JP5766494B2 - Assembly and exhaust gas treatment device - Google Patents

Description

  The present invention relates to an exhaust gas treatment device for a vehicle or the like, and more particularly to an assembly used for an exhaust gas treatment device.

  The number of automobiles has increased dramatically since the beginning of this century, and the amount of exhaust gas discharged from the internal combustion engine of automobiles has been increasing rapidly in proportion to this. In particular, various substances contained in the exhaust gas of a diesel engine cause pollution, and are now having a serious impact on the global environment.

  Under such circumstances, various exhaust gas treatment apparatuses have been proposed and put into practical use. A general exhaust gas treatment apparatus is provided with a cylindrical member (casing) in the middle of an exhaust pipe connected to an exhaust gas manifold of an engine, and has an exhaust gas inlet and outlet opening surfaces therein, It has a structure in which an exhaust gas processing body having a large number of fine pores is arranged inside. Examples of the exhaust gas processing body include a catalyst carrier and an exhaust gas filter such as a diesel particulate filter (DPF). For example, in the case of a DPF, due to the above-described structure, fine particles are trapped on the wall around the pores while exhaust gas is exhausted from the inlet opening surface of the exhaust gas processing body through the outlet opening surface. Can be removed.

  Usually, a holding sealing material is installed between the exhaust gas processing body and the casing. The holding sealing material is used to prevent damage due to contact between the exhaust gas processing body and the casing during traveling of the vehicle, and to prevent the exhaust gas from leaking from the gap between the casing and the exhaust gas processing body. Further, the holding sealing material has a role of preventing the exhaust gas processing body from falling off due to exhaust gas exhaust pressure. Furthermore, the exhaust gas treating body needs to be kept at a high temperature in order to maintain the reactivity, and the holding sealing material is also required to have heat insulation performance. As a member satisfying these requirements, there is a mat material containing inorganic fibers such as alumina fibers.

  The mat member is wound around at least a part of the outer peripheral surface excluding the opening surface of the exhaust gas treatment body, and then the end surfaces are joined to each other with an adhesive tape and fixed integrally with the exhaust gas treatment body. Functions as a material. Thereafter, the assembly is mounted in a casing, thereby constituting an exhaust gas treatment device.

JP-A-11-173140

  In the assembly having the holding sealing material and the exhaust gas processing body as described above, the holding sealing material may be composed of a plurality of mat members. When these mat members are combined with each other, they are formed in advance in a shape that exactly matches the outer peripheral shape of the exhaust gas treating body. Therefore, a holding sealing material can be constituted by combining these mat members.

  The holding sealing material constituted by the mat member having such a divided structure is advantageous in that it can be more adapted to exhaust gas treatment bodies having various outer peripheral shapes such as a drum shape and a barrel shape. That is, in the case of a “sheet-like” mat material, when the mat material and the exhaust gas treatment body do not sufficiently adhere to each other when wound around an exhaust gas treatment body having an outer peripheral shape other than a true cylindrical shape, a gap is generated. However, such a problem can be suppressed in the holding sealing material made of a mat member having a divided structure.

However, in the mat member having a divided structure, the number of end faces that need to be bonded increases when the mat member is configured as a holding sealing material, which increases the amount of adhesive tape used during assembly. (For example, when a holding sealing material is formed by a combination of two mat members, there are two end surfaces to be joined, and when a holding sealing material is formed by a combination of three mat members, the end surfaces to be joined are 3 places.)
Such an increase in the amount of adhesive tape used is not very preferable from an environmental point of view. That is, when a mat member having such a divided structure is used as a holding sealing material for an exhaust gas treatment device, it is included in the adhesive tape by the heat of the exhaust gas during actual use of the exhaust gas treatment device, particularly during initial use. This causes a problem that the organic component is thermally decomposed and discharged outside the apparatus. In recent years, regulations on organic components in exhaust gas have become more and more strict, and it is desirable to suppress such emissions of organic components as much as possible.

  On the other hand, in order to cope with this problem, when the usage amount of the adhesive tape is reduced, the bonding force between the end portions of the mat member may be reduced, and the two mat members may be easily separated.

  The present invention has been made in view of such problems, and the present invention is a case where the amount of adhesive tape used is suppressed in an assembly including a holding sealing material configured by combining a plurality of mat members. However, it aims at providing the assembly which has a holding sealing material which can fix edge parts with an appropriate joining force. Another object of the present invention is to provide an exhaust gas treatment apparatus including such an assembly.

In the present invention,
An assembly in which a holding sealing material configured by combining a plurality of mat members is disposed on the outer peripheral surface of the exhaust gas processing body,
The first mat member has an upper end surface and a lower end surface, and first and second side end surfaces connecting the upper end surface and the lower end surface, and a convex portion is formed on the first side end surface. ,
The second mat member has an upper end surface and a lower end surface, and first and second side end surfaces connecting the upper end surface and the lower end surface, and a recess is formed in the first side end surface.
By fitting the convex portion and the concave portion, the first and second mat members are joined,
The convex portion has a first contour portion extending from the first point A on the first side end surface of the first mat member as a starting point toward the second mat member, and the first Having a second contour portion extending from the second point B on the first side end surface of the mat member toward the second mat member;
The first point A is closer to the upper end surface of the first mat member than the second point B,
On the first side end surface, a line segment P1 connecting the first side end surface starting from the point A and the upper end surface and a line segment P2 passing through the point A of the first contour portion are formed. The angle α is α> 90 °,
On the first side end face, a line segment P3 connecting the first side end face starting from the point B and the lower end face and a line segment P4 passing through the point B of the second contour portion are formed. An assembly is provided wherein the angle β is β <90 °.

  Here, in the assembly according to the present invention, the convex portion may be substantially triangular, parallelogram, or trapezoidal.

  Moreover, the assembly by this invention WHEREIN: The said convex part may have a curvilinear outline part.

  In the assembly according to the present invention, a plurality of the convex portions may be formed on the first side end face of the first mat member.

In the assembly according to the present invention, the angle α may be in the range of 95 ° to 175 °, and / or the angle β may be in the range of 5 ° to 85 °.

  In the assembly according to the present invention, the exhaust gas processing body may be a catalyst carrier or an exhaust gas filter.

  In the assembly according to the present invention, the first mat member and / or the second mat member are selected from the group consisting of alumina fibers, mullite fibers, silica alumina fibers, and glass fibers, One may be included.

  In the assembly according to the present invention, the first mat member and / or the second mat member may further include at least one of an inorganic binder and an organic binder.

  In the assembly according to the present invention, the outer peripheral surface of the exhaust gas treating body may have a drum shape or a barrel shape.

Furthermore, in the present invention,
An assembly in which a holding sealing material configured by combining a plurality of mat members is disposed on an outer peripheral surface of an exhaust gas processing body having two opening surfaces through which exhaust gas flows;
A cylindrical member for housing the assembly;
An exhaust gas treatment device comprising:
The assembly is provided with an exhaust gas processing apparatus which is an assembly having the above-described features.

  In the present invention, in an assembly including a holding sealing material configured by combining a plurality of mat members, the ends can be fixed with an appropriate bonding force even when the amount of adhesive tape used is suppressed. It becomes possible to provide an assembly having a possible holding sealing material. Moreover, in this invention, an exhaust-gas processing apparatus provided with such an assembly can be provided.

It is the shi perspective view which showed an example of the conventional assembly typically. It is the figure which showed typically the assembly method of the holding sealing material contained in the conventional assembly. It is the figure which showed roughly an example of the fitting part of the 1st mat member 125A and the 2nd mat member 125B which comprise some holding seal materials 120 of a division structure. It is the figure which showed typically the mode at the time of joining two mat members. It is the figure which showed an example of the form of the convex part of 125 A of 1st mat members, and the recessed part of the 2nd mat member 125B. It is the figure which showed an example of another form of the convex part of 125 A of 1st mat members, and the recessed part of the 2nd mat member 125B. It is the figure which showed an example of another form of the convex part of 125 A of 1st mat members, and the recessed part of the 2nd mat member 125B. It is the schematic diagram which showed an example of the fitting part in case the convex part of 1st mat member 125A and the recessed part of 2nd mat member 125B have a curved-shaped outline part. It is the schematic diagram which showed an example of the fitting part in case the convex part of 1st mat member 125A and the recessed part of 2nd mat member 125B have a curved-shaped outline part. It is the perspective view which showed typically the example of 1 structure of the assembly 100 by this invention. It is sectional drawing which showed typically the example of 1 structure of the exhaust-gas processing apparatus provided with the assembly 100 by this invention. It is the flowchart which showed roughly an example of the manufacturing method of the assembly by this invention. It is the flowchart which showed roughly an example of the manufacturing method of the mat member for holding sealing materials of a division structure.

  The present invention will be described below.

  First, in order to better understand the present invention, a conventional holding sealing material will be described with reference to FIGS. 1 and 2.

  FIG. 1 schematically shows an example of a conventional assembly composed of an exhaust gas processing body and a holding sealing material. FIG. 2 schematically shows an example of the assembly manner of the holding sealing material.

  As described above, when a holding sealing material is installed on the outer peripheral surface of the exhaust gas processing body having an outer peripheral shape other than a true cylindrical shape, the sheet-like mat material is wound and held around the outer peripheral surface of the exhaust gas processing body. Instead of forming the seal material, it may be preferable to form a holding seal material by combining a plurality of mat materials. (Hereinafter, a holding sealing material constituted by combining a plurality of such mat members will be referred to as a “divided structure” holding sealing material).

  FIG. 1 schematically shows an example of an assembly 10 configured by disposing such a “divided structure” holding sealing material on the outer peripheral surface of an exhaust gas processing body. As shown in FIG. 1, the assembly 10 includes an exhaust gas processing body 12 and a holding sealing material 20 having a divided structure disposed on the outer peripheral surface of the exhaust gas processing body 12. For simplification, in FIG. 1, it is assumed that the outer peripheral shape of the exhaust gas processing body 12 is a true cylindrical shape.

  As shown in FIG. 2, the holding sealing material 20 having a divided structure is of a two-divided type, and includes two substantially semi-cylindrical mat members (a first mat member 25A and a second mat member 25B). . The first mat member 25A has a convex portion 60 at one end portion 26A, and the second mat member 25B has a concave portion 70 at one end portion 26B.

  In both mat members 25A and 25B configured in this way, by fitting the convex portion 60 of the end portion 26A of the first mat member 25A into the concave portion 70 of the end portion 26B of the second mat member 25B, End portions 26A and 26B of both mat members 25A and 25B can be joined. Similarly, by mating the other ends of the mat members 25A and 25B, the mat members 25A and 25B are integrated to form the holding sealing material 20 having a divided structure.

  However, in this state, the mating force between the mat members 25A and 25B is not sufficient, and when force is applied to the mat members 25A and 25B, for example, in the directions of arrows F1 and F2 in FIG. The force is referred to as “circumferential opposing force”), and the end portions 26A and 26B of both mat members 25A and 25B are easily detached, thereby separating both mat members 25A and 25B.

  Therefore, in general, as shown in FIG. 1, after mating the end portions 26A and 26B of the mat members 25A and 25B, it is necessary to further join the mat members with an adhesive tape 90 or the like. The same applies to the other ends of the mat members 25A and 25B.

  However, in the case of a holding sealing material with a divided structure, there are at least two end faces to be joined. For this reason, in the case of a holding sealing material with a divided structure, when a sheet-like mat material is wound and used In comparison with this, there arises a problem that the amount of the adhesive tape 90 used at the time of assembly increases.

  For example, as shown in FIG. 2, when the holding sealing material is formed by two mat members 25A and 25B, there are two end faces to be joined (double the amount of adhesive tape used), and the holding seal is made by three mat members. When the material is formed, there are three end faces to be joined (the amount of adhesive tape used is three times).

  Such an increase in the amount of tape used is not preferable from an environmental point of view. That is, when the holding seal material having such a divided structure is used in an exhaust gas treatment device, the organic component contained in the adhesive tape is caused by the heat of the exhaust gas when the exhaust gas treatment device is used, particularly at the initial use. There arises a problem that it is thermally decomposed and discharged outside the apparatus. In recent years, regulations on organic components in exhaust gas have become more and more strict, and it is necessary to suppress the emission of such organic components as much as possible.

In contrast, in the present invention,
An assembly in which a holding sealing material configured by combining a plurality of mat members is arranged on the outer surface of an exhaust gas processing body used in an exhaust gas processing apparatus,
The first mat member has an upper end surface and a lower end surface, and first and second side end surfaces connecting the upper end surface and the lower end surface, and a convex portion is formed on the first side end surface. ,
The second mat member has an upper end surface and a lower end surface, and first and second side end surfaces connecting the upper end surface and the lower end surface, and a recess is formed in the first side end surface.
By fitting the convex portion and the concave portion, the first and second mat members are joined,
The convex portion includes a first contour portion extending from the first point A of the first side end surface of the first mat member toward the second mat member, and the first mat. Having a second contour portion extending from the second point B of the first side end face of the member to the second mat member,
The first point A is closer to the upper end surface of the first mat member than the second point B,
On the first side end surface, a line segment P1 connecting the first side end surface starting from the point A and the upper end surface and a line segment P2 passing through the point A of the first contour portion are formed. The angle α is α> 90 °,
On the first side end face, a line segment P3 connecting the first side end face starting from the point B and the lower end face and a line segment P4 passing through the point B of the second contour portion are formed. An assembly member is provided, characterized in that the angle β satisfies β <90 °.

  Hereinafter, the function of the “divided structure” holding sealing material in the assembly of the present invention having such characteristics will be described with reference to the drawings.

  FIG. 3 schematically shows an example of a fitting portion of the first mat member 125A and the second mat member 125B constituting a part of the holding seal material 120 having a divided structure according to the present invention.

  As shown in FIG. 3, the first mat member 125A has an upper end surface 148A, a lower end surface 149A, and a side end surface 150A, and a convex portion 160 is formed on the side end surface 150A. The second mat member 125B has an upper end surface 148B, a lower end surface 149B, and a side end surface 150B, and a recess 170 is formed in the side end surface 150B. By fitting the convex portion 160 and the concave portion 170 together, the first mat member 125A and the second mat member 125B are joined at the side end surfaces 150A and 150B. In FIG. 3, the convex portion 160 and the concave portion 170 are formed in a substantially triangular shape, but the shapes of the convex portion 160 and the concave portion 170 are not particularly limited.

  As shown in FIG. 3, the convex portion 160 of the first mat member 125A has a contour portion R1 starting from the point A and a contour portion R2 starting from the point B. More specifically, the convex portion 160 protrudes toward the second mat member 125B starting from points A and B on the side end face 150A of the first mat member 125A. Here, in the side end face 150A, a point closer to the upper end face 148A is a point A, and a point closer to the lower end face 149A is a point B.

  Similarly, when viewed from the second mat member 125B side, the concave portion 170 of the second mat member 125B has a contour portion R1 starting from point A and a point B as shown in FIG. It has a contour portion R2. More specifically, the recess 170 protrudes toward the second mat member 125B starting from the point A and the point B on the side end face 150B of the second mat member 125B.

  Here, on the side end surface 150A, a line segment connecting the point A of the first mat member 125A and the upper end surface 148A is P1, and the portion starting from the point A among the contour portions R1 and R2 of the convex portion 160 is the line segment P2. Then, the angle α formed by P1 and P2 is an obtuse angle larger than 90 °. On the other hand, in the side end face 150A, a line segment connecting the point B of the first mat member 125A and the lower end face 149A is P3, and a part starting from the point B in the contour parts R1 and R2 of the convex part 160 is a line segment P4. Then, the angle β formed by P3 and P4 is an acute angle smaller than 90 °.

  When the convex portion 160 of the first mat member 125A is formed in such a manner, the two mat members 125A and 125B joined by the side end surfaces 150A and 150B are applied to the opposing forces F1 and F2 in the circumferential direction. And has significant resistance. This is because, even if a circumferential facing force F1 is applied to the first mat member 125A, the contour portion R2 of the convex portion 160, particularly the portion of the line segment P4, is in the right direction of the first mat member 125A. This is to resist movement. (In other words, even if the counter force F2 in the circumferential direction acts on the second mat member 125B, the contour portion R2 of the concave portion 170, particularly the portion of the line segment P4, is the second mat member 125B. It can be said that it becomes resistance to the leftward movement of).

  For this reason, in this invention, when two mat members like the past receive the opposing force of the circumferential direction, the problem that an edge part will remove | deviate and it will become difficult to arise. In addition, this makes it possible to significantly reduce the amount of adhesive tape used when assembling the holding seal material having a divided structure, and to significantly reduce the amount of organic components discharged from the assembly member. Become.

  In the example of FIG. 3, the number of convex portions 160 provided on the side end surface 150A of the first mat member 125A and the number of concave portions 170 provided on the side end surface 150B of the second mat member 125B are one. However, the number of convex portions and concave portions is not particularly limited. Two or more convex portions and concave portions may be provided.

  Further, according to one embodiment of the present invention, the first mat member 125A and the second mat member 125B can be fitted relatively easily.

  FIG. 4 schematically shows a state when two mat members are joined. In FIG. 4, the first mat member 125A has two convex portions 160 on the first side end face 150A, and also has two convex portions 160 ′ on the second side end face 151A. Further, the second mat member 125B has two concave portions 170 on the first side end surface 150B and also has two concave portions 170 ′ on the second side end surface 151B. In FIG. 4, although it is difficult to visually recognize, the convex portion 160 and the convex portion 160 ′ have the same shape, and the concave portion 170 and the concave portion 170 ′ have the same shape.

  Here, when joining the two mat members 125A and 125B, as shown in FIG. 4, the first mat member 125A having the convex portions 160 and 160 ′ is replaced by the second mat member 125A and the second mat having the concave portions 170 and 170 ′. The mat member 125B is moved from the upper right in the direction of the arrow A1, or the second mat member 125B having the concave portions 170 and 170 ′ is moved with respect to the first mat member 125A having the convex portions 160 and 160 ′. Then, it is moved in the direction of arrow A2 from the lower left. Thereby, each of the convex portion 160 and the concave portion 170 and the convex portion 160 ′ and the concave portion 170 ′ of both mat members can be easily fitted.

  The form in which the first mat member 125A and the second mat member 125B can be easily fitted is not limited to this. For example, the number or size of the projections 160 formed on the first side end surface 150A of the first mat member 125A and the number or size of the projections 160 ′ formed on the second side end surface 151A (similarly, The number or size of the recesses 170 formed on the first side end surface 150B of the second mat member 125B may be different from the number or size of the recesses 170 ′ formed on the second side end surface 151B. good.

  Further, for example, in FIG. 4, the first mat member 125A may have a convex portion 160 on the first side end face 150A and a concave portion 170 ′ on the second side end face 151A. Further, the second mat member 125B may have a concave portion 170 on the first side end surface 150B and a convex portion 160 ′ on the second side end surface 151B. In this case, if the convex portion 160 of the first mat member 125A and the convex portion 160 ′ of the second mat member 125B are configured to protrude in opposite directions (for example, in FIG. The mat member 125A and 125B can be easily fitted to each other by, for example, projecting the convex portion 160 of the mat member 125A obliquely downward and projecting the convex portion 160 ′ of the second mat member 125B obliquely upward). Can do.

  That is, the protruding direction of the convex portion formed on the first side end surface 150A of the first mat member 125A and the protruding direction of the convex portion formed on the second side end surface 151A of the first mat member 125A are as follows. The protrusions formed on the first side end face 150A of the first mat member 125A and the second side end face 151A of the first mat member 125A are formed so as to be in substantially the same direction. The mat members 125A and 125B are fitted to each other by forming convex portions or concave portions on the second side end surface 151A of the first mat member 125A so that the cut-out direction of the concave portions is substantially opposite. Can be easily performed.

  In addition, unless the direction of the convex portion formed on the first side end surface 150A of the first mat member 125A and the direction of the convex portion formed on the second side end surface 151B of the second mat member 125B are reversed. In this case, the directionality when the mat member is wound around the exhaust gas processing body, or the directionality when the assembly around which the mat member is wound is accommodated in the casing is determined by an identification means formed by printing an organic pigment or the like. Even if it is not provided separately, it is possible to easily determine and judge, and this makes it possible to further reduce organic components. Further, in such an embodiment, the process can be omitted compared to the case where the identification means is formed by the inorganic pigment, and the inorganic pigment may fall off from the mat member surface and disappear during the assembly operation. Therefore, it is possible to make a reliable identification judgment.

  In the above description, in the example of FIGS. 3 and 4, the convex portion 160 and the concave portion 170 are triangular. Therefore, in FIG. 3, the contour portions R1 and R2 of the convex portion 160 or the concave portion 170 coincide with the line segments P2 and P3, respectively. However, in the present invention, the shape of the convex portion 160 and the concave portion 170 is not limited to this.

  5 to 7 show an example of another form of the convex portion of the first mat member 125A (the concave portion of the second mat member 125B).

  In FIG. 5, the convex portion 161 of the first mat member 125A and the concave portion 171 of the second mat member 125B have a parallelogram shape. In FIG. 6, the convex portion 162 of the first mat member 125A and the concave portion 172 of the second mat member 125B are trapezoidal. Furthermore, in FIG. 7, the convex part 163 of the first mat member 125A and the concave part 173 of the second mat member 125B are shaped like an ellipse cut obliquely.

  In the mat member 125A having the convex portions 161 to 163 in such a form and the mat member 125B having the concave portions 171 to 173, there is less risk of damaging the tip portion at the time of fitting compared to the triangular shape, It will be apparent to those skilled in the art that the effects described above can be obtained.

  It is also possible to provide a plurality of convex portions of the above-described form at one end portion and use a combination of a plurality of different modes. Furthermore, it is also possible to use a combination of convex portions having different forms at the end of the first side end face 150A and the end of the second side end face 151A.

  When the convex portion of the first mat member 125A and the concave portion of the second mat member 125B have curved contour portions as shown in FIG. 7, the angles α and β are determined as follows. Can do.

  FIGS. 8 and 9 show an example of an enlarged view of the fitting portion when the convex portion of the first mat member 125A and the concave portion of the second mat member 125B have curved contour portions.

  In the example of FIG. 8, the convex portion 160 (concave portion 170) has a contour portion R <b> 1 extending in a convex shape starting from the point A and a contour portion extending in a convex shape starting from the point B. And R2.

  In such a case, instead of the line segment P2 in FIG. 3 described above, a straight line L1 that is in contact with the contour portion R1 at the point A may be drawn, and the angle formed by the straight line L1 and the line segment P1 may be α. Further, instead of the line segment P4 in FIG. 3 described above, a straight line L2 that is in contact with the contour portion R2 at the point B may be drawn, and an angle formed by the straight line L2 and the line segment P3 may be β.

  On the other hand, in the example of FIG. 9, the convex portion 160 (concave portion 170) extends in a convex shape upward from a point A as a starting point and a contour portion R1 extending in a convex shape upward and a point B as a starting point. And a contour portion R2.

  In such a case as well, as in the case of FIG. 8, instead of the line segment P2 in FIG. 3, the straight line L1 that is in contact with the contour portion R1 at the point A is drawn, and the angle formed by the straight line L1 and the line segment P1 α may be used. Further, instead of the line segment P4 in FIG. 3 described above, a straight line L2 that is in contact with the contour portion R2 at the point B may be drawn, and an angle formed by the straight line L2 and the line segment P3 may be β.

  It will be apparent that the above-described effects of the present invention can be obtained when the angle α obtained by such a method satisfies α> 90 ° and the angle β satisfies β <90 °. Therefore, the present invention is not limited to the case where the contour portion of the convex portion and the concave portion is formed only by a combination of linear shapes, but when the part or all of the contour portion of the convex portion and the concave portion is formed by a curve. Can be applied as well.

  Here, the angle α is particularly preferably in the range of 95 ° to 175 °, and more preferably in the range of 110 ° to 160 °. In addition, the angle β is particularly preferably in the range of 5 ° to 85 °, and more preferably in the range of 30 ° to 60 °.

  When the angle α is less than 95 °, an appropriate bonding force between the end portions is lost, and when the angle α exceeds 175 °, in the portion formed by the line segment P2 and the line segment P4 (convex portion 170), In some cases, sufficient strength cannot be obtained.

  Further, when the angle β is less than 5 °, an appropriate bonding force between the end portions is lost, and when the angle β exceeds 85 °, the portion formed by the line segment P3 and the line segment P4 is sufficient. Strength may not be obtained.

  Each mat member constituting such a “divided structure” holding sealing material has inorganic fibers, and may further contain an organic binder and / or an inorganic binder.

  As the inorganic fiber, at least one selected from alumina fiber, silica fiber, mullite fiber, silica alumina fiber, glass fiber and the like is usually used.

  The organic binder and / or the inorganic binder is usually contained in the range of 1 wt% to 10 wt% with respect to the total weight of the mat member.

  FIG. 10 schematically shows a perspective view of an assembly 100 according to the present invention.

  As shown in FIG. 10, the assembly 100 according to the present invention includes an exhaust gas processing body 112 and a holding sealing material 120 disposed on at least a part of the outer peripheral surface of the exhaust gas processing body 112. The holding sealing material 120 is configured by combining at least two mat members 125A and 125B. As described above, the first mat member 125A and the second mat member 125B are joined by fitting the convex portion 160 of the first mat member 125A and the concave portion 170 of the second mat member 125B. The

  As described above, the fitting portion exhibits a relatively good bondability with respect to the opposing force in the circumferential direction, so that the first mat member 125A and the second mat member 125B are fitted to each other. The problem of separation at a significantly reduced level.

  In FIG. 10, no adhesive tape is installed at the portion where the first mat member 125A and the second mat member 125B are joined. However, you may install an adhesive tape in the part where both are joined. However, as described above, it should be noted that in the assembly 100 according to the present invention, the amount of adhesive tape used is significantly suppressed.

  Such an assembly 100 is mounted in a cylindrical casing made of metal or the like, for example, by a press-fitting method or the like, and is used in an exhaust gas processing apparatus.

  FIG. 11 shows an example of the configuration of an exhaust gas processing apparatus including the assembly according to the present invention.

  As shown in FIG. 11, the exhaust gas processing apparatus 410 includes an assembly 100 configured by installing the holding sealing material 120 having the above-described characteristics on the outer peripheral surface of the exhaust gas processing body 112, and the assembly 100. And an exhaust gas inlet pipe 420 and an outlet pipe 430 connected to the inlet side and the outlet side of the casing 212, respectively.

  In the example of this figure, the inlet pipe 420 and the outlet pipe 430 are tapered so that the diameter is expanded at a position where the inlet pipe 420 and the outlet pipe 430 are connected to the casing 212. Further, in the example of this figure, the exhaust gas treating body 112 is a catalyst carrier having an opening surface for exhaust gas inlet and outlet, and a large number of through holes in a direction parallel to the gas flow. The catalyst carrier is made of, for example, honeycomb-shaped porous silicon carbide. However, the exhaust gas treatment device 410 of the present invention is not limited to such a configuration. For example, the exhaust gas treating body 112 can be a DPF in which a part of the through hole is sealed.

  Here, the holding sealing material 120 includes the first mat member 125A and the second mat member 125B having the above-described characteristics. Therefore, in this exhaust gas treatment device 410, the discharge of organic components is significantly suppressed during use.

(Method of manufacturing an assembly according to the present invention)
Next, an example of a method for manufacturing the assembly 100 according to the present invention will be described with reference to FIG.

In FIG. 12, the flow of the manufacturing method of the assembly 100 by this invention is shown typically. As shown in FIG. 12, the assembly 100 according to the present invention comprises:
Preparing an exhaust gas treating body having first and second opening surfaces and an outer peripheral surface connecting both opening surfaces (step S110);
Configuring a holding sealing material on the outer peripheral surface of the exhaust gas treating body by combining a plurality of mat members (step S120);
Have

  Hereinafter, each step will be described.

(Step S110)
First, an exhaust gas processing body is prepared. The exhaust gas processing body has first and second opening surfaces and an outer peripheral surface. A plurality of cells through which the exhaust gas flows and cell walls that partition the cells are formed on the first and second opening surfaces of the exhaust gas processing body. The number, shape, and dimensions of the cells and the dimensions of the cell walls are not particularly limited. Further, the material of the exhaust gas processing body is not particularly limited. In general, a ceramic containing cordierite, alumina, silicon carbide, and / or silicon nitride is used as the exhaust gas treating body.

  The exhaust gas treating body can be manufactured, for example, by forming a slurry containing inorganic particles as a formed body and firing the formed body.

  As described above, the exhaust gas processing body may be a catalyst carrier and an exhaust gas filter such as a diesel particulate filter (DPF).

  Further, the shape of the exhaust gas processing body is not particularly limited as long as it is columnar. The exhaust gas processing body may be, for example, a columnar shape, a prismatic shape, or a shape having an elliptical cross section perpendicular to the axial direction. Further, the exhaust gas treating body has a shape whose diameter changes along the axial direction, for example, a drum shape (a shape where the diameter is minimum at any position in the longitudinal direction), and a barrel shape (a longitudinal direction). It may be a shape that has a maximum diameter at any position.

  In particular, the holding sealing material used in the present invention is configured by combining a plurality of mat members. Such a “divided structure” holding sealing material is formed in advance in a shape that exactly matches the outer peripheral shape of the exhaust gas treating body when combined with each other. Therefore, such a “divided structure” holding sealing material is advantageous in that it can be more adapted to exhaust gas treatment bodies having various outer peripheral shapes such as a drum shape and a barrel shape. That is, in the method of forming a holding sealing material by winding a single flat “sheet-like” mat material, when the winding material is wound around an exhaust gas processing body having an outer peripheral shape other than a true cylindrical shape, the holding sealing material However, the “divided structure” holding sealing material can suppress such a problem.

(Step S120)
Next, a holding sealing material is installed on the outer peripheral surface of the exhaust gas processing body prepared in step S110 to form an assembly.

  As a method of forming the assembly, for example, a plurality of mat members are combined to form a substantially cylindrical holding sealing material, and then an exhaust gas treatment body is mounted inside the exhaust gas processing body. There is a method in which a plurality of mat members are combined on the outer peripheral surface of the gas processing body, and the assembly is configured simultaneously with the completion of the assembly of the holding sealing material.

  Basically, any method may be adopted. However, when the exhaust gas treating body has a shape whose diameter changes along the axial direction as described above, the latter method is used.

(Method for manufacturing mat member)
Next, with reference to FIG. 13, an example of a method for manufacturing a mat member for a holding sealing material having a “divided structure” will be briefly described. However, the mat member may be manufactured by a method other than the method described below.

As shown in FIG. 13, the mat member is, for example,
Preparing a slurry containing inorganic fibers (step S210);
Charging the slurry into a reticulated mold (S220);
Dehydrating the mold to obtain a wet molded body (S230);
Drying the wet molded body and removing it from the mold (S240);
It can be manufactured through.

  Hereinafter, each step will be described.

(Step S210)
First, a slurry containing inorganic fibers as a raw material for the mat member is prepared.

  The material of the inorganic fiber is not particularly limited, and for example, alumina fiber, silica fiber, and / or glass fiber may be used as the inorganic fiber.

  The slurry is prepared by mixing inorganic fibers and water, but the slurry may further contain an organic and / or inorganic binder.

(Step S220)
Next, the slurry prepared in step S210 is put into a substantially cylindrical mold capable of suction dewatering. The molding die has, for example, a net-like shape, and is formed so that the shape of the molding space corresponds to the shape of the outer peripheral surface of the exhaust gas processing body.

  Further, the molding die has a mask portion that protrudes toward the molding space so that the obtained molded body is composed of a plurality of parts. This mask part is arrange | positioned so that a molded object may be divided | segmented into a desired shape. For this reason, a several molded object of a desired shape can be obtained later by isolate | separating a molded object through a mask part.

(Step S230)
Next, a suction device is installed in the molding space of the molding die, and the slurry in the molding space is sucked and dehydrated. Thereby, only the slurry adhering to the surface of the mold remains, and a substantially cylindrical wet molded body can be obtained.

(Step S240)
Next, the obtained cylindrical wet molded body is dried by a dryer or the like. Then, the obtained dry molded object is removed from a shaping | molding die. Thereby, a plurality of mat members can be obtained. Moreover, a holding sealing material corresponding to the shape of the outer peripheral surface of the exhaust gas treating body can be obtained by combining the obtained mat members.

  In the above-described method, the molded body was separated into a plurality of parts by providing a mask portion on the mold. However, such a mask portion is not always necessary. For example, the molded body may be formed as a cylindrical integrated product and then cut into a predetermined shape, whereby a plurality of mat members may be obtained.

  In the above, one embodiment of the present invention has been described. In the present application, the terms “upper end surface” and “lower end surface” are used to indicate the relative positional relationship of the member parts. For example, “upper end surface” is referred to as “lower end surface”. It should be noted that both terms may be interchanged, such as “lower end surface” and “upper end surface”. Similarly, in this application, the terms "first" and "second" are used to indicate one of a plurality of similar parts, and these terms are interpreted interchangeably. It is necessary to keep in mind that it is also good.

  The present invention can be used for an assembly or the like in an exhaust gas treatment apparatus used for a vehicle or the like.

DESCRIPTION OF SYMBOLS 10 Assembly 12 Exhaust gas processing body 20 Holding sealing material 25A 1st mat member 25B 2nd mat member 26A, 26B End part 60 Convex part 70 Concave part 90 Adhesive tape 100 Assembly by this invention 112 Exhaust gas processing body 120 Holding | maintenance Seal material 125A First mat member 125B Second mat member 148A, 148B Upper end surface 149A, 149B Lower end surface 150A, 150B First side end surface 151A, 151B Second side end surface 160 Convex portion 170 Concave portion 212 Casing 410 Exhaust gas Processing apparatus 420 Inlet pipe 430 Outlet pipe P1-P4 Line segment R1, R2 Contour part.

Claims (9)

An assembly in which a holding sealing material configured by combining a plurality of mat members is disposed on the outer peripheral surface of the exhaust gas processing body,
The first mat member has an upper end surface and a lower end surface, and first and second side end surfaces connecting the upper end surface and the lower end surface, and the first convex portion is formed on the first side end surface. Formed on the second side end surface, the first concave portion or the first another convex portion is formed,
The second mat member has an upper end surface and a lower end surface, and first and second side end surfaces connecting the upper end surface and the lower end surface, and a second recess is formed on the first side end surface. A second convex portion or a second another concave portion is formed on the second side end surface,
By fitting the first convex part and the second concave part, and fitting the first convex part or the first another convex part and the second convex part or the second another concave part , The first and second mat members are joined;
The first convex portion has a first contour portion extending from the first point A on the first side end surface of the first mat member as a starting point toward the second mat member; and A second contour portion extending from the second point B on the first side end surface of the first mat member to the second mat member as a starting point;
The first point A is closer to the upper end surface of the first mat member than the second point B,
On the first side end surface, a line segment P1 connecting the first side end surface starting from the point A and the upper end surface and a line segment P2 passing through the point A of the first contour portion are formed. The angle α is α> 90 °,
On the first side end face, a line segment P3 connecting the first side end face starting from the point B and the lower end face and a line segment P4 passing through the point B of the second contour portion are formed. angle β is, β <90゜Dea is,
The first protrusion is substantially triangular, parallelogram-shaped, or trapezoidal,
The assembly is characterized in that the first and second mat members are molded so as to correspond to the shape of the outer peripheral surface of the exhaust gas treating body. The assembly according to claim 1, wherein the first convex portion has a curved contour portion. The assembly according to claim 1 or 2 , wherein a plurality of the first protrusions are formed on the first side end surface of the first mat member. Said angle α is 95 ° to 175 ° range, and / or the angle β is of any one of claims 1 to 3, characterized in that it is 5 ° to 85 ° range Assembly. The assembly according to any one of claims 1 to 4 , wherein the exhaust gas processing body is a catalyst carrier or an exhaust gas filter. The first mat member and / or the second mat member includes at least one selected from the group consisting of alumina fiber, mullite fiber, silica alumina fiber, and glass fiber. The assembly according to any one of claims 1 to 5 . The assembly according to claim 6 , wherein the first mat member and / or the second mat member further includes at least one of an inorganic binder and an organic binder. The assembly according to any one of claims 1 to 7 , wherein an outer peripheral surface of the exhaust gas processing body has a drum shape or a barrel shape. An assembly in which a holding sealing material configured by combining a plurality of mat members is disposed on an outer peripheral surface of an exhaust gas processing body having two opening surfaces through which exhaust gas flows;
A cylindrical member for housing the assembly;
An exhaust gas treatment device comprising:
The exhaust gas treatment apparatus according to any one of claims 1 to 8 , wherein the assembly is an assembly according to any one of claims 1 to 8 .

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