. 4 is a schematic diagram showing (see a region surrounded by a dashed circle).

Therefore, in the technical field, the following method has been proposed as a method for solving the above problem (for example, refer to Patent Document 3). For example, as shown in FIG. 16A, the first adhesive tape 23a is attached to the concave-convex fitting portion of the cushioning mat 22 so as to extend in the axial direction of the columnar body 21. Further, as shown in (b), a plurality of second adhesive tapes 23b are partially overlapped with each other so as to cover the entire end surface of the tip end side (the cylindrical member side at the start of press-fitting or insertion) of the columnar body 21. Are radially attached to each other, and as shown in (a), both ends of each second adhesive tape 23b are folded back so as to reach the outer peripheral surface of the cushioning mat 22 wound around the side surface of the columnar body 21. The first adhesive tape 21a and part of the second adhesive tape 23b partially overlap each other.

According to the above, it is possible to reduce the possibility that the abutting portion and/or the fitting portion of the cushioning mat will be displaced from each other or the end portion of the cushioning mat will be flipped over when being pressed into or inserted into the tubular member. it can. However, since the thickness of the adhesive tape is larger in the portion where the first adhesive tape and the part of the second adhesive tape are overlapped as described above than in the other portion, it is difficult to press-fit or insert into the tubular member. It may hinder or cause the displacement and/or turning of the cushioning mat.

Further, as described above, a flammable tape is used as the adhesive tape, and it may be completely burned out by the heat of the exhaust gas at the initial use of the exhaust treatment device (in most cases, when starting the internal combustion engine for the first time). As intended, it is desirable to keep the amount of adhesive tape used to a minimum. However, when a plurality of adhesive tapes are attached so as to cover the entire end face of the columnar body as described above, the adhesive tapes are not completely burned down and pass through the columnar body at the initial use of the exhaust treatment device. This may lead to problems such as obstructing the flow of exhaust gas.

JP-A-2002-349255 JP, 2007-260656, A Patent No. 3318822

The present invention was devised to address the above-mentioned problems. That is, the present invention can reduce the displacement, turning-up and/or deformation of the cushioning mat when the column unit is press-fitted or inserted into the tubular member without excessively increasing the amount of the adhesive tape used. It is an object to provide a method of manufacturing an exhaust treatment device that can be performed.

In view of the above, the method for manufacturing an exhaust gas treatment device according to the present invention (hereinafter sometimes referred to as the “invention method”) includes an exhaust gas including a tubular member, a pillar, and a cushioning mat. It is a manufacturing method of a processing device. The tubular member is a casing having a tubular shape. The column is an exhaust treatment unit having a columnar shape. The cushioning mat is interposed between the tubular member and the column body and holds the column body at a predetermined position inside the tubular member by a restoring force.

The method of the present invention includes the following first to third steps.
First step: A cushioning mat is wound around the side face of the column body so that exposed portions are exposed at both ends of the side face of the column body in the axial direction of the column body, and two end edges of the cushioning mat in the winding direction face each other. Then, the concave portion and the convex portion respectively formed on the two edges are fitted to each other to form a fitting portion.
Second step: sandwiched between a part of the first end surface, which is one of the two bottom surfaces of the columnar body, at least a part of the fitting portion, and the first end surface of the exposed portion and the fitting portion. The columnar unit is obtained by attaching an adhesive tape to the attachment area, which is an area consisting of the area and the area.
Third step: The columnar unit is press-fitted or inserted into the tubular member with the first end face as the head.

In the third step, the pillar unit may be press-fitted or inserted into the tubular member such that the first end face is located on the downstream side of the exhaust flow in the operating state of the exhaust treatment device. In addition, in the second step, the adhesive tape may be unwound in a direction perpendicular to the axial direction of the column body and attached to the attachment area. Furthermore, the adhesive tape attached to the attaching area in the second step has a dimension in the direction perpendicular to the axial direction of the columnar body, rather than a dimension in the axial direction of the columnar body, when developed on a single plane. It can have a larger shape.

The method of the present invention may further include the following fourth step after the third step.
Fourth step: reducing the diameter of at least a part of the region of the side wall of the tubular member facing the cushioning mat.

According to the method of the present invention, the displacement, turning-up and/or deformation of the cushioning mat at the time of press-fitting or inserting the pillar unit into the inside of the tubular member is reduced without excessively increasing the amount of the adhesive tape used. be able to.

Other objects, other features and attendant advantages of the present invention will be easily understood from the description of each embodiment of the present invention described with reference to the following drawings.

It is a schematic front view (a) and right side view (b) which show an example of a structure of a buffer mat. It is a schematic diagram which shows one representative example of the sticking methods which this inventor examined as a sticking method of the adhesive tape in a pillar unit. It is a schematic diagram which shows another typical example of the sticking method which this inventor examined as a sticking method of the adhesive tape in a pillar unit. It is a schematic diagram which shows another typical example of the sticking method which this inventor examined as a sticking method of the adhesive tape in a pillar unit. It is a flowchart which shows the flow of each process contained in the manufacturing method (1st method) of the exhaust treatment apparatus which concerns on 1st Embodiment of this invention. In the first step included in the first method, the cushioning mat is wound around the side surface of the column, and the recessed portions and the protrusions respectively formed at the two edges of the cushioning mat in the winding direction are fitted and fitted to each other. It is a typical perspective view which shows the state in which the joining part is formed. It is a typical perspective view showing the state where the adhesive tape was stuck in the sticking field and the pillar unit was obtained in the 2nd process included in the 1st method. It is a typical perspective view showing signs that a pillar unit is pressed in or inserted in an inside of a cylindrical member in the 3rd process included in a 1st method with a 1st end face as a head. It is a schematic diagram which shows an example of a structure of the exhaust treatment apparatus manufactured by the manufacturing method (2nd method) of the exhaust treatment apparatus which concerns on 2nd Embodiment of this invention. It is a schematic diagram which shows a mode that a roll-shaped adhesive tape is extended|stretched to the direction parallel to the axial direction of a pillar, and the front-end|tip part of the said extended adhesive tape is stuck to the sticking area|region of a pillar unit. It is a schematic diagram which shows a mode that a roll-shaped adhesive tape is extended|stretched to the direction perpendicular|vertical to the axial direction of a pillar, and the front-end|tip part of the said extended adhesive tape is stuck to the sticking area|region of a pillar unit. In the schematic perspective view (a) of the pillar unit obtained in the second step included in the method for manufacturing an exhaust treatment device (fourth method) according to the fourth embodiment of the present invention, and in the attachment area of the pillar unit. It is a typical top view (b) at the time of developing the adhesive tape stuck on a single plane. It is a flowchart which shows the flow of each process contained in the manufacturing method (5th method) of the exhaust treatment apparatus which concerns on 5th Embodiment of this invention. It is a schematic diagram which shows the manufacturing method of a general exhaust treatment apparatus. It is a schematic diagram which shows the state which the edge part of the abutting part of the cushioning mat turned up with the press fitting of the pillar unit in the inside of a cylindrical member, although the temporary fixing by the adhesive tape is performed. It is a typical front view (a) and bottom view (b) showing an example of composition of a pillar unit concerning a conventional technology.

<<First Embodiment>>
Hereinafter, a method for manufacturing the exhaust treatment device according to the first embodiment of the present invention (hereinafter, sometimes referred to as “first method”) will be described.

<Constitution>
The first method is a method of manufacturing an exhaust treatment device that includes a tubular member, a pillar, and a cushioning mat. The tubular member is a casing having a tubular shape. The material forming the tubular member and the shape of the tubular member are not particularly limited as long as they have a tubular shape and can withstand the use environment and use conditions as the exhaust treatment device. For example, the material forming the tubular member is a metal such as stainless steel, and the tubular member has a cylindrical shape. In addition, the tubular member may be formed as an integral body of, for example, a steel pipe or the like, or may be formed by assembling a plurality of constituent members.

The column is an exhaust treatment unit that has a columnar shape. Specific examples of the exhaust treatment unit include, for example, the filters such as the gasoline particulate filter (GPF) and the diesel particulate filter (DPF), the oxidation catalyst (OC), and the selective catalytic reduction denitration device (SCR) as described above. Exhaust gas purification catalyst can be mentioned. The material forming the exhaust treatment unit and the shape of the exhaust treatment unit have a columnar shape, and as long as they can withstand the use environment and use conditions as the exhaust treatment apparatus and can process a specific component contained in the exhaust, It is not particularly limited. Specific examples of the exhaust treatment unit include a ceramic or metal carrier on which a catalytic metal is supported and a ceramic or metal filter having a honeycomb structure.

The cushioning mat is interposed between the cylindrical member and the pillar to hold the pillar at a predetermined position inside the cylindrical member by a restoring force. As described above, the cushioning mat is wound around the side surface of the column body for the purpose of cushioning and sealing, and is interposed between the cylindrical member and the column body by a restoring force to a predetermined position inside the cylindrical member. Hold the pillar. Therefore, the shape of the cushioning mat is not particularly limited as long as it can be wound on the side surface of the column, but is typically a sheet-like or tape-like shape.

For example, FIG. 1 is a schematic diagram showing an example of the structure of a buffer mat. FIG. 1A is a schematic front view showing a state before the cushioning mat 22 is wound around a column, and FIG. 1B is a cushioning observed from a direction of an arrow α shown in FIG. FIG. 5 is a schematic right side view of the mat 22. As shown in (a), the cushioning mat 22 has an elongated tape-like shape, and two end edges (that is, both ends in the longitudinal direction) facing each other in the winding direction around the side surface of the columnar body, The concave portion 22a and the convex portion 22b are formed respectively. The concave portion 22a and the convex portion 22b are fitted to each other when the cushioning mat 22 is wound around the side surface of the column.

The material for forming the cushioning mat is resistant to the use environment and use conditions as the exhaust treatment device, and is interposed between the tubular member and the column body so that the column body is restored to a predetermined position inside the tubular member by a restoring force. There is no particular limitation as long as it can be held. Specific examples of the material for forming the buffer mat include inorganic fibers such as alumina-silica fibers, and such inorganic fibers to which a resin as a binder is added. Specific examples of the resin used as the binder include acrylic rubber, nitrile rubber, polyvinyl alcohol and acrylic resin.

Regarding the composition of the material forming the buffer mat, such as the thickness and fiber length of the inorganic fiber and the compounding ratio of the inorganic fiber and the binder, for example, flexibility and a tube that can withstand winding of the side wall of the column of the buffer mat It can be appropriately adjusted according to the function required as the cushioning mat, such as the magnitude of the restoring force required to hold the column at a predetermined position inside the shaped member. Further, the thickness and bulk density of the cushioning mat before press fitting or insertion also depend on the cushioning mat, for example, the magnitude of the restoring force required to hold the column in place inside the tubular member. Can be appropriately adjusted according to the function required as.

The first method is a method of manufacturing an exhaust treatment device having the above-mentioned configuration. Regardless of whether the first method corresponds to the press-fitting method or the sizing method described above, the abutting portions of the two edges facing each other in the winding direction around the side surface of the pillar body of the cushioning mat and/or these two Adhesive tapes are attached and fixed (temporarily fixed) to the fitting portions of the concave portions and the convex portions that are respectively formed on the one edge. This makes it possible to maintain the state (rolled state) in which the cushioning mat is wound around the column until the press-fitting or insertion of the column unit into the tubular member is started.

Further, as described above, a flammable tape is used as the adhesive tape, and it may be completely burned out by the heat of the exhaust gas at the initial use of the exhaust treatment device (in most cases, when starting the internal combustion engine for the first time). As intended, it is desirable to keep the amount of adhesive tape used to a minimum. The adhesive tape is preferably a thin adhesive tape coated with an adhesive on only one side. Specifically, for example, a commercially available masking tape (for example, one having a thickness of about 0.1 mm and a heat resistant temperature of about 150° C.) can be used as the adhesive tape.

In addition, as will be described later in detail, in the second step included in the first method, a part of the first end surface that is one of the two bottom surfaces of the columnar body and at least a part of the fitting portion. And a region sandwiched between the first end surface of the exposed portion and the fitting portion, an adhesive tape is attached to an attachment area that is an area formed of the column body unit. The outer peripheral surface of the fitting portion of the cushioning mat and the surface of the exposed portion (that is, a part of the side surface of the pillar) are curved surfaces, and the first end surface of the pillar is a flat surface. That is, the pasting area includes both the curved surface portion and the flat surface portion. Therefore, it is desirable that the adhesive tape has elasticity so that the adhesive tape can be attached to the attachment area at least without wrinkles.

By the way, the present inventor intends to reduce the displacement, turning-up and/or deformation of the cushioning mat at the time of press-fitting or inserting the pillar unit into the inside of the tubular member without excessively increasing the usage amount of the adhesive tape. We have earnestly conducted research to find a method of sticking adhesive tape that can be used.

2 to 4 are schematic diagrams showing typical examples of various pasting methods examined by the present inventor as a method for pasting an adhesive tape on a pillar unit. In any of the figures, (a) is the second end face side of the column, (b) is the side face side of the column, and (c) is the first end face side of the column, respectively, of the observed column unit. Show the appearance.

For example, in the example shown in FIG. 2, the adhesive tape 23 is attached only to the outer peripheral surface of the cushioning mat 22. In this case, the adhesive tape 23 has a fitting portion (indicated by a broken line) of a concave portion and a convex portion, which are respectively formed at two end edges facing each other in the winding direction of the cushion mat 22 around the side surface of the column body 21. It is attached so as to cover it. However, the adhesive tape 23 is not attached to any end surface or side surface of the columnar body 21. Therefore, in this case, although the wound state can be maintained in the period until the press-fitting or the insertion of the columnar unit 20 into the inside of the tubular member (not shown) is started, It is difficult to reduce the displacement, turning, and/or deformation of the cushioning mat 22 when the pillar unit 20 is press-fitted or inserted therein. In particular, as illustrated in FIG. 15, the end portion of the abutting portion of the cushioning mat 22 is likely to be turned up when the pillar unit 20 is press-fitted or inserted into the tubular member.

Therefore, in the example shown in FIG. 3, the adhesive tape 23 extends from the fitting portion (indicated by a broken line) on the outer peripheral surface of the cushioning mat 22 to the two end surfaces of the pillar 21 through the exposed portion of the side surface of the pillar 21. Is pasted. Therefore, in this case, not only the winding state is maintained in the period until the press-fitting or the insertion of the columnar unit 20 into the inside of the tubular member (not shown), but also the inside of the tubular member is maintained. It is also possible to reduce the displacement, turning and/or deformation of the cushioning mat 22 when the pillar unit 20 is press-fitted or inserted. However, as described above, it is intended that the adhesive tape 23 is completely burned down by the heat of the exhaust gas in the early stage of use of the exhaust gas treatment device, and therefore it is desirable to keep the amount of the adhesive tape 23 used to a minimum.

Therefore, as a result of earnest research, the present inventor has found that a part of the first end surface 21a, which is one of the two bottom surfaces of the columnar body 21, and at least a part of the fitting portion on the outer peripheral surface of the cushioning mat 22. And an area sandwiched between the first end surface of the exposed portion of the side surface of the columnar body 21 and the fitting portion, the adhesive tape 23 is attached to an attachment area that is an area formed by the adhesive tape 23. While suppressing an increase in the usage amount, not only the winding state is maintained in the period until the press-fitting or the insertion of the pillar body unit 20 into the inside of the tubular member is started, but also the pillar body inside the tubular member is provided. It has been found that a reduction in displacement, swelling and/or deformation of the cushioning mat 22 during the press-fitting or insertion of the unit 20 can also be possible.

For example, in the example shown in FIG. 4, one end face of the two end faces of the pillar body 21 is passed from the fitting portion (shown by a broken line) on the outer peripheral surface of the cushioning mat 22 to the exposed portion of the side surface of the pillar body 21. The adhesive tape 23 is attached only to the range extending to a certain first end surface 21a. As described above, in the example shown in FIG. 4, the adhesive tape 23 is not attached to the second end face 21b which is the other end face of the two end faces of the column body 21. However, also in this case, not only is the winding state maintained during the period until the press-fitting or insertion of the columnar unit 20 into the inside of the tubular member (not shown) is performed, but also inside the tubular member. It is also possible to reduce the displacement, swelling and/or deformation of the cushioning mat 22 when the column body unit 20 is pressed in or inserted. That is, in this case, since the amount of the adhesive tape 23 used is kept to a minimum, compared with the example shown in FIG. 3, the adhesive tape 23 is completely burned down by the heat of the exhaust gas at the beginning of use of the exhaust gas treatment device. Will be easier to do.

<procedure>
The first method conceived based on the findings obtained as described above includes the following first to third steps. FIG. 5 is a flowchart showing the flow of each step included in the first method. As shown in FIG. 5, in the first method, step S10 in which the first step is executed, step S20 in which the second step is executed, and step S30 in which the third step is executed are executed in this order. It In the following description, the first method will be described in detail with reference to FIGS. 6 to 8 showing the contents of each step.

First step (step S10): A cushioning mat is wound around the side surface of the pillar so as to expose exposed portions at both ends of the side surface of the pillar in the axial direction of the pillar, and two ends of the cushioning mat in the winding direction are wound. The edges are opposed to each other, and the recesses and the protrusions respectively formed on the two edges are fitted to each other to form a fitting portion.

In FIG. 6, in the first step, the cushioning mat 22 is wound around the side surface of the column body 21, and the recessed portions and the protrusions formed on the two edges of the cushioning mat 22 in the winding direction are fitted to each other. It is a typical perspective view showing the state where fitting part 22c (portion surrounded by a dashed line) is formed. As described above, the cushioning mat 22 is wound around the side surface of the pillar body 21 so that the exposed portions are exposed at both ends of the side surface of the pillar body 21 in the axial direction of the pillar body, respectively. By providing the exposed portion in this manner, for example, even when the cushioning mat 22 is slightly displaced during press-fitting or insertion into the tubular member of the columnar unit, the end portion of the cushioning mat 22 has the column 21. It is possible to reduce the possibility of protruding in the axial direction from the end face of the and preventing it from being stacked with other columnar units.

Further, the shape of the concave portion and the convex portion forming the fitting portion 22c of the cushioning mat 22 is not limited to that shown in FIG. 6, and, for example, in the abutting portion of the two edges of the cushioning mat 22 in the winding direction. As long as problems such as exhaust gas leakage do not occur, various shapes widely adopted in the technical field can be appropriately selected.

Second step (step S20): Part of the first end surface that is one of the two bottom surfaces of the pillar, at least part of the fitting portion, the first end surface of the exposed portion, and the fitting portion. The columnar unit is obtained by attaching an adhesive tape to an attachment area which is an area sandwiched between the area and the area.

FIG. 7 is a schematic perspective view showing a state in which the columnar unit 20 is obtained by attaching the adhesive tape 23 (hatched portion) to the attaching area in the second step. In the example shown in FIG. 7, a region extending from a region that covers most of the fitting portion 22c of the cushioning mat 22 to a part of the first end surface 21a of the columnar body 21 through the exposed portion of the side surface of the columnar body 21 (that is, , (Single piece) adhesive tape 23 is attached to the attachment area. Thereby, while suppressing the usage amount of the adhesive tape 23, not only is the winding state maintained in the period until the press-fitting or insertion of the columnar unit 20 into the inside of the tubular member (not shown) is started, It is also possible to achieve a reduction in displacement, curling and/or deformation of the cushioning mat 22 when the pillar unit 20 is press-fitted or inserted into the tubular member.

Third step (step S30): The columnar unit is press-fitted or inserted into the tubular member with the first end face as the head.

When the above-described sizing method is adopted in the first method, the pillar unit 20 is inserted into the tubular member 10 with the first end surface 21a of the pillar 21 at the beginning. At the time of press-fitting, the pillar body unit 20 is press-fitted to a predetermined position inside the cylindrical member 10 while pressing the end surface (that is, the second end surface 21b) of the pillar 21 on the side opposite to the cylindrical member 10. The compressed cushioning mat 22 generates a desired surface pressure (mat surface pressure, holding surface pressure) due to the restoring force, and resists vibration and/or exhaust pressure when the exhaust treatment device is used and the tubular member 10 The column body 21 is continuously held at a predetermined position inside. As described above, a guide jig (not shown) is fitted to one end (the opening on the side of the column unit 20) of the tubular member 10, and the cushioning mat 22 is slid on the funnel-shaped tapered surface of the guide jig. The column unit 20 may be pressed into the tubular member 10 while being moved and compressed.

On the other hand, when the above-described sizing method is adopted in the first method, the pillar unit 20 is inserted into the tubular member 10 with the first end face 21a of the pillar 21 as the head. At this time, as described above, by designing the dimensions of the column body unit 20 and the tubular member so that the column body 21 is not stressed when the column body unit 20 is inserted, the cushioning mat 22 is substantially compressed. Instead, the pillar unit 20 can be inserted into the tubular member 10. As a result, it is possible to reduce the possibility of damage to the columnar body 21 as described above. Further, the diameter reduction processing performed after the insertion can adjust the holding surface pressure of the columnar body 21 by the cushioning mat 22 at a predetermined position inside the tubular member 10 with high accuracy. Even when the sizing method is adopted in the first method as described above, the pillar unit 20 may be press-fitted into the tubular member 10 using the guide jig as described above.

In FIG. 8, the columnar unit 20 having the adhesive tape 23 (hatched portion) attached to the attachment area in the second step is press-fitted or inserted into the inside of the tubular member 10 with the first end surface 21 a as the head. It is a typical perspective view showing a situation. As shown in FIG. 7, a region extending from a region that covers most of the fitting portion 22c of the cushioning mat 22 to a part of the first end face 21a of the pillar 21 through the exposed portion of the side surface of the pillar 21 (attachment Adhesive tape 23 is attached to the area). Therefore, it is possible to maintain the winding state while suppressing the usage amount of the adhesive tape 23 and during the period until the press-fitting or the insertion of the pillar unit 20 into the inside of the tubular member 10 is started. Further, since the pillar unit 20 is press-fitted or inserted into the tubular member 10 with the first end face 21a as the leading end, the displacement, turning-up and/or deformation of the cushioning mat 22 during press-fitting or insertion can be effectively reduced. can do.

<effect>
As described above, according to the first method, when the columnar unit is press-fitted into or inserted into the tubular member, the cushioning mat is displaced, turned over, and/or turned up without excessively increasing the usage amount of the adhesive tape. Alternatively, deformation can be reduced.

<<Second Embodiment>>
Hereinafter, a method for manufacturing the exhaust treatment device according to the second embodiment of the present invention (hereinafter sometimes referred to as “second method”) will be described.

As described above, in the second step included in the first method, at least a part of the first end surface that is one of the two bottom surfaces of the pillar and the fitting portion on the outer peripheral surface of the cushioning mat. The adhesive tape is attached to the attachment area, which is an area including a part and an area sandwiched between the first end surface of the exposed portion of the side surface of the pillar and the fitting portion. That is, the adhesive tape is attached to a part of the first end surface that is the bottom surface of one of the two end surfaces of the pillar, but the adhesive tape is attached to the second end surface that is the other end surface. Not not.

When the first end face of the column is located on the upstream side of the exhaust flow in the operating state of the exhaust treatment device, the burned-up adhesive tape and the like burned by the heat of the exhaust at the beginning of use of the exhaust treatment device are inside the column. This may lead to problems such as flow-in, filter clogging, or reduction of the active surface of the exhaust purification catalyst.

<Constitution>
Therefore, the second method is the above-described first method, and in the third step, the inside of the tubular member is moved so that the first end surface is located on the downstream side of the flow of the exhaust gas in the operating state of the exhaust gas treatment device. It is a method of manufacturing an exhaust treatment device, in which a pillar unit is press-fitted or inserted.

The "operating state of the exhaust gas treatment device" means the exhaust gas discharged from the internal combustion engine to the exhaust gas treatment unit such as the filter and/or the exhaust purification catalyst, which constitutes the pillar of the exhaust gas treatment device manufactured by the second method. The state in which the exhaust treatment device is incorporated in the exhaust passage of the internal combustion engine so as to be guided. As a specific example of such a state, for example, a state in which an exhaust treatment device is installed in an exhaust passage of an internal combustion engine mounted on a vehicle can be cited.

FIG. 9 is a schematic diagram showing an example of the configuration of an exhaust treatment device manufactured by the second method. The tubular member 10 is depicted by broken lines in FIG. 9 for the purpose of making it easier to understand the configuration and orientation of the columnar unit held at a predetermined position inside the tubular member 10. In addition, the outline arrows shown in the drawing represent the flow direction of the exhaust gas in the operating state of the exhaust gas processing device. In the exhaust treatment device 100, the first end surface 21a, which is the bottom surface of the two end surfaces of the column body 21 to which the adhesive tape 23 is attached, is located on the downstream side of the flow of exhaust gas.

In the example shown in FIG. 9, the small-

diameter portions

10a and 10b at the upstream side (exhaust gas inlet side) end and the downstream side (exhaust gas outlet side) end of the tubular member 10 are formed, respectively. The tapered portions (cone portions) 10c and 10d are formed between the small diameter portion and the central portion where the columnar unit is held. The structure of such a tubular member can be formed by plastic working such as spinning. Alternatively, the individually formed small-diameter portion, cone portion and central portion may be assembled by a joining method such as welding. However, the structure of the tubular member does not necessarily have to have the small-diameter portion as described above, and is appropriately designed according to the configuration of the exhaust passage in the equipment or device (for example, vehicle) in which the exhaust treatment device is incorporated. be able to.

<effect>
As described above, in the third step included in the second method, the columnar unit is inserted into the tubular member so that the first end surface is located on the downstream side of the exhaust flow in the operating state of the exhaust treatment device. Pressed or inserted. As a result, the second end face, which is the end face to which the adhesive tape is not attached, of the two bottom faces of the columnar body is located on the upstream side of the flow of exhaust gas in the operating state of the exhaust treatment device. .. Therefore, in the initial stage of using the exhaust treatment device, the burned-up adhesive tape burned by the heat of the exhaust may flow into the column, leading to problems such as clogging of the filter or reduction of the active surface of the exhaust purification catalyst. It can be reduced.

<<Third Embodiment>>
Hereinafter, a method for manufacturing the exhaust treatment device according to the third embodiment of the present invention (hereinafter, sometimes referred to as “third method”) will be described.

As described above, in the second step, a part of the first end surface of the pillar, at least a part of the fitting portion of the cushioning mat, the first end surface of the exposed portion of the side surface of the pillar, and the fitting portion. The columnar unit is obtained by sticking the adhesive tape to the sticking area, which is an area sandwiched between and between the sticking areas. At this time, as long as the state in which the cushioning mat is wound around the side surface of the column (rolled state) is securely maintained and the positional relationship between the cushioning mat and the column is securely fixed, the adhesive tape is attached to the area. There is no particular limitation on the method of sticking to.

For example, as shown in FIG. 10, the roll-shaped adhesive tape 23 is extended in a direction parallel to the axial direction AX of the column 21, and the tip portion of the extended adhesive tape 23 is attached to the column unit 20. The adhesive tape 23 may be affixed to and cut at an appropriate place. Alternatively, as shown in FIG. 11, the roll-shaped adhesive tape 23 is extended in a direction perpendicular to the axial direction AX of the column 21, and the tip portion of the extended adhesive tape 23 is attached to the attachment area of the column unit 20. The adhesive tape 23 may be affixed to and cut at an appropriate place.

However, when the adhesive tape 23 is attached to the attachment area, it is desirable to apply tension in the winding direction of the buffer mat 22 to firmly wind the buffer mat 22 around the side surface of the pillar 21. From this point of view, as shown in FIG. 11, the adhesive tape 23 is extended in a direction perpendicular to the axial direction AX of the column 21 and the tip portion of the extended adhesive tape 23 is attached to the column unit 20. It is desirable to attach it to the attachment area. As shown in FIG. 10, when the adhesive tape 23 is extended in a direction parallel to the axial direction AX of the column 21 and the tip end portion of the adhesive tape 23 is attached to the attachment area of the column unit 20, It is difficult to apply the adhesive tape 23 to the application area while applying tension in the winding direction of the cushioning mat 22, and there is a problem in workability.

<Constitution>
Therefore, the third method is the above-described first method or second method, and in the second step, the adhesive tape is fed in a direction perpendicular to the axial direction of the columnar body and attached to the attachment area. It is a method of manufacturing an exhaust treatment device. The direction in which the adhesive tape is drawn out and the axis of the column do not necessarily need to be orthogonal to each other, and the direction in which the adhesive tape is drawn out (direction parallel to) and the axial direction of the column (direction parallel to) are perpendicular to each other. If Specifically, for example, the direction in which the adhesive tape is fed out and the axis of the column may have a twisted relationship.

<effect>
As described above, in the second step included in the third method, the adhesive tape is fed out in the direction perpendicular to the axial direction of the column and attached to the attachment area. As a result, it becomes easy to attach the adhesive tape to the attachment area while applying tension in the winding direction of the cushioning mat. Therefore, when the adhesive tape is applied to the application area, it is possible to apply tension in the winding direction of the cushioning mat and firmly wind the cushioning mat around the side surface of the pillar with high workability.

<<4th Embodiment>>
Hereinafter, a method for manufacturing the exhaust treatment device according to the fourth embodiment of the present invention (hereinafter, sometimes referred to as “fourth method”) will be described.

By the way, in order to maintain the state (rolled state) in which the cushioning mat is wound around the side surface of the column by applying tension in the winding direction of the cushioning mat, the adhesive tape attached to the attaching area is the cushioning mat. It is desirable to have a certain length or more in the longitudinal direction (that is, the winding direction). Specifically, the pressure-sensitive adhesive tape attached to the attachment area has a direction perpendicular to the axial direction of the columnar body (that is, It is desirable that the dimension in the winding direction of the cushioning mat) is larger.

<Constitution>
Therefore, the fourth method is any of the above-described first method to third method, and the adhesive tape attached to the attaching area in the second step is a pillar when expanded to a single plane. A method for manufacturing an exhaust treatment device, which has a shape in which a dimension in a direction perpendicular to an axial direction of a column is larger than a dimension in an axial direction of a body.

FIG. 12 is a schematic perspective view of the columnar unit obtained in the second step included in the fourth method (a) and the adhesive tape attached to the attachment area of the columnar unit is developed on a single plane. It is a schematic plan view (b) in the case. As shown in (a), the adhesive tape 23 is attached to the outer peripheral surface of the cushioning mat 22 in a long range including the fitting portion 22c in the winding direction. When the adhesive tape 23 is peeled off from the attachment area and developed on a plane, the adhesive tape 23 has a shape as shown in (b). Specifically, when the adhesive tape 23 attached to the attaching area in the second step included in the fourth method is expanded on a single plane, the pressure-sensitive adhesive tape 23 is larger than the dimension W of the column 21 in the axial direction. The dimension L in the direction perpendicular to the axial direction of 21 is larger.

<effect>
As described above, in the second step included in the fourth method, the dimension in the direction perpendicular to the axial direction of the pillar is smaller than the dimension in the axial direction of the pillar when developed on a single plane. An adhesive tape having a larger shape is attached to the attachment area. This makes it easy to reliably maintain the state in which the cushioning mat is wound around the side surface of the column (winding state) by applying tension in the winding direction of the cushioning mat.

<<Fifth Embodiment>>
Hereinafter, a method for manufacturing the exhaust treatment device according to the fifth embodiment of the present invention (hereinafter sometimes referred to as “fifth method”) will be described.

As described above, when the sizing method is adopted in the method of the present invention, after the columnar unit is inserted into the inside of the tubular member, the tubular member is subjected to the diameter reduction process so that a predetermined inside of the tubular member is obtained. The holding surface pressure of the column body by the cushioning mat at the position can be adjusted with high accuracy. Such a diameter reduction process can be applied not only when the sizing method is adopted in the method of the present invention, but also when the press-fitting method is adopted in the method of the present invention. For example, after the columnar unit is press-fitted into the tubular member at a compression ratio such that the columnar body is not damaged due to the press-fitting of the columnar unit into the tubular member as described above. By reducing the diameter of the member, the bulk density of the cushioning mat may be further increased to achieve the required holding surface pressure.

<Constitution>
Therefore, the fifth method is any of the above-described first to fourth methods, and after the third step, a diameter reducing process is performed on at least a part of the region of the sidewall of the tubular member facing the cushioning mat. It is a manufacturing method of an exhaust treatment equipment which further includes the 4th process of giving. FIG. 13 is a flowchart showing the flow of each step included in the fifth method. As shown in FIG. 13, the flow of each step in the fifth method is the same as that in the first method from the first step to the third step. The first step to the third step (from step S10 to step S30) have already been described with reference to FIG. 5 to FIG. 8 and thus will not be described here. The fifth method further includes step S40 in which, after step S30 in which the third step is performed, a fourth step in which a diameter reducing process is performed on at least a part of the region of the sidewall of the tubular member facing the cushioning mat is performed. Including. The diameter reducing process can be performed by plastic working such as spinning.

ㆍThe area to be reduced in diameter is at least part of the area facing the cushioning mat on the side wall of the tubular member. Therefore, the entire region may be subjected to the diameter reduction process, or the region may be subjected to the diameter reduction process only in consideration of the local mechanical strength of the column, for example. May be.

<effect>
As described above, in the fifth method, in the fourth step performed after the third step, the diameter reduction process is performed on at least a part of the region of the sidewall of the tubular member facing the cushioning mat. Accordingly, even when the sizing method is adopted in the fifth method, the holding surface pressure required to hold the columnar body at a predetermined position inside the tubular member can be achieved with high accuracy. .. Even when the press-fitting method is adopted in the fifth method, the bulk density of the cushioning mat is further increased by press-fitting the columnar unit into the tubular member and then further reducing the diameter of the tubular member. In addition, a higher holding surface pressure can be achieved.

Although some embodiments and modifications having a specific configuration have been described with reference to the accompanying drawings for the purpose of describing the present invention, the scope of the present invention is not limited to these exemplary embodiments. It should be understood that the present invention should not be construed as being limited to the embodiment and the modified examples, and appropriate modifications can be made within the scope of the matters described in the claims and the specification.

DESCRIPTION OF SYMBOLS 10... Cylindrical member, 20... Pillar unit, 21... Pillar, 21a... 1st end surface, 21b... 2nd end surface, 22... Buffer mat, 22a... Recessed part, 22b... Convex part, 22c... Fitting part, 23 ... Adhesive tape, and 100... Exhaust treatment device.

Claims

A tubular member which is a casing having a tubular shape,
A columnar body which is an exhaust treatment unit having a columnar shape,
A cushioning mat that is interposed between the tubular member and the column body and holds the column body by a restoring force at a predetermined position inside the tubular member,
A method of manufacturing an exhaust treatment device including:
The buffer mat is wound around the side surface of the column body so that exposed portions are exposed at both ends of the side surface of the column body in the axial direction of the column body, and two end edges in the winding direction of the buffer mat are provided. A first step of facing each other and fitting a concave portion and a convex portion respectively formed on the two end edges to each other to form a fitting portion;
Between a part of the first end surface that is one of the two bottom surfaces of the pillar body, at least a part of the fitting portion, and between the first end surface of the exposed portion and the fitting portion. A second step of sticking an adhesive tape to the sticking area, which is an area consisting of the sandwiched area, to obtain a pillar unit, and
A third step of press-fitting or inserting the pillar unit into the inside of the tubular member with the first end face as a head;
A method for manufacturing an exhaust treatment device, comprising:
A method for manufacturing an exhaust treatment device according to claim 1, wherein
In the third step, the pillar unit is press-fitted or inserted into the tubular member such that the first end surface is located on the downstream side of the flow of exhaust gas in the operating state of the exhaust gas treatment device.
Exhaust treatment device manufacturing method.
A method for manufacturing the exhaust treatment device according to claim 1 or 2, wherein
In the second step, the adhesive tape is fed out in a direction perpendicular to the axial direction of the columnar body and attached to the attaching area.
Exhaust treatment device manufacturing method.
A method for manufacturing the exhaust treatment device according to any one of claims 1 to 3,
The pressure-sensitive adhesive tape attached to the attachment area in the second step is a direction perpendicular to the axial direction of the columnar body, rather than the dimension in the axial direction of the columnar body, when developed on a single plane. Has a larger shape with dimensions at,
Exhaust treatment device manufacturing method.
A method for manufacturing the exhaust treatment device according to any one of claims 1 to 4, comprising:
After the third step, a diameter reducing process is performed on at least a part of a region of the side wall of the tubular member facing the cushioning mat, a fourth step,
A method for manufacturing an exhaust treatment device, further comprising: