CN-117412857-B - Mat, exhaust gas purifying device, and mat manufacturing method

Abstract

A mat comprising a base material mat comprising inorganic fibers and having a1 st main surface and a2 nd main surface, and a sheet provided on at least one of the 1 st main surface and the 2 nd main surface, wherein the sheet is a laminated sheet comprising longitudinally oriented fibers and transversely oriented fibers laminated, the sheet has openings surrounded by the longitudinally oriented fibers and the transversely oriented fibers, and the average opening area of the sheet is greater than 0mm 2 /and not more than 0.7mm 2 /.

Inventors

• Mukai Yuuta

Assignees

• 揖斐电株式会社

Dates

Publication Date

20260512

Application Date

20220621

Priority Date

20210630

Claims (7)

1. 1. A mat, comprising: a substrate mat comprising inorganic fibers having a 1 st major surface and a2 nd major surface, and A sheet provided on at least one of the 1 st main surface and the 2 nd main surface, The pad is characterized in that, The sheet is a laminated sheet formed by laminating longitudinally oriented fibers and transversely oriented fibers, The sheet has openings surrounded by the longitudinally oriented fibers and the transversely oriented fibers, The average open area of the sheet is greater than 0mm 2 /and less than 0.7mm 2 /, The sheet has an open pore ratio of more than 0% and not more than 40%.
2. 2. The mat according to claim 1, wherein the sheet is composed of at least one of an organic substance and an inorganic substance.
3. 3. The mat of claim 2, wherein the sheet is comprised of an organic material.
4. 4. A mat according to any one of claims 1 to 3, wherein the sheet is made of polyethylene terephthalate, polyethylene or polypropylene.
5. 5. The mat of any of claims 1-3, wherein the substrate mat further comprises at least one of an inorganic binder and an organic binder.
6. 6. An exhaust gas purifying device is provided with: an exhaust gas treatment body through which exhaust gas flows, A holding sealing material wound around the outer periphery of the exhaust gas treatment body, and A housing accommodating the exhaust gas treatment body wound with the holding sealing material, The exhaust gas purifying apparatus is characterized in that, The holding sealing material is the gasket according to any one of claims 1 to 5.
7. 7. A method for manufacturing a mat material, comprising the steps of: a substrate pad preparation step of preparing a substrate pad containing inorganic fibers and having a1 st main surface and a 2 nd main surface, Sheet preparation process, preparation of sheet, and A sheet material installation step of installing the sheet material on at least one of the 1 st main surface and the 2 nd main surface of the base material pad, The manufacturing method is characterized in that, The sheet is a laminated sheet formed by laminating longitudinally oriented fibers and transversely oriented fibers, The sheet has openings surrounded by the longitudinally oriented fibers and the transversely oriented fibers, The average open area of the sheet is greater than 0mm 2 /and less than 0.7mm 2 /, The sheet has an open pore ratio of more than 0% and not more than 40%.

Description

Mat, exhaust gas purifying device, and mat manufacturing method Technical Field The present invention relates to a mat, an exhaust gas purifying apparatus, and a method for manufacturing the mat. Background Exhaust gas discharged from an internal combustion engine such as a diesel engine contains particulate matter (hereinafter also referred to as PM), and in recent years, this PM has a problem in that it endangers the environment and the human body. Further, since the exhaust gas contains harmful gas components such as CO, HC, NOx, there is a concern that the harmful gas components may affect the environment and the human body. As an exhaust gas purifying apparatus for capturing PM in exhaust gas and purifying harmful gas components, various exhaust gas purifying apparatuses have been proposed, which are composed of an exhaust gas treating body (which is composed of porous ceramics such as silicon carbide and cordierite), a housing (tubular member) for accommodating the exhaust gas treating body, and a holding sealing material disposed between the exhaust gas treating body and the housing. The main purpose of the holding sealing material is to prevent the exhaust gas treatment body from being damaged by contact with the housing covering the outer periphery thereof by vibration or impact generated by running of the automobile or the like, to prevent the exhaust gas from leaking between the exhaust gas treatment body and the housing, and the like. As a holding sealing material used for such applications, a mat material composed of inorganic fibers is used. Gaskets made of inorganic fibers are also used for heat insulation and sound insulation for pipes wound around automobiles and the like. Patent document 1 discloses a composite mat used by being wound around an exhaust gas treatment body (catalytic converter) having a small diameter. As the composite mat, a mat composed of inorganic fibers, a binder, and a flexible sheet attached to at least one surface of a layer of inorganic fibers is disclosed. Patent document 2 discloses a holding sealing material in which a protective sheet having in-plane elongation anisotropy is provided on the surface of a mat base material. Further, patent document 3 discloses a holding sealing material in which a sheet having an opening in at least a part of the surface is provided on at least one of the 1 st main surface and the 2 nd main surface of a base material. Patent document 4 discloses a mat in which an oriented organic sheet is provided on the surface of a base mat. The organic sheets are formed by stacking at least 2 sheets of the 1 st organic sheet and the 2 nd organic sheet, and the orientation direction of the 1 st organic sheet is different from the orientation direction of the 2 nd organic sheet. Prior art literature Patent literature Patent document 1 Japanese patent application laid-open No. 2001-521847 Patent document 2 Japanese patent application laid-open No. 2008-51004 Patent document 3 Japanese patent laid-open No. 2009-85092 Patent document 4 Japanese patent application laid-open No. 2020-84798 Disclosure of Invention Problems to be solved by the invention In patent documents 1, 2 and 4, sheets such as flexible sheets are provided to prevent the mat from being broken during winding. In patent document 3, a sheet is provided to prevent scattering of inorganic fibers contained in a base material. As a method for producing such a mat, a method of punching using a punching die having a punching blade (also referred to as punching) has been conventionally used. In this step, a sheet-like member made of inorganic fibers and a large-sized adherend to which a flexible sheet is attached are prepared, and the adherend is die-cut, whereby a large number of mats can be obtained by a single die-cutting process. The backing material has a long side direction as a winding direction and a short side direction orthogonal to the long side direction. In the case of obtaining such a mat from 1 large-sized adherend, a portion where the mat is die-cut in the longitudinal direction of the adherend as the direction of the long side of the mat and a portion where the mat is die-cut in the lateral direction of the adherend as the direction of the long side of the mat are combined to obtain as many mats as possible from 1 large-sized adherend. In this case, two kinds of mats having different directions of the longitudinal direction of the adherend and the longitudinal direction of the mat are obtained. Here, when a sheet having elongation anisotropy is used, two kinds of mats having different relationships between the orientation of the longitudinal direction of the mat and the orientation of the tensile strength of the sheet can be obtained. Specifically, two kinds of gaskets (strong (hard) gaskets) in which the direction of the longitudinal direction of the gasket coincides with the direction in which the tensile strength of the sheet is strong, and gaskets (weak (easy) gaskets) i