WO2023163007A1 - Matériau de matelas, dispositif de purification de gaz d'échappement et procédé de production de matériau de matelas - Google Patents

Matériau de matelas, dispositif de purification de gaz d'échappement et procédé de production de matériau de matelas Download PDF

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Publication number
WO2023163007A1
WO2023163007A1 PCT/JP2023/006346 JP2023006346W WO2023163007A1 WO 2023163007 A1 WO2023163007 A1 WO 2023163007A1 JP 2023006346 W JP2023006346 W JP 2023006346W WO 2023163007 A1 WO2023163007 A1 WO 2023163007A1
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Prior art keywords
inorganic
mat
binder
mat material
region
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PCT/JP2023/006346
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English (en)
Japanese (ja)
Inventor
雄太 向後
貴之 川辺
友久 山崎
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イビデン株式会社
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Priority to CN202380023662.8A priority Critical patent/CN118786259A/zh
Publication of WO2023163007A1 publication Critical patent/WO2023163007A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/488—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/32—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/36—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/45—Oxides or hydroxides of elements of Groups 3 or 13 of the Periodic Table; Aluminates
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/77—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof
    • D06M11/79—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof with silicon dioxide, silicic acids or their salts
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/263—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors

Definitions

  • the present invention relates to a mat material, an exhaust gas purifier, and a method for manufacturing the mat material.
  • Exhaust gas emitted from internal combustion engines such as diesel engines contains particulate matter (hereinafter also referred to as PM), and in recent years, it has become a problem that this PM harms the environment and the human body. .
  • the exhaust gas contains harmful gas components such as CO, HC, and NOx, there are concerns about the effects of these harmful gas components on the environment and the human body.
  • an exhaust gas treating body made of porous ceramic such as silicon carbide or cordierite, and a casing accommodating the exhaust gas treating body are provided. and a holding sealing material (mat material) disposed between an exhaust gas treating body and a casing.
  • This holding sealing material prevents the exhaust gas treating body from coming into contact with and damaging the casing covering the outer periphery thereof due to vibrations and impacts caused by the running of the vehicle, and prevents the exhaust gas treating body and the casing from being damaged. It is arranged mainly for the purpose of preventing exhaust gas from leaking from between.
  • Patent Document 1 by setting the density ⁇ of the entangled points formed by the needling process to 0.5/cm 2 ⁇ 20/cm 2 , both the necessary strength and high repulsive force of the sheet material are achieved. It is disclosed that it has both characteristics. Further, Patent Document 1 discloses that by including an organic binder in the sheet material, adhesion between fibers is improved and scattering of fibers is prevented during handling of the sheet material.
  • Patent Document 1 only the organic binder is attached, so the shear modulus of the mat is low and the holding power is smaller than expected.
  • the organic binder contained in the sheet material is thermally decomposed and burned out by high-temperature exhaust gas immediately after the exhaust gas purifier is used, resulting in a decrease in holding power.
  • the mat material of the present invention contains inorganic fibers and has a plurality of entangled points formed by needling on at least one of the front surface and the back surface, and the density ⁇ of the entangled points is 0.5.
  • a first region that is a 4 mm ⁇ 4 mm region in the range of 5 / cm 2 ⁇ ⁇ ⁇ 18 / cm 2 and in which the entangled points do not exist in the 25 mm ⁇ 25 mm region, and the entangled At least one of the second regions, which is a region of 3 mm ⁇ 8 mm in which no points exist, is arranged, contains an inorganic binder, has a shear modulus of 0.20 or more, and has a surface pressure after firing of 50 kPa or more. , characterized in that
  • the mat material of the present invention has a density ⁇ of intertwined points in the range of 0.5/cm 2 ⁇ 18/cm 2 and is a 4 mm ⁇ 4 mm region in which the above-mentioned intertwined points do not exist. At least one of the first area and the second area, which is a 3 mm ⁇ 8 mm area in which the interlacing points do not exist, is arranged. When the density ⁇ of intertwined points is small, the shear modulus tends to be small. However, the mat material of the present invention has at least one of the first region and the second region and contains an inorganic binder.
  • the inorganic binder has a high shear modulus of 0.20 or more even though the density ⁇ of the entangled points is small. Further, the inorganic binder does not burn off even if high-temperature exhaust gas flows into the exhaust gas purifying device, so it has a high holding power and a surface pressure of 50 kPa or more after firing. Furthermore, since the inorganic binder is also present on the surface of the mat material, it is possible to prevent the position of the mat material from shifting due to vibration or impact.
  • the weight ratio of the inorganic binder to the mat material is preferably more than 0 wt % and 10 wt % or less.
  • the holding power can be sufficiently increased.
  • the mat material of the present invention preferably further contains an organic binder.
  • an organic binder in the mat material, the adhesiveness between the fibers is improved, and scattering of the fibers during handling of the mat material is prevented.
  • the weight ratio of the organic binder to the mat material is preferably more than 0 wt % and 10 wt % or less.
  • weight ratio of the organic binder to the mat material is within the above range, both the effect of preventing scattering of fibers and high holding power can be achieved.
  • the inorganic binder and the organic binder are attached to the surfaces of the inorganic fibers in a dispersed state.
  • the inorganic binder and the organic binder are attached to the surface of the inorganic fiber in a dispersed state, the inorganic binder is dispersed in the film formed by the organic binder. Since the film in such a state has excellent mechanical strength, it is possible to prevent the inorganic fibers from slipping and to increase the holding power.
  • the matting material of the present invention preferably further contains a polymeric dispersant.
  • a polymeric dispersant it becomes easier to attach the organic binder and the inorganic binder to the surfaces of the inorganic fibers in a dispersed state.
  • aggregates composed of the inorganic binder and the organic binder adhere to the surfaces of the inorganic fibers.
  • Aggregates composed of an inorganic binder and an organic binder can form unevenness on the surface of the inorganic fibers, so that the friction between the inorganic fibers can be increased to improve the holding power.
  • a coating layer made of a mixture of the inorganic binder and the organic binder is covered with a coating layer made of a mixture of the inorganic binder and the organic binder.
  • a coating layer comprising a mixture of an inorganic binder and an organic binder has higher mechanical strength than a coating layer comprising only an organic binder. Therefore, peeling of the coating layer is unlikely to occur, and the frictional resistance between the inorganic fibers can be increased.
  • the coating layer is formed by continuous scaly mixture of the inorganic binder and the organic binder.
  • the coating layer is formed of the scaly mixture, a large number of irregularities derived from the scaly mixture are formed on the surface of the coating layer, and the frictional resistance between the inorganic fibers can be further increased.
  • the shape of the coating layer is preferably multi-stepped.
  • the frictional resistance between the inorganic fibers can be further increased.
  • a particulate mixture of the inorganic binder and the organic binder adhere to the surface of the coating layer.
  • the frictional resistance between the inorganic fibers can be further increased compared to the coating layer alone.
  • the shear modulus of the mat material of the present invention is preferably 105% or more of the shear modulus of the mat material under the same conditions except that it does not contain an inorganic binder.
  • the mat material having the same conditions except that it does not contain an inorganic binder corresponds to the mat material of the present invention from which the inorganic binder has been removed.
  • a plurality of the first regions and/or the second regions are arranged within a region of 25 mm ⁇ 25 mm.
  • the surface pressure of the mat material can be increased.
  • the mat material of the present invention preferably further has a protective sheet provided on at least one surface. If the mat material further has a protective sheet provided on its surface, the mat material may be displaced and/or densely wrinkled when the mat material is wound around the exhaust gas treating body, and the gap between the fitting parts may occur. is suppressed.
  • the mat material of the present invention is preferably used in an exhaust gas purifier.
  • the mat material of the present invention has a high shear modulus and holding power. Therefore, it can be suitably used for an exhaust gas purifier.
  • An exhaust gas purifying apparatus of the present invention includes an exhaust gas treating body, a metal casing for housing the exhaust gas treating body, and a mat material disposed between the exhaust gas treating body and the metal casing for holding the exhaust gas treating body.
  • the exhaust gas purifier includes the mat member, wherein the mat member is the mat member of the present invention.
  • the exhaust gas purifying device of the present invention can stably hold the exhaust gas treating body.
  • a first embodiment of the method for producing a mat material of the present invention contains inorganic fibers, has a plurality of entangled points formed by needling on at least one of the front surface and the back surface, and the density ⁇ of the entangled points is 0.5 pieces/cm 2 ⁇ ⁇ 18 pieces/cm 2 , a first region that is a 4 mm ⁇ 4 mm region in which the entanglement points do not exist in a 25 mm ⁇ 25 mm region, and the entanglement It is characterized by having an attaching step of attaching an inorganic binder to the inorganic fiber aggregate in which at least one of the second areas, which are areas of 3 mm ⁇ 8 mm where no dots are present, is arranged.
  • a second embodiment of the method for producing a mat material of the present invention contains inorganic fibers, has a plurality of intertwined points formed by needling treatment on at least one of the front surface and the back surface, and the density ⁇ of the intertwined points is 0.5 pieces/cm 2 ⁇ ⁇ 18 pieces/cm 2 , a first region that is a 4 mm ⁇ 4 mm region in which the entanglement points do not exist in a 25 mm ⁇ 25 mm region, and the entanglement It has an attaching step of attaching both the inorganic binder and the organic binder to the inorganic fiber aggregate in which at least one of the second regions, which is a region of 3 mm ⁇ 8 mm in which no points are present, is arranged.
  • the inorganic fiber aggregate is attached with a dispersion liquid in which the inorganic binder and the organic binder are dispersed in a dispersion medium.
  • the inorganic fiber aggregates are attached with an aggregation dispersion obtained by aggregation of the inorganic binder and the organic binder.
  • the mat member of the present invention can be produced easily.
  • FIG. 1 is a perspective view schematically showing an example of the mat material of the present invention.
  • FIG. 2 is a cross-sectional view taken along line AA in FIG.
  • FIG. 3 is a schematic diagram showing an example of arrangement of intertwined points in the mat member of the present invention.
  • FIG. 4 is a schematic diagram showing an example of a mat member in which interlacing points are uniformly arranged.
  • FIG. 5 is an example of an enlarged electron microscope image of the mat material of the present invention.
  • FIG. 6 is another example of an enlarged electron microscope image of the mat material of the present invention.
  • FIG. 7 is still another example of an enlarged electron microscope image of the mat material of the present invention.
  • FIG. 8 is still another example of an enlarged electron microscope image of the mat material of the present invention.
  • FIG. 1 is a perspective view schematically showing an example of the mat material of the present invention.
  • FIG. 2 is a cross-sectional view taken along line AA in FIG.
  • FIG. 3 is
  • FIG. 9 is a conceptual diagram schematically showing a shear breaking load testing apparatus.
  • FIG. 10 is a perspective view schematically showing another example of the mat material of the present invention.
  • FIG. 11 is a cross-sectional view schematically showing an example of the exhaust gas purifier of the present invention.
  • the mat material of the present invention contains inorganic fibers and has a plurality of entangled points formed by needling on at least one of the front surface and the back surface, and the density ⁇ of the entangled points is 0.5. /cm 2 ⁇ 18 pieces/cm 2 , and a first region that is a 4 mm ⁇ 4 mm region in which the intertwined points do not exist in a 25 mm ⁇ 25 mm region, and the intertwined points are At least one of the second regions, which are 3 mm ⁇ 8 mm regions that do not exist, is arranged, contains an inorganic binder, has a shear modulus of 0.20 or more, and has a surface pressure of 50 kPa or more after firing. It is characterized by
  • FIG. 1 is a perspective view schematically showing an example of the mat material of the present invention
  • FIG. 2 is a cross-sectional view taken along the line AA in FIG.
  • the mat material 1 of the present invention has a predetermined length (indicated by arrow L in FIG. 1), width (indicated by arrow W in FIG. 1) and thickness (indicated by arrow W in FIG. 1). , indicated by an arrow T).
  • a protrusion 11 is formed at one end of the mat 10 in the longitudinal direction, and a recess 12 is formed at the other end.
  • the protrusions 11 and the recesses 12 of the mat 10 are shaped so that they are just fitted to each other when the mat 10 is wound around an exhaust gas treating body for assembling an exhaust gas purifying device, which will be described later.
  • convex portions 11 and concave portions 12 are provided, sealing performance is improved when the mat 10 is arranged in an exhaust gas purifying apparatus to be described later.
  • a plurality of interlaced points 15 (also referred to as needle punch marks) formed by needling are formed on the main surface of the mat 10 .
  • the mat 10 has two main surfaces, one of which is the front surface and the other of which is the back surface.
  • the mat used for the mat material of the present invention does not have to have projections and recesses at the ends.
  • the shape of the ends of the mat may be L-shaped so that the ends fit together when the mat material is wrapped around the object.
  • the mat itself may be a matting material, or may further include a protective sheet, which will be described later, on at least one surface of the mat.
  • each interlacing point 15 is formed on a straight line perpendicular to the thickness direction of the mat 10 .
  • the shape of the intertwined points 15 may be curved or may be inclined with respect to the thickness direction of the mat 10 . Further, the interlaced points 15 do not have to penetrate the mat 10 in the thickness direction.
  • the thickness of the mat is not particularly limited, it is preferably 2 to 40 mm. If the thickness of the mat exceeds 40 mm, the flexibility of the mat is lost, making it difficult to handle when winding the mat material around the exhaust gas treating body. In addition, winding wrinkles and cracks are likely to occur in the mat material. When the thickness of the mat is less than 2 mm, the holding power of the mat material is insufficient, and the exhaust gas treating body tends to fall off. In addition, when the volume of the exhaust gas treating body changes, the mat material becomes difficult to absorb the volume change of the exhaust gas treating body. Therefore, cracks and the like are likely to occur in the exhaust gas treating body.
  • the mat contains inorganic fibers.
  • the inorganic fibers are not particularly limited, but preferably consist of at least one selected from the group consisting of alumina fibers, silica fibers, alumina-silica fibers, mullite fibers, biosoluble fibers and glass fibers.
  • the inorganic fiber is at least one of alumina fiber, silica fiber, alumina-silica fiber, and mullite fiber, the exhaust gas treating body is exposed to a sufficiently high temperature because of its excellent heat resistance. However, deterioration or the like does not occur, and the function as a mat material can be sufficiently maintained.
  • the inorganic fiber is a biosoluble fiber, even if the scattered inorganic fiber is inhaled when fabricating an exhaust gas purifying device using a mat material, it will dissolve in the body, so it will be difficult for the worker. No harm to health.
  • Alumina fibers may contain additives such as calcia, magnesia, and zirconia in addition to alumina.
  • the mat can be produced by the needling method.
  • the inorganic fibers preferably have an average fiber length of 1 to 150 mm, more preferably 10 to 80 mm.
  • the average fiber length of the inorganic fibers is less than 1 mm, the fiber length of the inorganic fibers is too short, and the entanglement of the inorganic fibers becomes insufficient, the winding property around the exhaust gas treating body decreases, and the mat material becomes easily cracked.
  • the average fiber length of the inorganic fibers exceeds 150 mm, the fiber length of the inorganic fibers is too long, so that the number of fibers constituting the mat member decreases and the denseness of the mat member decreases. As a result, the shear strength of the mat material is lowered.
  • Intertwined points are formed on the surface or the back surface of the mat material.
  • the density ⁇ of intertwined points is in the range of 0.5/cm 2 ⁇ 18/cm 2 .
  • the density ⁇ of the intertwined points is measured on the main surface having the higher density of intertwined points among the front surface and the back surface. is the density of
  • first area 4 mm ⁇ 4 mm where no intertwined points exist
  • second area 3 mm ⁇ 8 mm where no intertwined points exist.
  • At least one of the regions is arranged.
  • at least one of the first region and the second region is arranged, thereby exerting a high contact pressure.
  • the principal surface of the mat member for determining whether or not the first region and/or the second region are arranged is the same principal surface as the principal surface for measuring the density of the intertwined points.
  • both the first area and the second area are preferably arranged within a 25 mm ⁇ 25 mm area on the front surface or the back surface.
  • the first region and the second region may be arranged separately, it is more preferable that the first region and the second region overlap each other. When the first region and the second region overlap each other, the area where no interlacing points are present becomes larger, so that the surface pressure of the mat material can be increased.
  • FIG. 3 is a schematic diagram showing an example of arrangement of intertwined points in the mat member of the present invention.
  • a plurality of intertwined points 15 are unevenly arranged. Therefore, the first region 17, which is a 4 mm ⁇ 4 mm region (region indicated by a solid square in FIG. 3) where no intertwined points 15 exist, and a 3 mm ⁇ 8 mm region (in FIG. 3) where no intertwined points 15 exist , a region indicated by a dashed rectangle) is arranged. Note that FIG. 3 does not show all of the first area 17 and the second area 18 .
  • FIG. 4 is a schematic diagram showing an example of a mat member in which interlacing points are uniformly arranged.
  • the interlacing points 15 are evenly spaced at intervals of 2.8 mm.
  • Both the 4 mm by 4 mm square and the 3 mm by 8 mm rectangle shown in FIG. 4 contain one or more entanglement points.
  • a 4 mm ⁇ 4 mm square that does not correspond to the first region and a 3 mm ⁇ 8 mm rectangle that does not correspond to the second region are marked with “x”. Therefore, neither the first area nor the second area can be arranged on the mat material shown in FIG.
  • a method for counting the number of first regions and second regions within a 25 mm ⁇ 25 mm region is as follows. (1) Find a 4 mm ⁇ 4 mm region (first region) in which no entanglement points are formed. At this time, the plurality of first regions are selected so as not to overlap each other. (2) Find a 3 mm ⁇ 8 mm region (second region) in which no entanglement points are formed. At this time, the plurality of second regions are selected so as not to overlap each other. The second region may overlap the first region. (3) Select a region of 25 mm ⁇ 25 mm that maximizes the number of first regions that do not overlap each other and the number of second regions that do not overlap each other. The above operation is performed on 10 samples and an average value is taken. Note that the above operation may be performed using commercially available image processing software or the like.
  • a plurality of first regions and/or second regions are arranged in a region of 25 mm ⁇ 25 mm.
  • the surface pressure of the mat material can be increased.
  • a plurality of the first regions and/or the second regions are arranged when the total number of the first regions and the number of the second regions is 2 or more, and the plurality of the first regions It includes a case where a plurality of second regions are arranged, a case where a plurality of first regions and a plurality of second regions are arranged, and the like.
  • a third area which is a 4 mm ⁇ 4 mm area in which four or more intertwining points are present, is arranged within a 25 mm ⁇ 25 mm area on the front surface or the back surface of the mat member.
  • the inorganic fibers are strongly entangled with each other in this region, so that the shear strength of the mat material can be increased.
  • the method of counting the number of the third regions within the 25 mm ⁇ 25 mm region is the same as the method of counting the number of the first regions described above.
  • the mat material contains an inorganic binder (also called an inorganic binder). Since the mat material of the present invention contains an inorganic binder, it has a high shear modulus. Furthermore, the inorganic binder has a high holding power because it does not burn off even if high-temperature exhaust gas flows into the exhaust gas purifying device. Furthermore, since the inorganic binder is also present on the surface of the mat material, it is possible to prevent the position of the mat material from shifting due to vibration or impact.
  • an inorganic binder also called an inorganic binder
  • inorganic binders examples include alumina sol and silica sol.
  • the weight ratio of the inorganic binder to the mat material is preferably more than 0 wt % and 10 wt % or less. When the weight ratio of the inorganic binder to the mat material is within the above range, the holding power can be sufficiently increased.
  • the mat material may further contain an organic binder (also referred to as an organic binder).
  • an organic binder also referred to as an organic binder.
  • organic binders examples include acrylic resins, acrylate latexes, rubber latexes, water-soluble organic polymers such as carboxymethyl cellulose and polyvinyl alcohol, thermoplastic resins such as styrene resins, and thermosetting resins such as epoxy resins.
  • the weight ratio of the organic binder to the mat material is preferably more than 0 wt % and 10 wt % or less. When the weight ratio of the organic binder to the mat material is within the above range, both the effect of preventing scattering of fibers and high holding power can be achieved.
  • the contents of the organic binder and the inorganic binder contained in the mat material can be measured, for example, by the following method.
  • First, the mat material whose content is to be measured is sampled as a constant weight sample.
  • an organic solvent for example, tetrahydrofuran
  • the organic binder contained in the sample dissolves is selected, and the organic binder is dissolved in a Soxhlet extractor and separated from the sample.
  • the inorganic binder contained in the dissolved organic binder is also separated from the sample, and the organic binder and the inorganic binder are recovered in the organic solvent.
  • an organic solvent composed of the organic binder and the inorganic binder is placed in a crucible, and heated to evaporate and remove the organic solvent.
  • the residue remaining in the crucible is regarded as the total weight of the organic binder and the inorganic binder with respect to the matting material, and the content (% by weight) of the matting material is calculated.
  • the crucible is heat-treated at 600° C. for 1 hour to burn off the organic binder. Since the inorganic binder remains in the crucible, this is regarded as the content (% by weight) of the inorganic binder with respect to the total of the organic binder and the inorganic binder, and the content is calculated. The remainder is the content (% by weight) of the organic binder.
  • the inorganic binder and the organic binder are attached to the surfaces of the inorganic fibers in a dispersed state.
  • the inorganic binder and the organic binder are attached to the surface of the inorganic fiber in a dispersed state, the inorganic binder is dispersed in the film formed by the organic binder. Since the film in such a state has excellent mechanical strength, it is possible to prevent the inorganic fibers from slipping and to increase the holding power.
  • a coating layer made of a mixture of an inorganic binder and an organic binder is covered with a coating layer made of a mixture of an inorganic binder and an organic binder.
  • a coating layer comprising a mixture of an inorganic binder and an organic binder has higher mechanical strength than a coating layer comprising only an organic binder. Therefore, peeling of the coating layer is unlikely to occur, and the frictional resistance between the inorganic fibers can be increased.
  • the coating layer is preferably formed by continuous scaly mixture (mixture of inorganic binder and organic binder).
  • scaly mixture mixture of inorganic binder and organic binder.
  • FIG. 5 is an example of an enlarged electron microscope image of the mat material of the present invention.
  • part of the surface of the inorganic fiber 20 is covered with a coating layer 30 made of a mixture of an inorganic binder and an organic binder.
  • the coating layer 30 is formed by a continuous scaly mixture of an inorganic binder and an organic binder.
  • a particulate mixture 40 of an inorganic binder and an organic binder is attached to the surfaces of the inorganic fibers 20 . Whether or not the coating layer and the particles are composed of a mixture of the inorganic binder and the organic binder can be confirmed by using both field observation with an electron microscope and elemental analysis.
  • FIG. 6 is another example of an enlarged electron microscope image of the mat material of the present invention.
  • a portion of the surface of the inorganic fiber 20 is covered with a coating layer 30 made of a mixture of an inorganic binder and an organic binder.
  • the coating layer 30 is formed by a continuous scaly mixture of an inorganic binder and an organic binder.
  • a particulate mixture 40 of an inorganic binder and an organic binder is attached to the surfaces of the inorganic fibers 20 .
  • the thickness of the coating layer may be uniform, but may not be uniform.
  • the shape of the coating layer whose thickness is not constant is also called a multi-step shape.
  • the shape of the coating layer is multi-stepped, it can be said that the coating layer has unevenness on the surface, so that the frictional resistance between the inorganic fibers can be further increased.
  • Whether the coating layer has unevenness on the surface can be determined by magnifying the surface of the inorganic fiber at a magnification of 3000 using a scanning electron microscope. It is determined by checking the presence or absence of unevenness on the surface of the
  • FIG. 7 is still another example of an enlarged electron microscope image of the mat material of the present invention.
  • part of the surface of the inorganic fiber 20 is covered with a coating layer 30 made of a mixture of an inorganic binder and an organic binder.
  • the thickness of the coating layer 30 is not uniform and is multi-stepped.
  • a particulate mixture 40 of an inorganic binder and an organic binder is attached to the surfaces of the inorganic fibers 20 .
  • Particles of a mixture of an inorganic binder and an organic binder are preferably attached to the surface of the coating layer.
  • the frictional resistance between the inorganic fibers can be further increased compared to when the particles are not attached.
  • FIG. 8 is still another example of an enlarged electron microscope image of the mat material of the present invention.
  • part of the surface of the inorganic fibers 20 is covered with a coating layer 30 made of a mixture of an inorganic binder and an organic binder.
  • the coating layer 30 is formed by a continuous scaly mixture of an inorganic binder and an organic binder.
  • the thickness of the coating layer 30 is not uniform and is multi-stepped.
  • a particulate mixture 40 of an inorganic binder and an organic binder is attached to the surface of the coating layer 30 .
  • the matting material preferably further contains a polymeric dispersant.
  • a polymeric dispersant When the matting material further contains a polymeric dispersant, it becomes easier to attach the organic binder and the inorganic binder to the surfaces of the inorganic fibers in a dispersed state.
  • the content of the polymeric dispersant is preferably 50 to 1000 ppm with respect to the weight of the inorganic fiber.
  • the mat material is an aggregate of an inorganic binder and an organic binder adhered to the surfaces of the inorganic fibers.
  • Aggregates composed of an inorganic binder and an organic binder can form unevenness on the surface of the inorganic fibers, so that the friction between the inorganic fibers can be increased to improve the holding power.
  • the mat material may further contain a flocculating agent. If the matting material further contains an aggregating agent, the organic binder and the inorganic binder can be easily adhered to the surface of the inorganic fibers in an agglomerated state.
  • the inorganic binder and the organic binder attached to the surface of the inorganic fiber are dispersed or agglomerated can be confirmed by observing the surface of the inorganic fiber with SEM-EDX or the like.
  • the mat material of the present invention has a shear modulus of 0.20 or more.
  • the shear modulus is 0.20 or more, the mat material is less likely to be sheared when the exhaust gas treating body is pressed into the metal casing using the mat material of the present invention.
  • the shear modulus is obtained by dividing the shear breaking load by the relaxation surface pressure.
  • FIG. 9 is a conceptual diagram schematically showing a shear breaking load testing apparatus.
  • test pieces 1a and 1b are arranged on both sides of a stainless steel plate 73, and the outside thereof is sandwiched between left jigs 71 and right jigs 72.
  • a large number of projecting members 74 are provided on the surfaces of the left jig 71, the right jig 72, and the stainless steel plate 73, which are in contact with the test piece.
  • test pieces 1 a and 1 b are fixed to the left jig 71 , the right jig 72 and the stainless steel plate 73 by being pierced by the projecting member 74 .
  • the test piece is compressed until the bulk density (GBD) reaches 0.3 g/cm 3 .
  • the stainless steel plate 73 is moved in the direction (upward) shown by the arrow in FIG. It cannot escape apart from pieces 1a and 1b. Therefore, when the test pieces 1a and 1b are subjected to a shear force equal to or greater than the shear fracture load of the test pieces, the test pieces 1a and 1b undergo shear failure. Obtain the shear force applied to the stainless steel plate when the test piece undergoes shear fracture.
  • the shear breaking load (kPa) can be obtained.
  • the shear breaking load may be measured using a test piece obtained by cutting out a part of the mat material.
  • the relaxation surface pressure can be measured by the following procedure. First, at room temperature, the mat material is compressed to a bulk density of 0.3 g/cm 3 , held for 20 minutes, and then the load is measured.
  • the relaxation surface pressure (kPa) can be obtained by dividing the obtained load by the area of the test piece. Alternatively, the relaxation surface pressure may be measured using a test piece obtained by cutting out a part of the mat material.
  • the surface pressure of the mat material after firing is 50 kPa or more.
  • the post-sintering surface pressure of the mat material can be measured by the following method using a hot surface pressure measuring device equipped with a heater at the portion of the plate that compresses the mat material to be the test piece. First, a test piece (mat material) is compressed to a bulk density of 0.3 g/cm 3 at room temperature, and then held for 10 minutes. After that, while the test piece is compressed and heated to 900°C on one side and 650°C on the other side at a heating rate of 45°C, the compression is released until the bulk density reaches 0.27 g/cm 3 and held for 5 minutes. .
  • the plate for compressing the mat material is moved at a speed of 1 inch (25.4 mm)/min until the bulk density reaches 0.3/cm 3 .
  • the contact pressure (kPa) is obtained, which is defined as the contact pressure after firing.
  • the mat material may further have a protective sheet placed on at least one surface.
  • a protective sheet is placed on at least one surface of the mat.
  • the material constituting the protective sheet is not particularly limited, a flexible resin such as polypropylene is preferable.
  • the protective sheet may be, for example, a nonwoven fabric made of flexible resin fibers.
  • two or more different materials may be used together for the protective sheet.
  • Two or more types of materials may form the same nonwoven fabric, or two or more different types of nonwoven fabrics may be laminated to form a protective sheet.
  • the thickness of the protective sheet is not particularly limited, it is preferably 1 ⁇ m to 1 mm. If the thickness of the protective sheet is less than 1 ⁇ m, the effect of alleviating deformation of the mat may not be sufficient. If the thickness of the protective sheet exceeds 1 mm, the handleability may deteriorate.
  • the ratio of the thickness of the protective sheet to the thickness of the mat is not particularly limited, but is preferably in the range of about 1:10 to about 1:1000, and in the range of about 1:50 to about 1:200. is more preferred.
  • the method of adhering the protective sheet and the mat is not particularly limited, but for example, a method of heating and melting hot-melt powder placed between the protective sheet and the mat can be used.
  • the surface on which the protective sheet is installed is the outer surface when the mat material is wound around the exhaust gas treating body.
  • a slit may be formed in the protective sheet.
  • the direction of the slit is not particularly limited, it may extend along the longitudinal direction of the mat member or along the width direction.
  • FIG. 10 is a perspective view schematically showing another example of the mat material of the present invention.
  • a mat member 2 shown in FIG. 10 has a mat 10 and a protective sheet 50 provided on one surface of the mat 10 .
  • the protective sheet may be provided only on one surface of the mat, or may be provided on both surfaces.
  • An exhaust gas purifying apparatus of the present invention includes an exhaust gas treating body, a metal casing for housing the exhaust gas treating body, and a mat material disposed between the exhaust gas treating body and the metal casing for holding the exhaust gas treating body.
  • the exhaust gas purifying apparatus is provided, wherein the mat material is the mat material of the present invention.
  • the exhaust gas purifying device of the present invention can stably hold the exhaust gas treating body.
  • FIG. 11 is a cross-sectional view schematically showing an example of the exhaust gas purifier of the present invention.
  • the exhaust gas purification apparatus 100 includes a metal casing 120, an exhaust gas treating body 130 housed in the metal casing 120, and a mat material 1 disposed between the exhaust gas treating body 130 and the metal casing 120. It has The mat material 1 is the mat material of the present invention.
  • the exhaust gas treating body 130 has a columnar shape in which a large number of cells 131 are arranged side by side in the longitudinal direction with cell walls 132 interposed therebetween.
  • An introduction pipe for introducing the exhaust gas discharged from the internal combustion engine and an exhaust pipe for discharging the exhaust gas that has passed through the exhaust gas purifier are connected to the ends of the metal casing 120 as necessary.
  • an exhaust gas filter in which one of the cells is plugged with a plugging material 133 is used as the exhaust gas treating body 130.
  • a catalyst carrier that is not plugged with a sealing material may also be used.
  • the exhaust gas discharged from the internal combustion engine and flowing into the exhaust gas purifying device 100 is an exhaust gas treating body (honeycomb filter) 130.
  • the exhaust gas flows into one cell 131 opened at the exhaust gas inflow side end face 130 a of the second cell 131 and passes through the cell wall 132 separating the cells 131 .
  • the PM in the exhaust gas is captured by the cell walls 132, and the exhaust gas is purified.
  • the purified exhaust gas flows out from another cell 131 opened at the exhaust gas outlet side end surface 130b and is discharged to the outside.
  • a first embodiment of the method for producing a mat material of the present invention contains inorganic fibers, has a plurality of entangled points formed by needling on at least one of the front surface and the back surface, and the density ⁇ of the entangled points is 0.5 pieces/cm 2 ⁇ ⁇ 18 pieces/cm 2 , a first region that is a 4 mm ⁇ 4 mm region in which the entanglement points do not exist in a 25 mm ⁇ 25 mm region, and the entanglement It is characterized by having an attaching step of attaching an inorganic binder to the inorganic fiber aggregate in which at least one of the second areas, which are areas of 3 mm ⁇ 8 mm where no dots are present, is arranged.
  • the inorganic fiber aggregate used in the first embodiment of the method for producing a mat material of the present invention is, for example, a spinning step of producing an inorganic fiber precursor by spinning a spinning mixture containing at least an inorganic compound and an organic polymer.
  • Specific examples of the spinning process, the compression process, the needle punching process, and the firing process are described below.
  • spinning process a spinning mixture containing at least an inorganic compound and an organic polymer is spun to produce an inorganic fiber precursor.
  • an inorganic fiber precursor having an average fiber diameter of 3 to 10 ⁇ m is produced by spinning a spinning mixture containing a basic aluminum chloride aqueous solution and silica sol as raw materials by a blowing method.
  • the inorganic fiber precursor obtained in the spinning step is compressed to produce a continuous sheet-like material having a predetermined size.
  • needle punching process In the needle-punching step, at least one surface of the sheet-like material obtained in the compression step is needle-punched to produce a needle-punched body.
  • the needle punching step it is preferable to set the needle arrangement density to 0.5 needles/cm 2 or more and less than 18 needles/cm 2 .
  • the positions where the needles are arranged in the needle punching process correspond to the entanglement points in the mat material. Therefore, by setting the arrangement density of the needles to 0.5/cm 2 or more and less than 18/cm 2 , the density ⁇ of the intertwined points can be reduced to 0.5/cm 2 ⁇ ⁇ by a single needle punching process.
  • a mat material in the range of ⁇ 18 pieces/cm 2 can be obtained.
  • the arrangement density of the needles is not limited to the above range.
  • the arrangement of the intertwined points formed in the needle-punched body is unevenly arranged, and the density ⁇ of the intertwined points is 0.5/cm. 2 ⁇ ⁇ ⁇ 18 pieces / cm 2 , in a 25 mm ⁇ 25 mm area, a 4 mm ⁇ 4 mm area (first area) where no intertwined points exist and / or a 3 mm ⁇ 8 mm area where no intertwined points exist A region (second region) can be formed.
  • a method of intentionally biasing the arrangement of the intertwined points for example, after performing needle punching treatment so that the intertwined points are uniformly arranged
  • a method of additionally performing needling treatment on a part can be mentioned.
  • a method of performing needle punching treatment multiple times while moving the inorganic fiber precursor a method of performing needle punching treatment using a needle board in which needles are not arranged at equal intervals, and the like can be used.
  • the needles may or may not penetrate the sheet-like material in the thickness direction.
  • the needle-punched body is fired to obtain an inorganic fiber aggregate made of inorganic fibers.
  • the temperature for firing the needle-punched body is not particularly limited, it is preferably 1000.degree. C. to 1600.degree.
  • an inorganic binder is attached to the inorganic fiber aggregate.
  • a method of attaching an inorganic binder to an inorganic fiber aggregate for example, a method of contacting an inorganic binder mixed liquid in which a solvent and an inorganic binder are mixed with an inorganic fiber aggregate and then drying the mixed liquid is mentioned.
  • a method for bringing the inorganic binder mixed liquid into contact with the inorganic fiber aggregates for example, a method of immersing the inorganic fiber aggregates in the inorganic binder mixed liquid, a method such as a curtain coating method, or the like is used to apply the inorganic binder mixed liquid to the inorganic fiber aggregates. A method of dropping it upward can be mentioned.
  • the content of the inorganic binder in the inorganic binder mixture is preferably 0.05 wt % or more and 5 wt % or less.
  • the inorganic binder mixture may contain a polymeric dispersant.
  • the inorganic binder mixed liquid contains a polymer-based dispersant, the inorganic binder is dispersed in the inorganic binder mixed liquid.
  • the inorganic binder mixed liquid in this state into contact with the inorganic fiber aggregate, the inorganic binder can be adhered to the surfaces of the inorganic fibers in a dispersed state.
  • Polymeric dispersants include polycarboxylic acid and/or its salts, naphthalene sulfonate formalin condensate and/or its salts, polyacrylic acid and/or its salts, polymethacrylic acid and/or its salts, polyvinyl sulfone Hydrophilic synthetic polymeric substances such as anionic polymeric dispersants such as acids and/or salts thereof, nonionic polymeric dispersants such as polyvinyl alcohol, polyvinylpyrrolidone, and polyethylene glycol; gelatin, casein, water-soluble Naturally hydrophilic polymeric substances such as starch; hydrophilic semi-synthetic polymeric substances such as carboxymethyl cellulose; Among these, hydrophilic synthetic polymeric substances are preferred, and anionic polymeric dispersants are more preferred.
  • polymeric dispersants may be used alone, or a plurality of types may be used in combination. Further, it may be a polymeric dispersant having both a structure exhibiting properties as an anionic polymeric dispersant and a structure exhibiting properties as a nonionic polymeric dispersant.
  • the inorganic binder mixture may contain a flocculating agent. If the inorganic binder mixed liquid contains an aggregating agent, the inorganic binder is aggregated in the inorganic binder mixed liquid. By bringing the inorganic binder mixed liquid in this state into contact with the inorganic fiber aggregate, the inorganic binder can be adhered to the surfaces of the inorganic fibers in an aggregated state.
  • a second embodiment of the method for producing a mat material of the present invention contains inorganic fibers, has a plurality of intertwined points formed by needling treatment on at least one of the front surface and the back surface, and the density ⁇ of the intertwined points is 0.5 pieces/cm 2 ⁇ ⁇ 18 pieces/cm 2 , a first region that is a 4 mm ⁇ 4 mm region in which the entanglement points do not exist in a 25 mm ⁇ 25 mm region, and the entanglement It has an attaching step of attaching both the inorganic binder and the organic binder to the inorganic fiber aggregate in which at least one of the second regions, which is a region of 3 mm ⁇ 8 mm in which no points are present, is arranged.
  • the second embodiment of the method for producing a mat material of the present invention is the same as the first method for producing a mat member of the present invention, except that in the attaching step, not only the inorganic binder but also the organic binder is attached to the inorganic fiber aggregates. It is common with the embodiment. Therefore, the attachment step of attaching both the inorganic binder and the organic binder to the inorganic fiber aggregate will be described below.
  • the content of the inorganic binder in the binder mixture is preferably 0.05 wt % or more and 5 wt % or less.
  • the content of the organic binder in the binder mixture is preferably 0.05 wt % or more and 5 wt % or less.
  • the binder mixed liquid may contain a polymeric dispersant.
  • the binder mixed liquid contains a polymeric dispersant
  • the inorganic binder and the organic binder are dispersed in the binder mixed liquid. That is, the binder mixed liquid becomes a dispersion liquid in which the inorganic binder and the organic binder are dispersed in the dispersion medium.
  • the binder mixture may contain a flocculating agent. If the mixed liquid contains an aggregating agent, the inorganic binder and the organic binder are aggregated in the mixed liquid. That is, the binder mixed liquid becomes an aggregate dispersion liquid in which aggregates formed by aggregation of the inorganic binder and the organic binder are dispersed in the dispersion medium. By bringing the binder mixed liquid (aggregated dispersion liquid) in this state into contact with the aggregate of inorganic fibers, the inorganic binder and the organic binder can be adhered to the surfaces of the inorganic fibers in an aggregated state.
  • the attachment of the inorganic binder and the attachment of the organic binder may be carried out separately.
  • a method of performing the attachment of the inorganic binder and the attachment of the organic binder separately for example, an inorganic binder mixed liquid containing an inorganic binder is brought into contact with the inorganic fiber aggregate to attach the inorganic binder, and then the organic binder is added.
  • a method of attaching the organic binder by bringing it into contact with the organic binder mixed solution can be mentioned.
  • the order of adhering the inorganic binder and the organic binder is not particularly limited, and the inorganic binder may come first, or the organic binder may come first.
  • an organic polymer polyvinyl alcohol
  • (c) Needle-punching process The sheet material obtained in the above-mentioned (b) compression process is needle-punched multiple times using a needle board provided with needles at a predetermined density to obtain a needle-punched body. made. First, a needle board having needles attached at a predetermined density was prepared. Next, the needle board is arranged above one surface of the sheet material, and the needle punching process is performed by moving the needle board up and down once along the thickness direction of the sheet material while moving the inorganic fiber precursor. This was repeated several times to produce a needle-punched body. At this time, the needle was pierced until the barb formed at the tip of the needle completely protruded from the opposite surface of the sheet-like material.
  • the needle-punched body obtained in the needle-punching step (c) above is continuously fired at a maximum temperature of 1250°C, and made of inorganic fibers containing alumina and silica in a ratio of 72 parts by weight to 28 parts by weight.
  • a fired sheet was produced.
  • the inorganic fibers had an average fiber diameter of 5.1 ⁇ m and a minimum fiber diameter of 3.2 ⁇ m.
  • the fired sheet material thus obtained had a bulk density of 0.15 g/cm 3 and a basis weight of 1400 g/m 2 .
  • the density ⁇ of the intertwined points is 9/cm 2 , and in the area of 25 mm ⁇ 25 mm, there are 10 first areas, which are 4 mm ⁇ 4 mm areas where no intertwined points exist, and 3 mm ⁇ 8 mm where no intertwined points exist. , four second regions were arranged.
  • the baked needle-punched body was cut to produce an inorganic fiber aggregate.
  • Inorganic binder mixed liquid preparation step Alumina, which is an inorganic binder, is diluted with water, a polymer-based dispersant is added, and the mixture is sufficiently stirred to obtain a solid content concentration of inorganic particles of 2.0 wt%. , an inorganic binder mixed solution in which the concentration of the polymer-based dispersant was 1000 ppm was prepared.
  • Binder mixture preparation step Mixing the inorganic binder mixture obtained in the inorganic binder mixture preparation step (e-2) with the organic binder obtained in the organic binder mixture preparation step (e-1) The liquid was added so that the weight ratio was 1:1 and sufficiently stirred, and the organic binder was 1.0 wt% in solid content concentration, the inorganic binder was 1.0 wt% in solid content concentration, and the concentration of the polymer dispersant was of 500 ppm was prepared.
  • (e-4) Contacting step The binder mixture obtained in the binder mixture preparing step (e-3) was brought into contact with the inorganic fiber aggregate obtained in the baking step (d) by a curtain coating method.
  • (e-5) Dehydration step The inorganic fiber aggregate to which the binder mixture is applied, which is obtained in the (e-4) contact step, is dehydrated by suction with a dehydrator, so that the binder mixture becomes the inorganic fibers 100 A matte was obtained by preparing a state in which 100 parts by weight was added to parts by weight.
  • Example 2 (e-1)
  • the mat material according to Example 2 was prepared in the same manner as in Example 1, except that the solid content concentration of the organic binder mixture prepared in the organic binder mixture preparation step was changed to 0.2 wt%. made.
  • Example 3 (e-1) Without performing the organic binder mixture preparation step, in the (e-3) binder mixture preparation step, the inorganic binder mixture obtained in the (e-2) inorganic binder mixture preparation step is mixed with water and 1 A mat member according to Example 3 was produced in the same manner as in Example 1, except that the solid content concentration of the inorganic particles was adjusted to 1.0 wt % by mixing and stirring at a weight ratio of 1:1.
  • Comparative example 1 (Comparative example 1) (e-2) Without performing the inorganic binder mixture preparation step, in the (e-3) binder mixture preparation step, the organic binder mixture obtained in the (e-1) organic binder mixture preparation step is added to the polymer-based Comparative Example 1 was prepared in the same manner as in Example 1, except that the concentration of the dispersant was mixed with water having a concentration of 500 ppm at a weight ratio of 1:1 and stirred to adjust the solid content concentration of the organic binder to 1.0 wt%. A mat material according to was produced.
  • the mat material of the present invention was found to have a high shear modulus of 0.20 or more.
  • the shear modulus of the mat material according to Example 1 was about 132% of the shear modulus of the mat material according to Comparative Example 1 under the same conditions except that it did not contain an inorganic binder.
  • the lower the weight ratio of the organic binder the higher the shear modulus.
  • the mat material according to Example 1 also has a shear modulus of 0.20 or more and a surface pressure of 50 kPa or more after firing. Therefore, it is considered that the prevention of scattering of the fibers by the organic binder and the high holding power can both be achieved.
  • Comparative Example 4 (c) By changing the type of needle board used in the needle punching process and the number of needling treatments, the density of intertwined points and the number of first and second regions in the 25 mm ⁇ 25 mm region are shown in Table 2.
  • a mat material according to Comparative Example 4 was produced in the same procedure as in Comparative Example 1 except for the changes shown, and the surface pressure and shear modulus after firing were measured. Table 2 shows the results.
  • the mat materials according to Examples 4 and 5 in which at least one of the first region and the second region is arranged in a region of 25 mm ⁇ 25 mm, have the first region in a region of 25 mm ⁇ 25 mm. It was found that the surface pressure after firing was higher than that of the mat materials according to Comparative Examples 2 to 4, in which the region and the second region were not arranged.

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Abstract

Matériau de matelas comprenant des fibres inorganiques et ayant de multiples points entrelacés formés par aiguilletage sur la surface avant et/ou la surface arrière de celui-ci, le matériau de matelas étant caractérisé en ce que : la densité ρ des points entrelacés est dans la plage de 0,5/cm2≤ρ<18/cm2 ; dans une région de 25 mm × 25 mm, une première région, qui est une région de 4 mm × 4 mm dans laquelle il n'y a pas de points entrelacés, et/ou une seconde région, qui est une région de 3 mm × 8 mm dans laquelle il n'y a pas de points entrelacés, est placée ; un liant inorganique est inclus ; le module de cisaillement est d'au moins 0,20 ; et la pression de surface après cuisson est d'au moins 50 kPa.
PCT/JP2023/006346 2022-02-28 2023-02-22 Matériau de matelas, dispositif de purification de gaz d'échappement et procédé de production de matériau de matelas WO2023163007A1 (fr)

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Citations (7)

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JP2001065337A (ja) * 1999-08-23 2001-03-13 Ibiden Co Ltd 触媒コンバータ
JP2003266572A (ja) * 2002-03-20 2003-09-24 Nichias Corp 防音断熱材およびその製造方法
JP2007292040A (ja) 2006-03-31 2007-11-08 Ibiden Co Ltd シート材、排気ガス処理装置およびその製造方法
US20140248814A1 (en) * 2011-10-06 2014-09-04 Zoltek Companies, Inc. Composite flame barrier
JP2014190191A (ja) * 2013-03-26 2014-10-06 Ibiden Co Ltd 排ガス浄化装置用の保持シール材、該保持シール材の製造方法、排ガス浄化装置、及び、排ガス浄化装置の製造方法
WO2015045636A1 (fr) * 2013-09-24 2015-04-02 イビデン株式会社 Matériau d'étanchéité de retenue, procédé de production de matériau d'étanchéité de retenue, procédé d'emmanchement à la presse de corps d'enroulement, et dispositif de purification de gaz d'échappement
WO2015170610A1 (fr) * 2014-05-08 2015-11-12 イビデン株式会社 Matériau d'étanchéité de fixation, procédé de production de matériau d'étanchéité de fixation, et purificateur de gaz d'échappement

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001065337A (ja) * 1999-08-23 2001-03-13 Ibiden Co Ltd 触媒コンバータ
JP2003266572A (ja) * 2002-03-20 2003-09-24 Nichias Corp 防音断熱材およびその製造方法
JP2007292040A (ja) 2006-03-31 2007-11-08 Ibiden Co Ltd シート材、排気ガス処理装置およびその製造方法
US20140248814A1 (en) * 2011-10-06 2014-09-04 Zoltek Companies, Inc. Composite flame barrier
JP2014190191A (ja) * 2013-03-26 2014-10-06 Ibiden Co Ltd 排ガス浄化装置用の保持シール材、該保持シール材の製造方法、排ガス浄化装置、及び、排ガス浄化装置の製造方法
WO2015045636A1 (fr) * 2013-09-24 2015-04-02 イビデン株式会社 Matériau d'étanchéité de retenue, procédé de production de matériau d'étanchéité de retenue, procédé d'emmanchement à la presse de corps d'enroulement, et dispositif de purification de gaz d'échappement
WO2015170610A1 (fr) * 2014-05-08 2015-11-12 イビデン株式会社 Matériau d'étanchéité de fixation, procédé de production de matériau d'étanchéité de fixation, et purificateur de gaz d'échappement

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