JP2015028326A - Holding seal material, method of manufacturing holding seal material, exhaust emission control device, and method of manufacturing exhaust emission control device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a holding seal material capable of reducing scattering of inorganic fiber, preventing the holding seal material from deviating from an exhaust gas treatment body and extruding from an end portion of a metallic casing when the exhaust gas treatment body on which the holding seal material is wound, is accommodated in the metallic casing by press-fitting, and further preventing the holding seal material from deviating from the exhaust gas treatment body in introducing an exhaust gas.SOLUTION: A film 50 is stuck to a first main surface 41, a second main surface 42, a first long side face 45 and a second long side face 46, the second main surface is provided with an exposure portion 49 as a region where the film is not stuck, the exposure portion is formed into the band-shape connecting a first short side face 43 and a second short side face 44, and a shortest distance from the first long side face to the exposure portion is longer than a shortest distance from the second long side face to the exposure portion.

Description

The present invention relates to a holding seal material, a method for manufacturing a holding seal material, an exhaust gas purification device, and a method for manufacturing an exhaust gas purification device.

Particulate matter (hereinafter also referred to as PM) is contained in exhaust gas discharged from an internal combustion engine such as a diesel engine. In recent years, it has been a problem that this PM is harmful to the environment and the human body. . Further, since the exhaust gas contains harmful gas components such as CO, HC and NOx, there is a concern about the influence of the harmful gas components on the environment and the human body.

Therefore, as an exhaust gas purification device that collects PM in exhaust gas and purifies harmful gas components, an exhaust gas treatment body made of porous ceramics such as silicon carbide and cordierite, and a metal that houses the exhaust gas treatment body Various exhaust gas purifying apparatuses comprising a casing and a holding sealing material made of inorganic fibers disposed between an exhaust gas treating body and a metal casing have been proposed. This holding sealing material prevents the exhaust gas treating body from being damaged by contact with the metal casing covering the outer periphery due to vibrations or impacts caused by traveling of an automobile or the like, or from between the exhaust gas treating body and the metal casing. The main purpose is to prevent the exhaust gas from leaking.

Moreover, since the holding sealing material is made of inorganic fibers, it contains a large amount of irritating fine inorganic fibers (for example, fibers having a diameter of about 3 to 8 μm). When an exhaust gas treating body is prepared using such a holding sealing material, there is a problem that when an operator handles the holding sealing material, inorganic fibers are scattered from the holding sealing material to the surroundings, and the working environment is deteriorated. .
Furthermore, when the holding sealing material is wound around the exhaust gas treating body, a tear or the like may occur on the outer surface of the holding sealing material. Fine inorganic fibers may scatter from such a tear.

Patent Document 1 discloses a two-layer holding sealing material composed of a mat made of ceramic fibers arranged on the exhaust gas treating body side and a mat made of ceramic fibers arranged on the metal casing side.
In the holding sealing material disclosed in Patent Document 1, a mat having excellent heat resistance is arranged on the exhaust gas treating body side that becomes high temperature, and a mat having excellent flexibility is arranged on the metal casing side, thereby deforming the holding sealing material. Quality deterioration is prevented and adhesion to the exhaust gas treating body and metal casing is improved.
Furthermore, in the holding sealing material of Patent Document 1, the holding sealing material is hermetically sealed with an airtight sheet, thereby preventing the ceramic fiber from being damaged and facilitating the assembly to the metal casing.

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

Japanese Patent Laid-Open No. 2003-129832 JP 2010-101308 A

When a holding sealing material having a configuration as described in Patent Document 1 is wound around an exhaust gas treatment body, an airtight sheet exists between the holding sealing material and the exhaust gas treatment body. Adhesion with is reduced. That is, the holding sealing material and the exhaust gas treating body are liable to shift. For this reason, if the exhaust gas treating body wound with the holding sealing material having the configuration described in Patent Document 1 is to be accommodated in the metal casing by press-fitting, the holding sealing material is displaced from the exhaust gas treating body, and the end of the metal casing. There was a problem of protruding from the club. The holding seal material having the structure described in Patent Document 2 has the same problem.

Further, after the holding sealing material having the configuration described in Patent Documents 1 and 2 is accommodated in the metal casing and the exhaust gas is allowed to flow, the hermetic sheet is softened by the heat of the exhaust gas, so that the holding sealing material becomes slippery, There has also been a problem that the holding sealing material is displaced by the pressure of.

The present invention has been made in order to solve such problems, and can reduce scattering of inorganic fibers and accommodate an exhaust gas treatment body around which a holding seal material is wound by press-fitting into a metal casing. Holding sealing material that can prevent the holding sealing material from shifting from the exhaust gas treatment body and protruding from the end of the metal casing, and that the holding sealing material is displaced from the exhaust gas processing body when introducing the exhaust gas. An object of the present invention is to provide an exhaust gas treatment apparatus using the holding sealing material.

That is, the holding sealing material of the present invention includes a first main surface, a second main surface opposite to the first main surface, a first long side surface, and a first long side surface opposite to the first long side surface. A holding sealing material comprising a substantially rectangular mat in plan view including inorganic fibers having a second long side surface, a first short side surface, and a second short side surface opposite to the first short side surface, A film is attached to the first main surface, the second main surface, the first long side surface, and the second long side surface, and the film is attached to the second main surface. An exposed portion, which is a non-wearing region, is provided, and the exposed portion is formed in a band shape that connects the first short side surface and the second short side surface, and from the first long side surface. The shortest distance to the exposed portion is longer than the shortest distance from the second long side surface to the exposed portion.

The holding sealing material of the present invention usually includes an exhaust gas treatment body, a metal casing that houses the exhaust gas treatment body, and a holding seal material that is disposed between the exhaust gas treatment body and the metal casing. Used for. The holding sealing material of the present invention is wound around the exhaust gas treating body, and the exhaust gas treating body (hereinafter also referred to as a wound body) around which the holding sealing material of the present invention is wound is housed in a metal casing.

The holding sealing material of the present invention is wound around the exhaust gas treatment body to form a wound body, and the first long side surface of the holding sealing material is on the exhaust gas introduction side so that the second main surface and the exhaust gas treatment body are in contact with each other. It is accommodated in a metal casing so as to be arranged.
Since the holding sealing material of the present invention has a film attached to the first main surface, the second main surface, the first long side surface and the second long side surface, when handling the holding sealing material, and It is possible to reduce the scattering of inorganic fibers when accommodated in the metal casing.
In addition, the holding sealing material of the present invention is wound around the exhaust gas treatment body so that the second main surface provided with the exposed portion is in contact with the exhaust gas treatment body, so that the holding seal material and the exhaust gas treatment body When the wound body is housed in the metal casing by press fitting, it is possible to prevent the holding sealing material from protruding from the end of the metal casing.
Furthermore, in the holding sealing material of the present invention, the shortest distance from the first long side surface to the exposed portion is longer than the shortest distance from the second long side surface to the exposed portion. Therefore, the exposed part is present at a position closer to the second long side than the first long side, in other words, a large amount of film is present on the exhaust gas introduction side. When many films exist on the exhaust gas introduction side, more films are likely to be decomposed at an early stage due to the heat of the exhaust gas. Therefore, it is possible to reduce the portion where the film becomes soft and slippery, thereby preventing the metal casing and the holding sealing material from shifting when the exhaust gas is introduced.

In the holding sealing material of the present invention, the width of the exposed portion is preferably 5 to 80% of the width of the mat.
When the width of the exposed portion is 5 to 80% of the width of the mat, the frictional resistance works firmly between the holding sealing material and the exhaust gas treating body, and the holding sealing material does not slip during housing. Furthermore, when the exhaust gas flows in, the film is easily decomposed quickly, and it is easy to prevent the holding sealing material and the exhaust gas treating body from shifting due to the softening of the film.

In the holding sealing material of the present invention, it is desirable that the shortest distance from the first long side surface to the exposed portion is 11 to 80% of the width of the mat.
When the shortest distance from the first long side surface to the exposed portion is 11 to 80% of the width of the mat, the film is easily decomposed when the exhaust gas flows in, and the holding sealing material and the exhaust gas are softened by the softening of the film. It becomes easy to prevent the processing body from shifting.

In the holding sealing material of the present invention, it is desirable that the constituent material of the film is at least one selected from the group consisting of polyester, polyethylene, and polypropylene.
When the constituent material of the film is at least one selected from the group consisting of polyester, polyethylene and polypropylene, the coefficient of friction between the metal casing and the holding sealing material can be reduced, and the exhaust gas treatment body wrapped with the holding sealing material Can be accommodated when the metal casing is accommodated by press fitting.

In the holding sealing material of the present invention, the film is preferably fixed to the mat by an adhesive or thermocompression bonding.
When the film is fixed to the mat by an adhesive or thermocompression bonding, the film is difficult to peel off from the mat when the holding sealing material is handled or during the storing operation.

The method for manufacturing the holding sealing material of the present invention is a method for manufacturing the holding sealing material of the present invention, wherein the first main surface, the second main surface opposite to the first main surface, and the first main surface, A plane including inorganic fibers having one long side, a second long side opposite to the first long side, a first short side, and a second short side opposite to the first short side. A mat preparation step of preparing a generally rectangular mat;
It is a region where a film is attached to the first main surface, the first long side surface and the second long side surface of the mat, and the film is not attached to the second main surface. And an adhering step of adhering the film so that the exposed portion is formed.

In the method for producing a holding sealing material of the present invention, a film is attached to the first main surface, the first long side surface, and the second long side surface, and the film is attached to the second main surface. Since it includes a sticking step of sticking a film so that an exposed portion that is not a region is formed, it is suitable for the method for producing the holding sealing material of the present invention.

The exhaust gas purifying apparatus of the present invention is an exhaust gas purifying apparatus comprising an exhaust gas treating body, a holding seal material disposed around the exhaust gas treating body, and a metal casing that houses the exhaust gas treating body. The sealing material includes a first main surface and a second main surface opposite to the first main surface; a first long side; a second long side opposite to the first long side; It consists of a mat | matte of the substantially rectangular shape in planar view containing the inorganic fiber which has a 1st short side surface and the 2nd short side surface on the opposite side to the said 1st short side surface, The said 1st main surface and the said 2nd main surface The first long side surface and the second long side surface are bonded with a film, and the second main surface is provided with an exposed portion that is a region where the film is not bonded. The exposed portion is formed in a belt shape connecting the first short side surface and the second short side surface. The shortest distance from the first long side surface to the exposed portion is longer than the shortest distance from the second long side surface to the exposed portion, and the exposed portion of the second main surface is the exhaust gas treatment. The holding sealing material is disposed so as to be in contact with the body and so that the first long side surface is located on the exhaust gas introduction side.

In the exhaust gas purifying apparatus of the present invention, since the holding sealing material of the present invention is used, it is possible to prevent the holding sealing material and the exhaust gas treating body from shifting when introducing the exhaust gas.

An exhaust gas purification device manufacturing method of the present invention is an exhaust gas purification device comprising an exhaust gas treatment body, a holding sealing material disposed around the exhaust gas treatment body, and a metal casing that houses the exhaust gas treatment body. The holding sealing material includes a first main surface, a second main surface opposite to the first main surface, a first long side, and a second long side opposite to the first long side. The first main surface, the second main surface, the first long side surface and the second long side surface have a film attached thereto. In addition, an exposed portion where the film is not attached to the second main surface in a substantially strip shape substantially parallel to the longitudinal direction of the mat is formed, and the exposed portion is formed from the first long side surface. Is shorter than the shortest distance from the second long side surface to the exposed portion. In addition, the exhaust gas purifying apparatus in which the holding sealing material is disposed so that the exposed portion of the second main surface is in contact with the exhaust gas treating body and the first long side surface is located on the exhaust gas introduction side. A method comprising: a first main surface; a second main surface opposite to the first main surface; a first long side surface; and a second long side opposite to the first long side surface. A mat preparing step of preparing a mat having a substantially rectangular shape in a plan view including inorganic fibers, a film is attached to the first main surface, the first long side surface, and the second long side surface of the mat; and The sticking step of sticking the film so that an exposed portion, which is a region where the film is not stuck, is formed on the second main surface, and the mat on which the film is stuck by the sticking step. Is wound so that the second main surface is in direct contact with the exhaust gas treating body. A winding step for, characterized in that in the first long side are arranged so as to be located on the exhaust gas introducing side and a housing step of housing the wound body in a metal casing.

The manufacturing method of the exhaust gas purification apparatus of the present invention is suitable for the method of manufacturing the exhaust gas purification apparatus of the present invention.

FIG. 1A is a perspective view schematically showing an example of the holding sealing material of the present invention, and FIG. 1B is a perspective view schematically showing an example of a mat constituting the holding sealing material of the present invention. It is. Fig.2 (a)-FIG.2 (c) are figures which show typically an example of the shape of the film stuck on the holding | maintenance sealing material of this invention. FIG. 3 is a cross-sectional view taken along line AA in FIG. FIG. 4 is a perspective view schematically showing an example of the exhaust gas treating body constituting the exhaust gas purifying apparatus of the present invention. Fig.5 (a) is a perspective view which shows typically an example of the process of accommodating the waste gas processing body by which the holding | maintenance sealing material of this invention was wound around the metal casing, FIG.5 (b) is FIG. It is sectional drawing in the longitudinal direction of the waste gas processing body which showed typically an example of the waste gas processing body around which the holding sealing material was wound. FIG. 6 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention.

(Detailed description of the invention)
Hereinafter, the present invention will be specifically described. However, the present invention is not limited to the following description, and can be appropriately modified and applied without departing from the scope of the present invention. Note that the present invention also includes a combination of two or more desirable configurations of the present invention described below.

First, the holding sealing material 30 of the present invention will be described.

FIG. 1A is a perspective view schematically showing an example of the holding sealing material of the present invention.
The holding sealing material 30 of the present invention shown in FIG. 1A has a predetermined length in the longitudinal direction (hereinafter also simply referred to as a total length, indicated by a double arrow L in FIG. 1A), a width (FIG. 1 ( It is composed of a mat 40 having a rectangular shape in plan view and having inorganic fibers and having a thickness (indicated by a double arrow W) and a thickness (indicated by a double arrow T in FIG. 1A). On the surface of the mat 40, the film 50 is continuously attached from the winding start portion 47 to the winding end portion 48, and further, an exposed portion 49 that is an area where the film 50 is not attached is provided. Yes. The width of the exposed portion 49 is the length from the winding start portion 47 to the winding end portion 48 (indicated by a double arrow d in FIG. 1A).
FIG.1 (b) is a perspective view which shows typically an example of the mat | matte which comprises the holding sealing material of this invention. As shown in FIG. 1B, the mat 40 includes a first main surface 41 and a second main surface 42 that is a main surface opposite to the first main surface 41. Further, the mat 40 includes a first short side surface 43 in which a convex portion 43a is formed, a second short side surface 44 in which a concave portion 44a is formed, a first long side surface 45 that is a longitudinal side surface, And a second long side surface 46 which is a side surface opposite to the first long side surface 45. The side surface in the longitudinal direction is a surface located at a portion that forms a long side of a substantially rectangular shape when the mat 40 is viewed in plan. The convex portion 43a and the concave portion 44a are shaped so as to be fitted to each other when the holding sealing material 30 is wound around the exhaust gas treatment body 10 in order to manufacture the exhaust gas purification device 1.

The mat 40 is a needle mat obtained by performing a needling process on a base mat made of inorganic fibers. The needling process means that fiber entanglement means such as a needle is inserted and removed from the base mat. In the mat 40, inorganic fibers having a relatively long average fiber length are entangled three-dimensionally by needling treatment. This mat is needling processed in the width direction perpendicular to the longitudinal direction.
In addition, in order to exhibit an entanglement structure, it is desirable that the inorganic fibers have a certain average fiber length. For example, the average fiber length of the inorganic fibers is desirably 5 to 150 mm, and is 50 to 100 mm. It is more desirable.
If the average fiber length of the inorganic fibers is less than 5 mm, the fiber length of the inorganic fibers is too short, so that the entanglement between the inorganic fibers becomes insufficient, and the shear strength of the holding sealing material decreases. Moreover, since the fiber length of an inorganic fiber will be too long when the average fiber length of an inorganic fiber exceeds 150 mm, the handleability of the inorganic fiber at the time of manufacture of a holding sealing material will fall. As a result, the windability around the exhaust gas treating body is lowered, and the holding sealing material is easily broken.

The average fiber diameter of the inorganic fibers constituting the mat 40 is preferably 1 to 20 μm, and more preferably 3 to 10 μm.
When the average fiber diameter of the inorganic fibers is 1 to 20 μm, the strength and flexibility of the inorganic fibers are sufficiently high, and the shear strength of the mat 40 can be improved.
If the average fiber diameter of the inorganic fibers is less than 1 μm, the inorganic fibers are easily cut into thin pieces, so that the tensile strength of the inorganic fibers becomes insufficient. On the other hand, when the average fiber diameter of the inorganic fibers exceeds 20 μm, the flexibility of the inorganic fibers is insufficient because the inorganic fibers are not easily bent.

The inorganic fiber constituting the mat 40 is not particularly limited, but may be composed of at least one selected from the group consisting of alumina fiber, silica fiber, alumina silica fiber, mullite fiber, biosoluble fiber, and glass fiber. desirable.

In addition to alumina, the alumina fiber may contain additives such as calcia, magnesia, zirconia, and the like.
The composition ratio of the alumina silica fiber is preferably Al ₂ O ₃ : SiO ₂ = 60: 40 to 80:20 by weight, and Al ₂ O ₃ : SiO ₂ = 70: 30 to 74:26. More desirable.
The biosoluble fiber is, for example, an inorganic fiber containing at least one compound selected from the group consisting of an alkali metal compound, an alkaline earth metal compound, and a boron compound in addition to silica and the like.

Since the biosoluble fiber made of these compounds is easily dissolved even when taken into the human body, the mat containing these inorganic fibers is excellent in safety to the human body.

The specific composition of the biosoluble fiber includes 60 to 85% by weight of silica and 15 to 40% by weight of at least one compound selected from the group consisting of alkali metal compounds, alkaline earth metal compounds and boron compounds. Composition. The silica refers to SiO or SiO ₂ .

Examples of the alkali metal compound include sodium and potassium oxides, and examples of the alkaline earth metal compound include magnesium, calcium, and barium oxides. Examples of the boron compound include boron oxide.

In the composition of the biosoluble fiber, when the silica content is less than 60% by weight, it is difficult to produce by a glass melting method, and it is difficult to fiberize.
In addition, when the silica content is less than 60% by weight, the alkali metal compound, the alkaline earth metal compound, and boron are structurally fragile because the content of the flexible silica is small, and are easily soluble in physiological saline. Since the ratio of at least one compound selected from the group consisting of compounds is relatively high, the biosoluble fiber tends to be too soluble in physiological saline.

On the other hand, if the content of silica exceeds 85% by weight, the proportion of at least one compound selected from the group consisting of alkali metal compounds, alkaline earth metal compounds and boron compounds is relatively low, so that the biosoluble fiber is It tends to be too difficult to dissolve in physiological saline.
The silica content is calculated by converting the amounts of SiO and SiO ₂ into SiO ₂ .

In the composition of the biosoluble fiber, the content of at least one compound selected from the group consisting of an alkali metal compound, an alkaline earth metal compound, and a boron compound is preferably 15 to 40% by weight. When the content of at least one compound selected from the group consisting of an alkali metal compound, an alkaline earth metal compound, and a boron compound is less than 15% by weight, the biosoluble fiber is hardly dissolved in physiological saline.

On the other hand, when the content of at least one compound selected from the group consisting of an alkali metal compound, an alkaline earth metal compound and a boron compound exceeds 40% by weight, it is difficult to produce and fiberize by the glass melting method. Further, when the content of at least one compound selected from the group consisting of an alkali metal compound, an alkaline earth metal compound and a boron compound exceeds 40% by weight, it is structurally fragile and the biosoluble fiber is easily soluble in physiological saline. Too much.

The solubility of the biosoluble fiber in physiological saline is desirably 30 ppm or more. If the solubility of the biosoluble fiber is less than 30 ppm, when the inorganic fiber is taken into the body, it is difficult to be discharged out of the body, which is undesirable for health.

The glass fiber is a glassy fiber containing silica and alumina as main components and containing calcia, titania, zinc oxide and the like in addition to the alkali metal.

Basis weight of the mat 40 (weight per unit area) is not particularly limited, is preferably a 200~4000g / ^{m 2,} and more desirably 1000 to 3000 g / ^{m 2.} When the basis weight of the mat 40 is less than 200 g / m ² , the holding power is not sufficient, and when the basis weight of the mat 40 exceeds 4000 g / m ² , the bulk of the mat 40 is not easily lowered. Therefore, when manufacturing the exhaust gas purification apparatus 1 using such a mat 40, the exhaust gas treating body 10 is likely to drop off.

Further, the bulk density of the mat 40 (bulk density of the holding sealing material before winding) is not particularly limited, but is desirably 0.10 to 0.30 g / cm ³ . If the bulk density of the mat 40 is less than 0.10 g / cm ³ , the entanglement of the inorganic fibers is weak and the inorganic fibers are easily peeled off, so that it is difficult to keep the shape of the mat 40 in a predetermined shape.
Moreover, when the bulk density of each mat exceeds 0.30 g / cm ³ , the mat 40 becomes hard and the wrapping property around the exhaust gas treating body 10 is lowered, and each mat is easily broken.

The mat 40 may further include a binder such as an organic binder in order to suppress bulkiness and improve workability before assembly of the exhaust gas treatment apparatus 1.
Further, the thickness of the mat 40 is desirably 2.0 to 20 mm, and more desirably 1.5 to 15 mm.
When the thickness of the mat 40 exceeds 20 mm, the flexibility of the holding sealing material 30 is lost, so that it becomes difficult to handle the holding sealing material 30 when it is wound around the exhaust gas treating body 10. Further, winding wrinkles and cracks are likely to occur in the holding sealing material 30.
If the thickness of the mat 40 is less than 2.0 mm, the surface pressure of the holding sealing material 30 is not sufficient to hold the exhaust gas treating body 10. For this reason, the exhaust gas treating body 10 is easily dropped off. Further, when a volume change occurs in the exhaust gas treatment body 10, the holding sealing material 30 hardly absorbs the volume change of the exhaust gas treatment body 10. Therefore, cracks and the like are likely to occur in the exhaust gas treating body 10.

The “substantially rectangular shape in plan view” described in this specification is a concept including a convex portion and a concave portion. The “substantially rectangular shape in plan view” also includes a shape having a corner other than 90 °. For example, the corner of the mat may have a sharp or obtuse angle or may have a curvature.

The mat 40 may further contain an expansion material. It is desirable that the expansion material has a characteristic of expanding in the range of 400 to 800 ° C.
When the mat 40 contains an expansion material, the mat 40 expands in the range of 400 to 800 ° C., and therefore the holding sealing material even in a high temperature range exceeding 700 ° C. where the strength of the glass fiber is reduced. As a result, the holding power can be improved.

Examples of the expanding material include vermiculite, bentonite, phlogopite, pearlite, expandable graphite, and expandable fluoride mica. These expanding materials may be used alone or in combination of two or more.
The addition amount of the expansion material is not particularly limited, but is preferably 10 to 50% by weight and more preferably 20 to 30% by weight with respect to the total weight of the mat 40.

Fig.2 (a)-FIG.2 (c) are figures which show typically an example of the shape of the film stuck on the holding | maintenance sealing material of this invention. In Fig.2 (a)-FIG.2 (c), the state which stuck the film to the holding | maintenance sealing material is perspective.
As the shape of the film 50, any shape as shown in FIGS. 2A to 2C can be adopted.

The film 50a shown in FIG. 2A is substantially rectangular and has a long side 51a and a short side 52a. A convex portion 53a is formed on one short side 52a of the film 50a.
When sticking the film 50a to the mat 40, the film 50a is stuck to the mat 40 so that the convex part 53a of the film 50a covers a part of the convex part 43a of the mat 40.
The film 50b shown in FIG. 2B is substantially rectangular and has a long side 51b and a short side 52b. A concave portion 54b is formed on one short side 52b of the film 50b.
When the film 50b is attached to the mat 40, the film 50b is attached to the mat 40 so that the concave portion 54b of the film 50b covers the concave portion 44a of the mat 40.
A film 50c shown in FIG. 2C is substantially rectangular and has a long side 51c and a short side 52c. A convex portion 53c is formed on one short side 52c of the film 50c, and a concave portion 54c is formed on the other short side 52c.
When sticking the film 50c to the mat 40, the convex portion 53c of the film 50c covers the entire convex portion 43a of the mat 40, and the concave portion 54c of the film 50 covers the concave portion 44a of the mat 40. The film 50c is adhered to the mat 40.
Thus, by reducing the area of the mat 40 that is not covered with the film 50, the scattering of inorganic fibers from the mat 40 can be further reduced. Therefore, among these, the shape of the film 50c is most desirable.
That is, in the holding sealing material of the present invention, the film 50 may cover both the convex portion 43a and the concave portion 44a of the mat 40, or may cover either one of the convex portion 43a and the concave portion 44a. Only a part of the portion 43a and the concave portion 44a may be covered, and neither the convex portion 43a nor the concave portion 44a may be covered, but the film 50 is formed so as to connect the concave portion 43a to the convex portion 44a. It is desirable that

In the present specification, the long side of the film 50 is a side arranged in a direction parallel to the longitudinal direction of the mat 40 when the film 50 is attached to the mat 40, and the short side of the film 50 is the side of the mat 40. The side is arranged in a direction perpendicular to the longitudinal direction. Therefore, the length of the long side and the short side of the film 50 varies depending on the dimensions of the mat 40, and the long side of the film 50 may be shorter than the short side of the film 50.

FIG. 3 is a cross-sectional view taken along line AA in FIG.
As shown in FIG. 3, a film 50 is attached to the holding sealing material 30. The film 50 is a single sheet, and is continuously wound in a direction perpendicular to the longitudinal direction of the mat 40 from the winding start portion 47 to the winding end portion 48 of the second main surface 42 of the mat 40 and pasted. It is worn. That is, the film 50 has the winding start portion 47 of the second main surface 42 of the mat 40 as a winding start portion, and the second main surface 42, the first long side surface 45, and the first main surface 45 of the mat 40. It is continuously wound along the surface 41, the second long side surface 46, and the second main surface 42 to the winding end portion 48 of the second main surface 42 of the mat 40. Further, the winding start portion 47 and the winding end portion 48 are separated so that a part of the second main surface 42 of the mat 40 is exposed, and have a predetermined width (indicated by a double arrow d in FIG. 3). An exposed portion 49 is formed.
The shortest distance from the first long side surface 45 to the exposed portion 49 is a distance represented by a double-pointed arrow M in FIG. 3, and the shortest distance from the second long side surface 46 to the exposed portion 49 is both in FIG. This is the distance represented by the arrow N.
The holding sealing material 30 of the present invention is characterized in that the shortest distance from the first long side surface 45 to the exposed portion 49 is longer than the shortest distance from the second long side surface 46 to the exposed portion 49.

In the holding sealing material 30 of the present invention, the shortest distance from the first long side surface 45 to the exposed portion 49 is preferably 11 to 80% of the width of the mat 40, and more preferably 11 to 50%. .
When the shortest distance from the first long side surface to the exposed portion is within the above range, the film is easily decomposed quickly.

In the holding sealing material of the present invention, it is desirable that the width of the exposed portion is 5 to 80% of the width of the mat.
Note that the width of the exposed portion 49 may not be constant at all locations of the exposed portion, and the width of the widest portion of the exposed portion is preferably 150% or less of the width of the narrowest portion of the exposed portion. .

In the holding sealing material 30 of the present invention, the film 50 is bonded to the first long side surface 45 and the second long side surface 46 of the mat 40.
The scattering of the inorganic fibers from the holding sealing material 30 occurs not only from the first main surface 41 of the mat 40 but also from the first long side surface 45 and the second long side surface 46 of the mat 40.
In particular, when the exhaust gas treating body 10 around which the holding sealing material 30 is wound is accommodated in the metal casing 20, the holding sealing material 30 is compressed in the thickness direction. Therefore, air can easily escape from the first long side surface 45 and the second long side surface 46 of the mat 40. As the air escapes, the inorganic fibers are likely to be scattered.
When the film 50 is adhered to the first long side surface 45 and the second long side surface 46 of the mat 40 as in the holding sealing material 30 of the present invention, inorganic fibers are introduced from the portion where the film 50 is adhered. Scattering can be reduced. Therefore, the scattering of inorganic fibers can be reduced when the holding sealing material 30 is handled.

As described above, the film 50 is a single sheet and continuously makes a round from the winding start portion 47 to the winding end portion 48 of the second main surface 42 of the mat 40 in a direction perpendicular to the longitudinal direction of the mat 40. It is wound and stuck. Therefore, the film 50 to be attached has no seam. Therefore, inorganic fibers are not scattered from the seam of the film. As a result, scattering of inorganic fibers from the holding sealing material 30 can be reduced.

In the holding sealing material 30 of the present invention, the film 50 is not formed on the second main surface 42 of the mat 40, and an exposed portion 49 where the second main surface 42 is exposed is formed.
Therefore, the inorganic fibers contained in the mat 40 are in direct contact with the exhaust gas treatment body 10, and the inorganic fibers are entangled with the surface of the exhaust gas treatment body 10. Therefore, the adhesion between the mat 40 and the exhaust gas treating body 10 is improved. As a result, when the exhaust gas treating body 10 around which the holding sealing material 30 is wound is housed in the metal casing 20 due to the friction between the inorganic fibers and the exhaust gas treating body 10, the mat 40 and the exhaust gas treating body 10 are accommodated. And the mat 40 can be prevented from protruding from the end of the metal casing 20.

In the holding sealing material 30 of the present invention, the constituent material of the film 50 is preferably made of at least one selected from the group consisting of polyester, polyethylene, and polypropylene.
As described above, the holding sealing material 30 of the present invention is wound around the exhaust gas treating body 10 and accommodated in the metal casing 20. At this time, the mat 40 comes into contact with the metal casing 20 through the film 50.
When the constituent material of the film 50 is made of at least one selected from the group consisting of polyester, polyethylene, and polypropylene, the friction coefficient between the mat 40 and the metal casing 20 becomes small. Therefore, the exhaust gas treating body 10 around which the holding sealing material 30 is wound can be smoothly pressed into the metal casing 20.
The constituent material of the film 50 is preferably at least one selected from the group consisting of polyester, polyethylene, and polypropylene, polyethylene terephthalate (PET) is particularly desirable as the polyester, and polyethylene is JIS K 6922-1 (1997). High density polyethylene (HDPE) as defined is particularly desirable.

In the holding sealing material 30 of the present invention, the thickness of the film 50 is desirably 20 to 60 μm, and more desirably 30 to 40 μm.
If the thickness of the film 50 is less than 20 μm, the film 50 is too thin and easily broken.
When the thickness of the film 50 exceeds 60 μm, the amount of sticking per unit weight of the inorganic fiber becomes too large, so that it can be accommodated in the metal casing 20 without any problem, but hydrocarbon gas generated by decomposition, etc. The amount of too much.

In the holding sealing material 30 of the present invention, the film 50 is desirably fixed to the holding sealing material 30 by an adhesive or thermocompression bonding.
If an adhesive or thermocompression bonding is used, the film 50 can be firmly fixed to the holding sealing material 30.

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

FIG. 4 is a perspective view schematically showing an example of the exhaust gas treating body constituting the exhaust gas purifying apparatus of the present invention.

As shown in FIG. 4, the exhaust gas treating body 10 is a columnar shape in which a large number of cells are arranged in the longitudinal direction with a cell wall therebetween, and is mainly made of a porous ceramic. In addition, an outer peripheral coat layer 14 is provided on the outer periphery of the exhaust gas treatment body 10 for the purpose of reinforcing the outer periphery of the exhaust gas treatment body 10, adjusting the shape, and improving the heat insulation of the exhaust gas treatment body 10. ing. Furthermore, when the exhaust gas treating body 10 is viewed from one end face, the cells in which the sealing portions are formed and the cells in which the sealing portions are not formed are alternately arranged.
In addition, although the sealing part is formed in the exhaust gas processing body 10 shown in FIG. 4, the sealing part does not need to be formed in the exhaust gas processing body which comprises the exhaust gas purification apparatus of this invention. This is because the exhaust gas treating body in which the sealing portion is not formed can be suitably used as a catalyst carrier.

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

When the exhaust gas treating body 10 is a silicon carbide porous ceramic, the porosity of the porous ceramic is not particularly limited, but is preferably 35 to 60%.
If the porosity is less than 35%, the exhaust gas treating body may be clogged immediately. On the other hand, if the porosity exceeds 60%, the strength of the exhaust gas treating body is lowered and easily destroyed. Because there is.
The average pore diameter of the porous ceramic is preferably 5 to 30 μm.
When the average pore diameter is less than 5 μm, the PM may easily clog. On the other hand, when the average pore diameter exceeds 30 μm, the PM passes through the pores and cannot be collected. This is because it may not function as a filter.
The porosity and pore diameter can be measured by a conventionally known method using a scanning electron microscope (SEM).

The cell density in the cross section of the exhaust gas treating body 10 is not particularly limited, but a desirable lower limit is 31.0 / cm ² (200 / inch ² ), and a desirable upper limit is 93.0 / cm ² (600 / Inch ² ), the more desirable lower limit is 38.8 / cm ² (250 / inch ² ), and the more desirable upper limit is 77.5 / cm ² (500 / inch ² ).

The exhaust gas treating body 10 may carry a catalyst for purifying exhaust gas. As the catalyst to be carried, for example, a noble metal such as platinum, palladium, rhodium or the like is desirable, and among these, platinum is more desirable. Further, as other catalysts, for example, alkali metals such as potassium and sodium, and alkaline earth metals such as barium can be used. These catalysts may be used alone or in combination of two or more.
When these catalysts are supported, it is easy to burn and remove PM, and toxic exhaust gas can be purified.

Next, the metal casing 20 which comprises the exhaust gas purification apparatus 1 of this invention is demonstrated.
FIG. 5A is a perspective view schematically showing an example of a process of accommodating the exhaust gas treating body in which the holding sealing material of the present invention is wound around the metal casing 20.

In FIG. 5A, the holding sealing material 30 of the present invention is an exhaust gas so that the first main surface 41 of the mat 40 is on the metal casing 20 side and the second main surface 42 is on the exhaust gas treatment body 10 side. It is wound around the processing body 10.
The exhaust gas treating body 10 around which the holding sealing material 30 of the present invention is wound is accommodated in the metal casing 20.

The metal casing 20 is mainly made of a metal such as stainless steel, and the shape thereof may be a substantially cylindrical shape in which the inner diameters at both ends are smaller than the inner diameter at the center as shown in FIG. As shown to 5 (a), the substantially cylindrical shape with a constant internal diameter may be sufficient.
When the wound body is accommodated in the metal casing by the press-fitting method (stuffing method), the inner diameter of the metal casing (the inner diameter of the portion accommodating the exhaust gas treatment body) is preferably slightly shorter than the outer diameter of the wound body. .

FIG.5 (b) is sectional drawing in the longitudinal direction of the waste gas processing body which showed typically an example of the waste gas processing body around which the holding sealing material of this invention was wound.
The holding sealing material 30 of the present invention is wound around the exhaust gas treatment body 10 so that the second main surface 42 on which the exposed portion 49 is formed is in contact with the exhaust gas treatment body 10. Therefore, when the exhaust gas treating body 10 around which the holding sealing material 30 is wound is accommodated in the metal casing 20 by press fitting, the holding sealing material 30 is caused by the frictional resistance between the inorganic fibers constituting the holding sealing material 30 and the exhaust gas treating body 10. And the exhaust gas treating body 10 become difficult to slip. Therefore, it is possible to prevent the holding sealing material 30 and the exhaust gas treating body 10 from being shifted during storage and the holding sealing material 20 from protruding from the metal casing 20.
As shown in FIGS. 5A and 5B, the exhaust gas purifying apparatus 1 is obtained by housing the exhaust gas treating body 10 around which the holding sealing material 30 is wound in the metal casing 20.

FIG. 6 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention.
As shown in FIG. 6, the exhaust gas purification apparatus 1 as an example of the exhaust gas purification apparatus of the present invention includes an exhaust gas treatment body 10, a metal casing 20 that covers the outside of the exhaust gas treatment body 10, an exhaust gas treatment body 10, and a metal casing. An inlet pipe 21 connected to an internal combustion engine such as an engine is connected to the end of the metal casing 20 on the side where the exhaust gas is introduced. A discharge pipe 22 connected to the outside is connected to the other end portion of the metal casing 20.
In the present specification, the exhaust gas introduction side refers to the end on the introduction pipe 21 side among the ends of the holding seal material and the exhaust gas treatment body disposed in the metal casing, and the exhaust gas outflow side is It refers to the end opposite to the exhaust gas introduction side.

In the exhaust gas purification apparatus 1 shown in FIG. 6, an exhaust gas filter (honeycomb filter) in which any one of the cells is sealed with the sealing material 13 is used as the exhaust gas treatment body 10.

A case where the exhaust gas passes through the exhaust gas purification apparatus 1 having the above configuration will be described below with reference to FIG.
As shown in FIG. 6, the exhaust gas discharged from the internal combustion engine and flowing into the exhaust gas purification device 1 (in FIG. 6, the exhaust gas is indicated by G and the flow of the exhaust gas is indicated by an arrow) is the exhaust gas inflow side of the exhaust gas treatment body 10. It flows into one cell 11 opened in the end face 10 a and passes through the cell wall 12 separating the cell 11. At this time, PM in the exhaust gas is collected by the cell wall 12 and the exhaust gas is purified. The purified exhaust gas flows out from the other cells 11 opened in the exhaust gas outflow side end face 10b and is discharged to the outside.
At this time, in the exhaust gas purifying apparatus 1 of the present invention, the second main surface 42 of the holding sealing material 30 is in contact with the exhaust gas treating body 10 at the exposed portion 49. Further, the shortest distance from the first long side surface 45 of the holding sealing material 30 to the exposed portion 49 (indicated by a double arrow M in FIG. 6) is the shortest distance from the second long side surface 46 to the exposed portion 49 (see FIG. 6, the first long side surface 45 is arranged on the exhaust gas introduction side. In other words, in the exhaust gas purifying apparatus of the present invention, the film 50 is biased to the exhaust gas introduction side. If the film 50 is biased toward the exhaust gas introduction side, when the exhaust gas is introduced, more film 50 is likely to be decomposed at an early stage due to the heat of the exhaust gas. Therefore, it is possible to reduce the portion where the film becomes soft and slippery, thereby preventing the metal casing and the holding sealing material from shifting when the exhaust gas is introduced.

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

(A) Mat preparation process First, the process of preparing the mat which consists of inorganic fiber in which the needle punching process was performed is performed.
The mat can be obtained by various methods. For example, the mat can be produced by the following method. That is, first, for example, an inorganic fiber precursor having an average fiber diameter of 3 to 10 μm is prepared by spinning a spinning mixture using a basic aluminum chloride aqueous solution and silica sol as raw materials by a blowing method. Subsequently, the inorganic fiber precursor is compressed to produce a continuous sheet material having a predetermined size, which is subjected to a needle punching process, and then subjected to a firing process. The manufacturing of the mat 40 is completed through such steps.

(B) Adhesion process Next, the process of adhering the film 50 to the mat | matte 40 is performed.
First, the film 50 is cut into a predetermined shape. Subsequently, the film 50 is continuously wound in a direction perpendicular to the longitudinal direction of the mat 40 from the winding start portion 47 to the winding end portion 48 of the second main surface 42 of the mat 40 and attached. At this time, the winding start portion 47 and the winding end portion 48 are separated so that a region where the film 50 is not formed is provided on a part of the second main surface 42 of the mat 40 to form an exposed portion 49. To do.
Regarding the attachment of the film 50, an adhesive may be applied to the film 50 in advance, and the mat 40 may be attached at the same time as the film 50 is covered. After the mat 40 is covered with the film 50, the adhesive is applied by thermocompression bonding. Also good.

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

The (a) mat preparation step may include a step of attaching an organic binder and an inorganic binder to inorganic fibers.
A method and a procedure for attaching the organic binder and the inorganic binder to the inorganic fiber are not particularly limited. For example, the mat may be impregnated with the binder by dipping the mat in a solution containing the binder, and the curtain coating may be performed. The mat may be impregnated with the binder by dropping the binder onto the mat by a method such as a method. Thereafter, the amount of the binder attached can be adjusted by sucking and dehydrating the mat to which the binder is attached.

The organic binder is not particularly limited, and examples thereof include acrylic resins, polyethylene resins, polypropylene resins, polyvinyl chloride resins, polystyrene resins, rubber resins, and the like, and two or more kinds of resins are included. May be. Among these, acrylic resins are preferable, and acrylic rubber is more preferable.
The content of the organic binder is preferably 0.5 to 4.5% by weight, more preferably 0.5 to 3.0% by weight with respect to the inorganic fibers constituting the mat 40, More preferably, the content is 0.5 to 2.0% by weight.

The inorganic binder is not particularly limited as long as it can fix the inorganic fibers by adhering to the adjacent inorganic fibers, but is preferably alumina sol, silica sol or the like.

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

The method of manufacturing the exhaust gas purification apparatus 1 of the present invention includes an exhaust gas treatment body 10, a metal casing 20 that houses the exhaust gas treatment body 10, and a holding sealing material that is disposed between the exhaust gas treatment body 10 and the metal casing 20. 30, the holding sealing material 30 is a holding sealing material manufactured by the method for manufacturing a holding sealing material of the present invention, and the holding sealing material 30 is A winding step in which the second main surface 42 is wound so that the second main surface 42 is in direct contact with the exhaust gas treatment body 10 and a first long side surface 45 is located on the exhaust gas introduction side, and the winding body is disposed. A housing step of housing in a metal casing.

(C) Winding process The holding sealing material 30 of the present invention is wound around the exhaust gas treating body 10 to form a wound body.
In this step, the holding sealing material is such that the second main surface 42 of the mat 40 constituting the holding sealing material 30 of the present invention is in contact with the outer periphery of the substantially cylindrical exhaust gas treating body 10 produced by a conventionally known method. Wrap 30. At this time, the convex portion 43a of the mat 40 and the concave portion 44a are fitted.

(D) Accommodation process Next, the accommodation process of accommodating the exhaust gas treating body 10 around which the holding sealing material 30 is wound in the metal casing 20 mainly made of metal or the like is performed.
As a method for accommodating the exhaust gas treating body 10 around which the holding sealing material 30 is wound in the metal casing 20, for example, as shown in FIG. 5A, the holding sealing material 30 is wound up to a predetermined position inside the metal casing 20. A press-fitting method (stuffing method) for press-fitting the exhaust gas treatment body 10 may be used, or a sizing method (swaging type) for compressing from the outer peripheral side so as to reduce the inner diameter of the metal casing 20 may be used. The first casing and the second casing are separated from each other, and the exhaust gas treatment body 10 around which the holding sealing material 30 is wound is placed on the first casing, and then the second casing is covered. The clamshell method for sealing may be used, but from the viewpoint of manufacturing cost, the press-fitting method (stuffing method) It is desirable.
The holding sealing material of the present invention is particularly effective when the wound body is accommodated in the metal casing by the press-fitting method. However, even if the other accommodating methods are used, the holding sealing material can be prevented from shifting when the exhaust gas is introduced. It is valid.

The exhaust gas purification apparatus 1 which is an example of the exhaust gas purification apparatus of this invention is manufactured through the process so far.

Furthermore, the holding sealing material of the present invention and the exhaust gas purification apparatus of the present invention may have the following configurations.

In the description of the exhaust gas purification apparatus of the present invention so far, the exhaust gas treatment body has been an integrated exhaust gas treatment body, but the exhaust gas treatment body constituting the exhaust gas purification apparatus of the present invention has a plurality of units of adhesive layers. It may be a collective exhaust gas treating body that is bundled through a gap.

The shape of the exhaust gas treating body constituting the exhaust gas purifying apparatus of the present invention is not limited to a cylindrical shape, and may be an arbitrary shape such as an elliptical column shape or a prismatic shape.

Below, it lists about the effect of the manufacturing method of the holding | maintenance sealing material of this invention, an exhaust gas purification apparatus, and an exhaust gas purification apparatus.
(1) In the holding sealing material of the present invention, films are adhered to the first main surface, the second main surface, the first long side surface, and the second long side surface.
Inorganic fibers are scattered from the surface of the mat. In particular, when the holding sealing material is wound around the exhaust gas treating body and accommodated in a metal casing, the holding sealing material is compressed, and thus inorganic fibers are particularly likely to be scattered. However, when a film is stuck like the holding sealing material of the present invention, such scattering of inorganic fibers can be reduced.
(2) In the holding sealing material of the present invention, an exposed portion which is a region where no film is attached to the second main surface is provided.
Since the exposed portion, which is a region where no film is attached, is provided on the second main surface in contact with the exhaust gas treatment body, the holding sealing material is exhausted so that the second main surface is in contact with the exhaust gas treatment body. When wound around the treatment body, the inorganic fibers constituting the holding seal material are entangled with the surface of the exhaust gas treatment body, and the adhesion between the holding seal material and the exhaust gas treatment body is improved. As a result, the holding seal material and the exhaust gas treatment body are less likely to be displaced due to friction between the inorganic fiber and the exhaust gas treatment body, and when the wound body is housed in the metal casing by press-fitting, the holding seal material is attached to the end of the metal casing. Protruding from the part can be prevented.
(3) In the holding sealing material of the present invention, the shortest distance from the first long side surface to the exposed portion is longer than the shortest distance from the second long side surface to the exposed portion.
When such a holding sealing material is wound around a metal casing such that the first long side surface is disposed on the exhaust gas introduction side, the film is unevenly distributed on the exhaust gas introduction side. That is, when the exhaust gas is introduced, the film is quickly decomposed by the heat of the exhaust gas. Therefore, it is possible to reduce the portion where the film is softened and slippery, and as a result, it is possible to prevent the holding sealing material and the exhaust gas treating body from shifting when the exhaust gas is introduced.

(Example)
Examples in which the present invention is disclosed more specifically are shown below. In addition, this invention is not limited only to this Example.
Example 1
(A) Matt preparation step (a-1) Spinning step For basic aluminum chloride aqueous solution prepared such that Al content is 70 g / l and Al: Cl = 1: 1.8 (atomic ratio). The silica sol is blended so that the composition ratio in the inorganic fiber after firing is Al ₂ O ₃ : SiO ₂ = 72: 28 (weight ratio), and an appropriate amount of an organic polymer (polyvinyl alcohol) is added and mixed. A liquid was prepared.
The obtained mixture was concentrated to obtain a spinning mixture, and this spinning mixture was spun by a blowing method to prepare an inorganic fiber precursor having an average fiber length of 100 mm and an average fiber diameter of 5.1 μm.

(A-2) Compression step The inorganic fiber precursor obtained in the step (a-1) was compressed to produce a continuous sheet-like material.

(A-3) Needle punching treatment step A needle punching treatment body was produced by continuously performing needle punching treatment on the sheet-like material obtained in the step (a-2) using the conditions shown below. .
First, a needle board to which needles were attached at a density of 21 pieces / cm ² was prepared. Next, the needle board is disposed above the one surface of the sheet-like material, and the needle board is moved up and down once along the thickness direction of the sheet-like material to perform needle punching treatment. Was made. At this time, the needle was penetrated until the barb formed at the tip of the needle completely penetrated the surface on the opposite side of the sheet-like material.

(A-4) Firing step The needle punched body obtained in the above step (a-3) is continuously fired at a maximum temperature of 1250 ° C. to produce a fired sheet-like material made of inorganic fibers containing alumina and silica. did. The average fiber diameter of the inorganic fibers was 5.1 μm, and the minimum value of the inorganic fiber diameter was 3.2 μm. The alumina fiber holding sealing material thus obtained has a bulk density of 0.15 g / cm ³ and a basis weight of 1400 g / m ² .

(A-5) Cutting step The fired sheet-like material obtained in the step (a-4) was cut to produce a cut sheet-like material.

(A-6) Impregnation step The cut sheet-like material obtained in the above step (a-5) is flow-coated with an organic binder solution (acrylic latex) containing an acrylic resin as an organic binder, and the cut sheet-like material is obtained. An impregnated sheet was produced by impregnating with an organic binder.

(A-7) Drying step After excess organic binder solution is removed by suction from the impregnated sheet-like material obtained in the step (a-6), the thickness is reduced by compressing and drying. An 8 mm needle punching mat was produced.

(A-8) The mat obtained through the cutting step (a-7) is a convex portion having a plan view dimension of 1023 mm in length and 371 mm in width, having a length of 24.5 mm and a width of 100 mm at one end. Was formed, and the mat was formed by cutting so that a concave portion fitted to the convex portion was formed at the other end.

(B) Adhering step A film with a polyester adhesive material (thickness 40 μm; manufactured by Kato Seiko Co., Ltd.) was cut into a substantially rectangular shape having a total length of 974 mm and a width of 460 mm.
Subsequently, using the winding start portion of the second main surface of the mat formed by the cutting step (a-8) as the winding start portion, the film is used as the second main surface and the first long side surface of the mat. The first main surface, the second long side surface, and the second main surface were continuously wound and adhered to the winding end portion of the second main surface of the mat. The winding start portion is positioned 50 mm from the first long side surface of the mat to the second long side surface, and the winding end portion is positioned from the second long side surface of the mat to the first long side surface. It was located at a position of 25 mm in the direction of.
Here, the distance from the first long side surface to the winding start portion corresponds to the shortest distance from the first long side surface to the exposed portion, and the distance from the second long side surface to the winding end portion is 2 corresponds to the shortest distance from the long side surface to the exposed portion, and the distance from the winding start portion to the winding end portion corresponds to the width of the exposed portion.
The width of the exposed portion was 296 mm, which was 79.8% of the mat width.

The holding sealing material thus produced becomes the holding sealing material according to Example 1. When the holding sealing material according to Example 1 is cut in a direction perpendicular to the longitudinal direction, a cross section as shown in FIG. 4 is obtained.

(C) Winding step (c-1) Preparation of molded product of exhaust gas treating body 52.8% by weight of silicon carbide coarse powder having an average particle diameter of 22 μm and fine powder of silicon carbide having an average particle diameter of 0.5 μm 6% by weight, and 2.1% by weight of acrylic resin, 4.6% by weight of organic binder (methyl cellulose), 2.8% by weight of lubricant (Unilube, manufactured by NOF Corporation), After adding 1.3% by weight of glycerin and 13.8% by weight of water and kneading to obtain a wet mixture, extrusion molding is performed, and either one of the cells is sealed with a sealing material, thereby treating exhaust gas. A molded body was produced.

(C-2) Drying step The molded body of the exhaust gas treating body obtained in the above step (c-1) was dried using a microwave dryer to obtain a dried body of the exhaust gas treating body.

(C-3) Degreasing process The dry body of the exhaust-gas-treatment body obtained at the said process (c-2) was degreased at 400 degreeC, and it was set as the degreased body of the exhaust-gas-treatment body 10.

(C-4) Firing step The degreasing body of the exhaust gas treating body obtained in the step (c-3) is subjected to a firing step under a normal pressure argon atmosphere at 2200 ° C for 3 hours, with a porosity of 45%, A honeycomb fired body having an average pore diameter of 15 μm, a cell number (cell density) of 300 cells / inch ² , and a cell wall thickness of 0.25 mm (10 mil) was produced.

(C-5) Catalyst supporting step After the honeycomb fired body obtained in the above step (c-4) is immersed in a platinum nitrate solution, the honeycomb fired body is held at 600 ° C. for 1 hour, whereby the cell wall 12 of the honeycomb fired body is formed. The exhaust gas treating body 10 was manufactured by supporting the platinum catalyst.
The exhaust gas treating body was substantially cylindrical with a total length of 350 mm, and the outer diameter was 326 mm.

(C-6) Holding sealing material winding step The holding sealing material of this example was wound around the exhaust gas treating body obtained in the step (c-5). At this time, the holding sealing material was wound so that the second main surface of the mat constituting the holding sealing material of this example was in contact with the exhaust gas treating body. Furthermore, the convex part of the mat and the concave part were fitted.

(D) Accommodation process The wound body obtained by the above-mentioned (c-6) holding sealing material winding process was accommodated in a metal casing by a press-fitting method (stuffing method). The gap bulk density (GBH) of the holding sealing material was 0.4 g / cm ³ .

The exhaust gas purification apparatus thus manufactured is the exhaust gas purification apparatus according to the first embodiment.

(Comparative Example 1)
In the above (b) sticking step, the winding start part and the winding end part are matched, and the film is stuck so that the exposed part is not formed on the second main surface. An exhaust gas purification device was produced.

(Comparative Example 2)
(B) In the attaching step, the film is attached so that the exposed portion is formed so that the shortest distance from the first long side surface to the exposed portion is equal to the shortest distance from the second long side surface to the exposed portion. Otherwise, an exhaust gas purification apparatus was produced in the same manner as in Example 1.

(Press-in test)
The holding sealing materials of Example 1 and Comparative Examples 1 and 2 were wound around the exhaust gas treating body and accommodated in a metal casing by press fitting. In the holding sealing materials of Example 1 and Comparative Example 2, the holding sealing material and the exhaust gas treating body did not deviate. However, in the holding sealing material of Comparative Example 1, the holding sealing material and the exhaust gas treating body slipped and held. The sealing material protruded from the metal casing.

(Exhaust gas inflow test)
The holding sealing materials of Example 1 and Comparative Examples 1 and 2 were wound around an exhaust gas treatment body and accommodated in a metal casing to obtain an exhaust gas purification device. This exhaust gas purification device was connected to a 2L common rail type diesel engine and operated at a rotation speed of 6000 rpm and a torque of 72 Nm for 1080 minutes. Then, the exhaust gas purification device was removed, and it was confirmed whether the holding sealing material was displaced.
In the holding sealing material of Example 1, the holding sealing material was not displaced at all, but in the holding sealing materials of Comparative Examples 1 and 2, the holding sealing material was displaced from the exhaust gas treating body.
Thus, the holding sealing material according to Example 1 not only can suppress the scattering of inorganic fibers, but also is superior to the holding sealing material of Comparative Example 1 in terms of press fit into the metal casing, and at the time of exhaust gas inflow It was found that it was superior to the holding sealing materials of Comparative Examples 1 and 2 in terms of preventing deviation.

DESCRIPTION OF SYMBOLS 1 Exhaust gas purification apparatus 10 Exhaust gas processing body 11 Cell 12 Cell wall 13 Sealing material 14 Outer peripheral coat layer 20 Metal casing 30 Holding sealing material 40 Mat 41 First main surface 42 Second main surface 43 First short side surface 44 First Two short side surfaces 43a, 44a Convex portions 43b, 44b Concavity 45 First long side surface 46 Second long side surface 47 Winding start portion 48 Winding end portion 49 Exposed portion 50 Film

Claims (8)

A first main surface and a second main surface opposite to the first main surface; a first long side; a second long side opposite to the first long side; and a first short side. A holding sealing material comprising a mat having a substantially rectangular shape in a plan view including inorganic fibers having a side surface and a second short side surface opposite to the first short side surface,
A film is attached to the first main surface, the second main surface, the first long side surface, and the second long side surface,
The second main surface is provided with an exposed portion that is an area where the film is not attached,
The exposed portion is formed in a band shape that connects the first short side surface and the second short side surface,
The holding sealing material, wherein a shortest distance from the first long side surface to the exposed portion is longer than a shortest distance from the second long side surface to the exposed portion. The holding sealing material according to claim 1, wherein a width of the exposed portion is 5 to 80% of a width of the mat. The holding sealing material according to claim 1 or 2, wherein the shortest distance from the first long side surface to the exposed portion is 11 to 80% of the width of the mat. The holding sealing material according to claim 1, wherein the constituent material of the film is at least one selected from the group consisting of polyester, polyethylene, and polypropylene. The holding sealing material according to any one of claims 1 to 4, wherein the film is fixed to the mat by an adhesive or thermocompression bonding. A method for producing the holding sealing material according to claim 1,
A first main surface and a second main surface opposite to the first main surface; a first long side; a second long side opposite to the first long side; and a first short side. A mat preparing step of preparing a mat having a substantially rectangular shape in plan view including inorganic fibers having a side surface and a second short side surface opposite to the first short side surface;
It is an area where a film is attached to the first main surface, the first long side surface and the second long side surface of the mat, and the film is not attached to the second main surface. And a sticking step of sticking the film so that an exposed portion is formed. An exhaust gas treating body;
A holding sealing material disposed around the exhaust gas treating body;
An exhaust gas purification apparatus comprising a metal casing that houses the exhaust gas treating body,
The holding sealing material includes a first main surface, a second main surface opposite to the first main surface, a first long side surface, and a second long side opposite to the first long side surface. A mat having a substantially rectangular shape in a plan view including inorganic fibers having a side surface, a first short side surface, and a second short side surface opposite to the first short side surface;
A film is attached to the first main surface, the second main surface, the first long side surface, and the second long side surface,
The second main surface is provided with an exposed portion that is an area where the film is not attached,
The exposed portion is formed in a band shape that connects the first short side surface and the second short side surface,
The shortest distance from the first long side surface to the exposed portion is longer than the shortest distance from the second long side surface to the exposed portion,
Exhaust gas purification characterized in that the holding sealing material is arranged so that the exposed portion of the second main surface is in contact with the exhaust gas treating body and the first long side surface is located on the exhaust gas introduction side apparatus. It is a manufacturing method of the exhaust gas purification device according to claim 7,
A first main surface and a second main surface opposite to the first main surface; a first long side; a second long side opposite to the first long side; and a first short side. A mat preparing step of preparing a mat having a substantially rectangular shape in plan view including inorganic fibers having a side surface and a second short side surface opposite to the first short side surface;
It is an area where a film is attached to the first main surface, the first long side surface and the second long side surface of the mat, and the film is not attached to the second main surface. A sticking step of sticking the film so that an exposed portion is formed;
A winding step in which the mat to which the film has been attached by the attaching step is wound so that the second main surface is in direct contact with the exhaust gas treating body,
And a housing step of housing the wound body in a metal casing so that the first long side surface is located on the exhaust gas introduction side.

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