Gasket and exhaust gas purification device

Abstract

A padding material comprising a multi-layered pad containing inorganic fibers, which is rectangular in plan view, and a fixing member for fixing the multi-layered pad, characterized in that the multi-layered pad includes a first pad and a second pad, and in a sag test measured by stacking two identical pads and fixing them, the sag of the first pad is greater than the sag of the second pad, and the sag of the padding material measured with the second pad below and the first pad above is 60 mm or less.

Description

Technical Field

[0001] This invention relates to cushioning materials and waste gas purification devices. Background Technology

[0002] The exhaust gases from internal combustion engines such as diesel engines contain particulate matter (PM), and in recent years, the damage caused by PM to the environment and human health has become a concern. In addition, the exhaust gases also contain harmful gaseous components such as CO, HC, and NOx, raising concerns about their potential impact on the environment and human health.

[0003] Therefore, various exhaust gas purification devices have been proposed as exhaust gas purification devices for capturing PM or purifying harmful gas components in exhaust gases. These devices include: an exhaust gas treatment body made of porous ceramics such as silicon carbide or cordierite; a metal shell housing the exhaust gas treatment body; and a retaining and sealing material (shielding material) disposed between the exhaust gas treatment body and the metal shell. The main purpose of this retaining and sealing material (shielding material) is to prevent damage to the exhaust gas treatment body from contact with the metal shell covering its periphery due to vibrations or impacts caused by vehicle movement, and to prevent exhaust gas leakage between the exhaust gas treatment body and the metal shell.

[0004] As a padding material used in such applications, Patent Document 1 discloses a padding material formed by stacking multiple pads made of inorganic fibers and binding the multiple pads together with a strip.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2012-233433 Summary of the Invention

[0008] The problem that the invention aims to solve

[0009] When performing the operation of wrapping the pad material around the exhaust gas treatment body, sometimes a portion of the pad material is carried out within the work area.

[0010] The pad material is used to wrap around the exhaust gas treatment body. Because of its flexibility, if a portion is held during transport, a portion of the pad material will sag due to gravity.

[0011] Here, if the padding material is soft and has a large amount of sag, it may sometimes collide with other devices, columns, etc. in the work area during transportation, so it is necessary to reduce the amount of sag.

[0012] The present invention was made in view of the above-mentioned problems, and its object is to provide a padding material that can prevent the padding material from sagging.

[0013] Methods for solving problems

[0014] The padding material of the present invention comprises a multi-layered pad consisting of multiple pads containing inorganic fibers, which are rectangular in plan view, and a fixing member for fixing the multi-layered pad. The multi-layered pads include a first pad and a second pad. In a sag test, which measures the sag by stacking two identical pads and fixing them, the sag of the first pad is greater than the sag of the second pad. The sag of the padding material measured with the second pad below and the first pad above is 60 mm or less.

[0015] The padding material of the present invention includes a first pad and a second pad with different sags.

[0016] The first pad is one that is prone to sagging, and the second pad is one that is not prone to sagging.

[0017] If the first and second pads are combined to form a laminated pad for conveying, the second pad is less prone to sagging. Therefore, even including the first pad, which is prone to sagging, the pad material as a whole is less prone to sagging, and the sagging amount of the pad material can be kept below 60mm. Thus, it becomes a pad material that can prevent sagging.

[0018] In the padding material of the present invention, the pad preferably further comprises an organic adhesive, the content of which is less than 10.0% by weight relative to the weight of the laminated pad.

[0019] If the pad contains organic adhesive, its strength can be increased, resulting in a pad that is less prone to sagging.

[0020] On the other hand, the padding material is used in exhaust gas purification devices, but because the environment in which exhaust gas purification devices are used is high-temperature, the organic adhesives may sometimes volatilize. Therefore, for padding materials intended for use in exhaust gas purification devices, it is required that the content of organic adhesives not be increased.

[0021] Increasing the content of organic adhesive in the pad makes it harder and less prone to sagging, but the first pad can be prone to sagging. Therefore, a pad with a low organic adhesive content can be used as the first pad. By using a first pad with low organic adhesive content, sagging of the padding material can be prevented even if the total organic adhesive content in the laminated pads is reduced to less than 10.0% by weight.

[0022] In the padding material of the present invention, it is preferable that the content of organic adhesive in the second pad is greater than the content of organic adhesive in the first pad.

[0023] Increasing the amount of organic adhesive in the pad makes it harder and less prone to sagging. Therefore, a method that makes the organic adhesive content of the second pad greater than that of the first pad can be used as a means to make the sagging of the second pad less than that of the first pad.

[0024] In the padding material of the present invention, it is preferable that the content of organic adhesive in the first pad is 0.1% by weight or more and less than 4.0% by weight, and the content of organic adhesive in the second pad is 4.0% by weight or more and less than 12.0% by weight.

[0025] If the content of the organic adhesive in the second pad is 4.0% by weight or more and 12.0% by weight or less, it becomes a pad with a hardness and low sagging, thus becoming an effective pad that can prevent the overall sagging of the padding material. Furthermore, if the content of the organic adhesive in the first pad is 0.1% by weight or more and less than 4.0% by weight, it becomes a pad with a low organic adhesive content, thus becoming an effective pad for suppressing the content of the organic adhesive to below a specified amount.

[0026] In the padding material of the present invention, it is preferable that the length of the second pad in the longitudinal direction is longer than the length of the first pad in the longitudinal direction.

[0027] By placing the second pad, which is longer in the longitudinal direction, on the outside during winding, the effect of the difference between the inner and outer circumferences caused by winding can be mitigated, making it suitable as a pad with good winding properties.

[0028] In addition, by placing the first pad, which has a relatively large amount of droop and is soft, on the inside during winding, it is easy to wind along the outer periphery of the object to which the pad is to be wound.

[0029] In the padding material of the present invention, it is preferred that both the first pad and the second pad are needle-punched pads.

[0030] Furthermore, in the padding material of the present invention, it is preferable that both the first pad and the second pad are paper-made pads.

[0031] The fact that both the first and second pads are needle-punched pads or both are paper-made pads means that the first and second pads are of the same type of pad. That is, it can be said that the difference in the amount of sag between the first and second pads is not due to the different types of padding materials.

[0032] In the padding material of the present invention, preferably, the fixing member is a strip, which is wrapped around the laminated pad to fix the laminated pad.

[0033] Furthermore, in the padding material of the present invention, it is preferable that the fixing member is a stitch, which is sewn onto the laminated pad to fix the laminated pad.

[0034] Furthermore, in the padding material of the present invention, it is preferable that the fixing component is an adhesive, which bonds multiple pads together to fix the stacked pads.

[0035] By using these fixing components to fix the stacked pads, a pad material can be made by stacking and fixing multiple pads.

[0036] The exhaust gas purification device of the present invention comprises: an exhaust gas treatment body; a metal shell for housing the exhaust gas treatment body; and a pad material disposed between the exhaust gas treatment body and the metal shell to hold the exhaust gas treatment body, characterized in that the pad material is the pad material of the present invention, and the first pad is disposed on the side of the exhaust gas treatment body.

[0037] In the exhaust gas purification device of the present invention, the content of organic adhesive in the pad material is set to a predetermined amount or less. Therefore, even when the exhaust gas purification device is exposed to a high temperature environment during use, the volatilization of organic adhesive can be suppressed.

[0038] Furthermore, when the pad material is wound onto the exhaust gas treatment body, conveying it with the second pad below and the first pad above effectively prevents the pad material from sagging. When conveying and winding the pad material onto the exhaust gas treatment body in this configuration, the first pad is positioned on the side of the exhaust gas treatment body. Attached Figure Description

[0039] Figure 1 This is a perspective view schematically showing an example of a padding material.

[0040] Figure 2 This is a side view used to illustrate the sag test.

[0041] Figure 3 This is a schematic cross-sectional view illustrating an example of an exhaust gas purification device.

[0042] Figure 4 This is a perspective view schematically showing an example of a padding material with stitching as the fixing component.

[0043] Figure 5 This is a perspective view schematically showing an example of a padding material for fixing components using adhesive. Detailed Implementation

[0044] Hereinafter, an example of the pad material and exhaust gas purification device of the present invention will be described in detail with reference to the accompanying drawings.

[0045] Figure 1 This is a perspective view schematically showing an example of a padding material.

[0046] Figure 1 The pad material 10 shown has a stacked pad 20 formed by stacking multiple pads and a fixing member 30 for fixing the pad. Figure 1 In the pad material 10 shown, the fixing member 30 is a strip wrapped around the laminated pad 20.

[0047] The stacked pad 20 is composed of two pieces, the first pad 21 and the second pad 22, stacked together.

[0048] The first pad 21 and the second pad 22 are along their length direction ( Figure 1The first pad 21 is shorter in length than the second pad 22, indicated by the double arrow L1. The second pad 22 is longer in length than the first pad 21, indicated by the double arrow L2.

[0049] The laminated pad 20 has two main surfaces. The main surface with the shortest length in the length direction of the pad is the first main surface 23, and the main surface with the longest length in the length direction of the pad is the second main surface 24.

[0050] The first main surface 23 is the upper main surface of the first pad 21, and the second main surface 24 is the lower main surface of the second pad 22.

[0051] The laminated pad 20 has four sides, with the first long side 25 and the second long side 26 along its length. Additionally, the pad has sides along its width (…). Figure 1 The sides (in the direction indicated by the double arrow W) are the first short side 27 and the second short side 28.

[0052] A recess is formed on the first short side 27, and a protrusion is formed on the second short side 28. When the recess and protrusion are wrapped with padding material on the outer cylindrical waste gas purification device, waste gas treatment body, or waste gas pipe, they form a shape that fits perfectly into each other.

[0053] Furthermore, in the padding material of this embodiment, the shape of the mating part is set as a concave part and a convex part, but the shape of the mating part can also be set as a combination of L-shaped parts.

[0054] In addition, Figure 1 In the diagram, the double arrow T indicates the direction of the padding material's thickness.

[0055] The pads that make up the laminated mats contain inorganic fibers. There are no particular limitations on the inorganic fibers; they can be alumina fibers, silica fibers, etc. Alternatively, they can be glass fibers or biosoluble fibers. The types can be changed according to the required properties of the padding material, such as heat resistance and wind erosion resistance. It is preferable to use coarse-diameter fibers and long fibers that can meet the environmental restrictions of various countries.

[0056] Among these, inorganic fibers with low crystallinity alumina are preferred, and inorganic fibers with low crystallinity alumina composed of mullite are more preferred. Furthermore, inorganic fibers containing spinel-type compounds are even more preferred.

[0057] The number of pads stacked in a laminated pad is not particularly limited as long as there are multiple pads. Preferably, there are 2 or 3 pads, more preferably 2 pads. When there are 3 or more pads, one of the outermost pads in the laminated pad is designated as the first pad, and the other is designated as the second pad.

[0058] The preferred range of dimensions for the laminated pads is as follows.

[0059] Length of the stacked pad in the longitudinal direction ( Figure 1 The length indicated by the double arrow L1 (the length of the first pad 21 having the first main surface 23 in the length direction) is preferably 333 mm or more, and preferably 1500 mm or less.

[0060] The length of the stacked pads in the width direction ( Figure 1 The length indicated by the double arrow W is preferably 40mm to 400mm.

[0061] The thickness of the laminated pad ( Figure 1 The length indicated by the double arrow T is preferably 4mm to 60mm.

[0062] If the thickness of the laminated pad is less than 4mm, it is too thin, thus reducing its thermal and sound insulation performance. On the other hand, when the thickness of the laminated pad exceeds 60mm, its flexibility decreases, reducing its ease of installation on the components to be installed.

[0063] The laminated pad has a long side direction that forms the winding direction and a short side direction that is perpendicular to the long side direction.

[0064] In the laminated pad, it is preferable that a protrusion is formed at the first end, which is one end of the laminated pad along its length, and a recess is formed at the second end, which is the other end. The protrusion and recess of the laminated pad are preferably in a shape that fits together perfectly when the laminated pad is wound around an exhaust gas purification device, exhaust gas treatment body, or exhaust pipe with a cylindrical outer periphery.

[0065] Alternatively, the laminated pad can also be a shape without convex and concave portions.

[0066] In addition, in the stacked pad of this embodiment, the shape of the mating part is set as concave and convex, but the shape of the mating part can also be set as a combination of L-shaped parts.

[0067] The first and second pads included in the padding material are pads with different sags.

[0068] The amount of sagging in the padding material of the present invention will be explained.

[0069] Figure 2 This is a side view used to illustrate the sag test.

[0070] Sagging is determined by a sagging test, which involves stacking two identical pads. Identical pads are those with the same composition and dimensions.

[0071] Figure 2 The image shows a stacked pad 20 with two second pads 22 stacked on top of each other.

[0072] When measuring sag, two identical pads are stacked to form a laminated pad, which is then fixed at its center along its length using a fixing component. The fixing conditions for the fixing component are the same as those for the pad material itself.

[0073] Figure 2 This illustrates a case where a strip, serving as a fixing member 30, is wound around the laminated pad 20 to fix the laminated pad.

[0074] The sag was measured as follows: simulating the state of conveying a portion of the padding material, the sag was measured using a fixture when a portion of the padding material sagged.

[0075] Figure 2 The diagram illustrates the measurement of sagging when the pad material 10 is held by the gripping portions 41a and 41b of the clamp 40. The interval between the gripping portions 41a and 41b (along the length of the pad material) is indicated by a double arrow B. The interval B between the gripping portions is the same as the dimension X of the fixing member 30 along the length of the pad material.

[0076] like Figure 2 As shown, when holding the padding material, the ends of the padding material sag along their length. The amount of this sag is measured. Figure 2 The length indicated by the double arrow D is used as the sag of the pad.

[0077] If the sag of a padding material that is a laminated pad consisting of two pads used as a first pad is defined as D1, and the sag of a padding material that is a laminated pad consisting of two pads used as a second pad is defined as D2, then D1 > D2.

[0078] A first and second pad with such a relationship are combined to form a laminated pad, which is then fixed with a fixing component to form a pad material.

[0079] For a pad material having a laminated pad formed by combining a first pad and a second pad, a pad material whose sag is measured with the second pad facing down and the first pad facing up is 60 mm or less is the pad material of the present invention.

[0080] The first pad is a padding material that is prone to sagging, while the second pad is a padding material that is not prone to sagging. By placing the second pad below and the first pad above, even if the first pad saggings, the second pad, which is not prone to sagging, is located below the first pad. Therefore, the sagging portion of the first pad is supported by the second pad. As a result, the overall sagging amount of the padding material is roughly determined by the sagging amount of the second pad.

[0081] Conversely, if the sag is measured with the first pad at the bottom and the second pad at the top, the first pad will not be supported and will sag. Therefore, the overall sag of the pad material is roughly determined by the sag of the first pad, making it a pad material with a large overall sag.

[0082] Therefore, when conveying the pad material of the present invention, by conveying the second pad downwards, the effect of reducing sagging can be achieved.

[0083] For the padding material of the present invention, the sag of the padding material measured with the second pad below and the first pad above is preferably 50 mm or less, more preferably 40 mm or less.

[0084] The sag of the first pad and the second pad is not particularly limited. Two pads of the same type are stacked together and the sag is measured based on the sag test. The sag of the first pad is preferably 40mm to 120mm, and more preferably 70mm to 100mm.

[0085] Furthermore, the sag of the second pad is preferably 60 mm or less, more preferably 50 mm or less, and even more preferably 40 mm or less. It is also preferable to have a sag of 20 mm or more.

[0086] The sag can be measured using a pad that is 600mm long, 100mm wide, and 8mm thick, with the grip interval set to 300mm.

[0087] The first and second pads have different sag amounts. As a method to make the first and second pads have different sag amounts, one example is to adjust the strength of the pads by including organic adhesives in them.

[0088] That is, in the padding material of the present invention, the pad preferably further comprises an organic adhesive.

[0089] If an organic adhesive is included, the strength of the pad increases and the pad is less likely to sag, so it is preferable to include an organic adhesive in the second pad.

[0090] In addition, it is preferable that both the first pad and the second pad contain organic adhesives, with the second pad containing more organic adhesives than the first pad.

[0091] In the padding material of the present invention, the content of organic adhesive is preferably 10.0% by weight or less relative to the weight of the laminated pad.

[0092] The padding material is used in exhaust gas purification devices, but the environment in which these devices operate is high-temperature, causing the organic adhesives to sometimes volatilize. Therefore, for padding materials intended for use in exhaust gas purification devices, it is required that the content of organic adhesives not be increased.

[0093] As a benchmark for the content of organic adhesives, when it is less than 10.0% by weight relative to the weight of the laminated pad, there are few practical problems.

[0094] In the padding material of the present invention, the first pad can be a pad that is prone to sagging, so a pad with a low content of organic adhesive can be used as the first pad. By using a first pad with a low content of organic adhesive, sagging of the padding material can be prevented even if the content of organic adhesive in the entire laminated pad is reduced to less than 10.0% by weight.

[0095] Examples of organic adhesives include rubber-based resins, styrene-based resins, silicone-based resins, acrylic resins, polyester resins, and polyurethane resins.

[0096] As a polymer resin component, the solvent is removed by attaching an emulsion containing acrylic resins, rubber resins, etc., to inorganic fibers, thus enabling the pad to contain an organic adhesive.

[0097] The glass transition temperature of the organic adhesive is preferably below 5°C, more preferably below -5°C, further preferably below -10°C, and particularly preferably below -30°C.

[0098] In the padding material of the present invention, it is preferable that the content of the organic adhesive in the first pad is 0.1% by weight or more and less than 4.0% by weight.

[0099] In addition, the content of the organic adhesive in the second pad is preferably 4.0% by weight or more and 12.0% by weight or less.

[0100] If the content of the organic adhesive in the second pad is 4.0% by weight or more and 12.0% by weight or less, it becomes a pad with a hardness and low sagging, and thus becomes an effective pad that can prevent the overall sagging of the padding material. In addition, the content of the organic adhesive in the second pad is more preferably 7.0% by weight or more and 12.0% by weight or less.

[0101] If the content of organic adhesive in the first pad is 0.1% by weight or more and less than 4.0% by weight, it becomes a pad with a low content of organic adhesive, and thus becomes a pad that is effective in suppressing the content of organic adhesive below a specified amount.

[0102] Furthermore, the content of the organic adhesive in the first pad is more preferably 0.2% by weight or more and 2.0% by weight or less.

[0103] The ratio of the content of the organic adhesive in the second pad to the content of the organic adhesive in the first pad is preferably 3.5 to 60.

[0104] In addition, the first and second pads may each contain an inorganic binder. By changing the content of the inorganic binder, the strength and sag of the pads can also be adjusted.

[0105] In the padding material of the present invention, preferably, the fixing component is a strip, which is wrapped around the laminated pad to fix the laminated pad.

[0106] The dimension of the strip in the length direction of the padding material is Figure 1 The length indicated by the double arrow X is preferably 20mm to 400mm.

[0107] If the strip is long, the area that fixes the padding material is large, thus making the padding material less likely to sag. However, if the strip is long, the wrapping ability is reduced.

[0108] Preferably, the strip is positioned in the central region along the length of the padding material, thereby securing the laminated padding at the center of the padding material's length. Alternatively, the strip can be divided into multiple pieces and wound together to secure the laminated padding. In this case, it is preferable that the center of the padding material's length is contained within the region held by the multiple strips. Furthermore, the dimension of the strip along the length of the padding material is equal to the width of the region held by the multiple strips.

[0109] The ribbon preferably comprises at least one material selected from the group consisting of organic materials, ceramic materials and metallic materials.

[0110] When the strip is made of organic material, the organic material is not particularly limited. Examples include paper, resin film, and non-woven fabric made of organic fibers.

[0111] The strip is preferably made of at least one resin selected from the group consisting of polyester, polyethylene and polypropylene.

[0112] These materials are preferred because they are soft and elastic and can be heat-sealed to laminated pads.

[0113] As a type of nonwoven fabric made of organic fibers, one example is a nonwoven fabric made by fusing PE (polyethylene) powder onto PET (polyethylene terephthalate) fibers.

[0114] Other usable organic fibers include PP (polypropylene) and rayon.

[0115] In addition, when the strip is a resin film, examples of organic materials constituting the resin film include PET (polyethylene terephthalate), PP (polypropylene), and PE (polyethylene).

[0116] When the strip is made of ceramic material, the ceramic material is not particularly limited. Examples include sheets of alumina, silicon dioxide, and titanium dioxide. Alternatively, it can be a cloth made of ceramic fibers, such as alumina cloth, silicon dioxide cloth, and titanium dioxide cloth.

[0117] When the strip is made of a metallic material, the metallic material is not particularly limited. Examples include sheets of stainless steel, aluminum, and nickel. Alternatively, it can be a mesh made of metal fibers, such as stainless steel mesh or aluminum mesh.

[0118] The strip may also be unattached to the laminated pad.

[0119] If the strip is not bonded to the laminated pad, the position of the pads that make up the laminated pad can be adjusted.

[0120] Alternatively, the strip can be bonded to the laminated mat using an adhesive. When the strip is made of organic material, it can also be heat-sealed onto the laminated mat without the use of an adhesive, thereby bonding the strip to the laminated mat.

[0121] When bonding strips and laminated pads using adhesives, acrylic adhesives, acrylic latexes, polyurethane adhesives, epoxy resin adhesives, etc., can be used as adhesives.

[0122] When heat-sealing the strip itself onto a laminated pad, the heat sealing can be performed at an appropriate heating temperature depending on the type of organic material constituting the strip.

[0123] Preferably, the length of the second pad in the longitudinal direction is longer than that of the first pad in the longitudinal direction.

[0124] exist Figure 1 In this context, the pad with the longer length in the longitudinal direction is designated as the second pad 22, and the pad with the shorter length in the longitudinal direction is designated as the first pad 21.

[0125] By placing the second pad, which is longer in the longitudinal direction, on the outside during winding, the effect of the difference between the inner and outer circumferences caused by winding can be mitigated, making it suitable as a pad with good winding properties.

[0126] In addition, by placing the first pad, which has a relatively large amount of droop and is soft, on the inside during winding, it is easy to wind along the outer periphery of the object to which the pad is to be wound.

[0127] In addition, by placing the second pad, which is longer in the longitudinal direction and has less sag, below during transport, the transport is stable and there are no problems caused by the pad sagging during transport.

[0128] The pads that make up the laminated pads can be obtained by various methods, such as papermaking or needle punching.

[0129] In the case of copying, it can be manufactured, for example, by the following methods.

[0130] Inorganic fibers are split open, and the split inorganic fibers are dispersed in a solvent to form a mixture. The mixture is then fed into a forming device with a filter screen on its bottom surface to remove the solvent, thereby obtaining an inorganic fiber assembly. The inorganic fiber assembly is then dried to obtain a pad.

[0131] In the case of acupuncture, it can be manufactured, for example, by the following methods.

[0132] An inorganic fiber precursor with an average fiber diameter of 3 μm to 10 μm is produced by spinning a mixture of alkaline aluminum chloride aqueous solution and silica sol using a blow spinning method. Next, the inorganic fiber precursor is compressed to form continuous sheets of a specified size, which are then subjected to a firing treatment to obtain a pad. A needle-punching treatment is performed either before or after this firing treatment to interweave the inorganic fibers.

[0133] Both the first and second pads are preferably needle-punched pads. Needle-punched pads are pads manufactured using a needle-punching method.

[0134] Alternatively, both the first and second pads can be paper-made pads. Paper-made pads are pads manufactured using the paper-making method.

[0135] The fact that both the first and second pads are needle-punched pads or both are paper-made pads means that the first and second pads are of the same type of pad. That is, it can be said that the difference in the amount of sag between the first and second pads is not due to the different types of padding materials.

[0136] In addition, it is preferable to apply an organic adhesive to the first pad and the second pad. By adjusting the amount of organic adhesive applied, the sag of the first pad and the second pad can be adjusted, so that the sag of the first pad and the second pad can be adjusted to an appropriate range.

[0137] The first and second pads are stacked to form a laminated pad, and the laminated pad is fixed by methods such as winding a strip, thereby obtaining the pad material of the present invention.

[0138] Figure 3 This is a schematic cross-sectional view illustrating an example of an exhaust gas purification device.

[0139] like Figure 3 As shown, the exhaust gas purification device 100 of the present invention includes: a metal housing 110, an exhaust gas treatment body 120 housed in the metal housing 110, and a pad material 10 disposed between the exhaust gas treatment body 120 and the metal housing 110.

[0140] The exhaust gas treatment body 120 is a columnar structure with multiple through holes 121 arranged side by side in the length direction through partition walls 122.

[0141] Additionally, at the end of the metal casing 110, an inlet pipe for introducing exhaust gas discharged from the internal combustion engine and an outlet pipe for discharging the exhaust gas after passing through the exhaust gas purification device to the outside are connected as needed.

[0142] The following is for reference Figure 3 The case of exhaust gas passing through the exhaust gas purification device 100 having the above-described structure will be explained.

[0143] like Figure 3 As shown, the exhaust gas discharged from the internal combustion engine and flowing into the exhaust gas purification device 100 ( Figure 3 In the diagram, (G represents exhaust gas, and arrows indicate the flow of exhaust gas) the exhaust gas flows into the through hole 121 on the exhaust gas inflow side end face of the exhaust gas treatment body 120. Through the action of the catalyst supported on the partition wall 122, the harmful substances in the exhaust gas are purified. The purified exhaust gas flows out from the outflow side end face and is discharged to the outside.

[0144] exist Figure 3 In the exhaust gas purification device 100 shown, the pad material 10 is the pad material of the present invention, and the first pad 21 is disposed on the exhaust gas treatment body 120 side. The second pad 22 is disposed on the metal shell 110 side.

[0145] The material of the metal shell constituting the exhaust gas purification device of the present invention is not particularly limited as long as it is a heat-resistant metal. Specifically, stainless steel, aluminum, iron and other metals can be cited.

[0146] In addition to a roughly cylindrical shape, the shell shape can also preferably be a clam shell shape, a roughly elliptical cross-section, or a roughly polygonal shape.

[0147] The waste gas treatment unit can be composed of non-oxide porous ceramics such as silicon carbide and silicon nitride, or oxide porous ceramics such as alumina, cordierite, and mullite. Among them, silicon carbide is preferred.

[0148] Preferably, a catalyst for purifying the waste gas is supported on the waste gas treatment body. Preferred catalysts include, for example, precious metals such as platinum, palladium, and rhodium, with platinum being more preferred. Other catalysts may also be used, such as alkali metals like potassium and sodium, or alkaline earth metals like barium. These catalysts can be used alone or in combination of two or more.

[0149] If these catalysts are carried, they can be easily burned to remove PM and also purify toxic waste gases.

[0150] Hereinafter, as another embodiment of the padding material of the present invention, examples of different fixing components will be described.

[0151] Figure 4 This is a perspective view schematically showing an example of a padding material with stitching as the fixing component.

[0152] Figure 4 The padding material 11 shown has stitches instead of strips as fixing components 31.

[0153] In the padding material 11, the first pad 21 and the second pad 22, which are multiple pads constituting the laminated pad 20, are fixed by stitches.

[0154] The stitching can be used to fix the thread in one central location or at multiple locations with specified intervals.

[0155] exist Figure 4 The image shows a method of securing layered pads using two stitches.

[0156] When the seams are placed in multiple locations, the dimension of the fixing component along the length of the padding material is the width of the area sandwiched by the multiple seams. Figure 4 The width is indicated by a double arrow X in the middle.

[0157] Except for the structure of the fixing component, it can be the same as the padding material with a strip-shaped fixing component described earlier.

[0158] Figure 5 This is a perspective view schematically showing an example of a padding material for fixing components using adhesive.

[0159] Figure 5 The pad material 12 shown has an adhesive instead of a strip as a fixing component 32.

[0160] In the pad material 12, the first pad 21 and the second pad 22, which are multiple pads constituting the laminated pad 20, are fixed together by an adhesive that bonds the surfaces of the pads.

[0161] The fixing using adhesive is preferably carried out in the central region along the length of the padding material.

[0162] The dimension of the fixing component secured by adhesive along the length of the pad material is: Figure 5 The length indicated by the double arrow X.

[0163] Except for the structure of the fixing component, it can be the same as the padding material with a strip-shaped fixing component described earlier.

[0164] The following matters are disclosed in this specification.

[0165] The present invention (1) is a padding material having a multi-layered pad consisting of multiple pads containing inorganic fibers that are rectangular in plan view, and a fixing component for fixing the multi-layered pad. The multi-layered pads include a first pad and a second pad. In a sag test measured by stacking two pads of the same type and fixing them, the sag of the first pad is greater than the sag of the second pad. The sag of the padding material measured with the second pad below and the first pad above is less than 60 mm.

[0166] The present invention (2) is the pad material described in the present invention (1), wherein the pad further comprises an organic adhesive, the content of which is less than 10.0% by weight relative to the weight of the laminated pad.

[0167] The present invention (3) is the pad material described in the present invention (2), wherein the content of organic adhesive in the second pad is greater than the content of organic adhesive in the first pad.

[0168] The present invention (4) is the pad material described in the present invention (2) or (3), wherein the content of organic adhesive in the first pad is 0.1% by weight or more and less than 4.0% by weight, and the content of organic adhesive in the second pad is 4.0% by weight or more and less than 12.0% by weight.

[0169] The present invention (5) is the pad material described in any one of the present invention (1) to (4), wherein the length of the second pad in the length direction is longer than the length of the first pad in the length direction.

[0170] The present invention (6) is the pad material described in any one of the present invention (1) to (5), wherein the first pad and the second pad are both needle-punched pads.

[0171] The present invention (7) is the pad material described in any one of the present invention (1) to (5), wherein the first pad and the second pad are both paper-made pads.

[0172] The present invention (8) is the pad material described in any one of the present invention (1) to (7), wherein the fixing component is a strip body, and the strip body is wrapped around the laminated pad to fix the laminated pad.

[0173] The present invention (9) is a pad material according to any one of the present inventions (1) to (7), wherein the fixing component is a sewing thread, which is sewn onto the laminated pad to fix the laminated pad.

[0174] The present invention (10) is the pad material described in any one of the present invention (1) to (7), wherein the fixing component is an adhesive, and the adhesive bonds multiple pads together to fix the stacked pads.

[0175] The present invention (11) is a waste gas purification device, comprising: a waste gas treatment body; a metal shell for housing the waste gas treatment body; and a pad material disposed between the waste gas treatment body and the metal shell to hold the waste gas treatment body, characterized in that the pad material is any one of the pad materials described in the present invention (1) to (10), and the first pad material is disposed on the side of the waste gas treatment body.

[0176] Example

[0177] Using the needle punching method, a fiber weight per unit area (fiber weight per unit area) of 1400 g / m² was achieved. 2 A sheet-like component made of inorganic fibers (mullite fibers).

[0178] The sheet-like part is punched to produce a needle-punched pad with a length of 600mm, a width of 100mm, and a thickness of 8mm.

[0179] Needle-punched pads are characterized by... Figure 1 The shapes of the concave and convex portions shown.

[0180] Three types of pads were obtained by applying organic adhesive to the needle-punched pad with different amounts of organic adhesive.

[0181] Pad A: Organic adhesive content 10.0% by weight

[0182] Pad B: Organic adhesive content 4.5% by weight

[0183] Pad C: Organic adhesive content 1.0% by weight

[0184] For pads A, B, and C, two of the same type of pads are stacked together, and a 300mm wide non-woven fabric is wrapped around and fixed as pad material. The sag is then measured.

[0185] Regarding the measurement of sagging amount, Figure 2 In the method for measuring the sag shown, the interval B of the holding parts is 300 mm.

[0186] The results of the sag measurement are shown in Table 1 as test numbers 1 to 3. The sag measured in test numbers 1 to 3 are the sag measurements of pads A, B, and C, respectively.

[0187] For different types of mats, place the mat with less sag at the bottom and the mat with more sag at the top, and stack them. Wrap and fix a 300mm wide non-woven fabric as the mat material, and measure the sag.

[0188] The results of the droop measurement are shown in Table 1 as test numbers 4-5.

[0189] Table 1

[0190] Test numbers 4 and 5 correspond to the padding material of the present invention, which is a padding material with low sag. Furthermore, compared to the padding material of test number 1 (two-piece laminated pad A), the organic adhesive content can be reduced. Additionally, compared to the padding material of test number 2 (two-piece laminated pad B) and the padding material of test number 3 (two-piece laminated pad C), the sag can be reduced.

[0191] Label Explanation

[0192] 10, 11, 12: Padding material; 20: Layered pad; 21: First pad; 22: Second pad; 23: First main surface of the layered pad; 24: Second main surface of the layered pad; 25: First long side surface of the layered pad; 26: Second long side surface of the layered pad; 27: First short side surface of the layered pad; 28: Second short side surface of the layered pad; 30: Fixing component (strip); 31: Fixing component (seam); 32: Fixing component (adhesive); 40: Clamp; 41a, 41b: Holding part; 100: Exhaust gas purification device; 110: Metal shell; 120: Exhaust gas treatment body; 121: Through hole; 122: Partition wall.

Claims

1. A padding material comprising a multi-layered pad consisting of multiple pads containing inorganic fibers, which are rectangular in plan view, and a fixing member for fixing the multi-layered pad, characterized in that, The multiple pads comprise a first pad and a second pad, In the sag test conducted by stacking two identical pads, the sag of the first pad was greater than that of the second pad. The sagging of the padding material, measured with the second pad below and the first pad above, is less than 60 mm.

2. The padding material according to claim 1, wherein, The pad also contains an organic adhesive, the content of which is less than 10.0% by weight relative to the weight of the laminated pad.

3. The padding material according to claim 2, wherein, The second pad contains more organic adhesive than the first pad.

4. The padding material according to claim 2 or 3, wherein, The organic adhesive content of the first pad is 0.1% by weight or more and less than 4.0% by weight. The content of the organic adhesive in the second pad is more than 4.0% by weight and less than 12.0% by weight.

5. The padding material according to any one of claims 1 to 4, wherein, The length of the second pad in the longitudinal direction is longer than that of the first pad in the longitudinal direction.

6. The padding material according to any one of claims 1 to 5, wherein, Both the first pad and the second pad are needle-punched pads.

7. The padding material according to any one of claims 1 to 5, wherein, Both the first pad and the second pad are paper-made pads.

8. The padding material according to any one of claims 1 to 7, wherein, The fixing component is a strip-shaped body. The strip is wrapped around the laminated pad to secure it.

9. The padding material according to any one of claims 1 to 7, wherein, The fixing component is a stitch, which is sewn onto the laminated pad to fix the laminated pad.

10. The padding material according to any one of claims 1 to 7, wherein, The fixing component is an adhesive, which bonds multiple pads together to fix the stacked pads.

11. A waste gas purification device, comprising: Waste gas treatment system; A metal casing housing the exhaust gas treatment unit; and A padding material, disposed between the exhaust gas treatment body and the metal outer shell, holds the exhaust gas treatment body in place. Its features are, The padding material is the padding material according to any one of claims 1 to 10. The first pad is disposed on the side of the exhaust gas treatment body.

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