Exhaust Mat Orthogonal Interlaced Rows Winding
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Solution Overview
Problem
Conventional holding seal materials for exhaust gas purification apparatuses face challenges in operability, yield, wrinkle formation, and adhesion properties due to the orientation of interlaced parts, which affect their ability to be wound and extended without deformation or protrusion between casing members.
Innovation Solution
A mat with inorganic fibers, featuring a first interlaced part group and a second interlaced part group arranged in orthogonal rows on opposite surfaces, allowing for easier winding and reduced wrinkle formation, and an organic binder for enhanced holding force at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If interlaced parts are arranged in a single direction, then the mat structure is simple, but the mat is difficult to wind and extends/deforms easily
Solution Approach 1:
The mat is divided into multiple interlaced part groups (first and second groups) with different orientations. The first interlaced part group has interlaced parts extending in a first direction, while the second interlaced part group has interlaced parts extending in a second direction different from the first. This segmentation allows each group to contribute to different aspects of structural integrity and flexibility during winding operations.
Solution Approach 2:
The patent introduces asymmetry in the arrangement of interlaced parts by having two distinct orientations. The first interlaced part group and second interlaced part group are arranged in different directions, creating an asymmetric structure that prevents uniform deformation and improves winding operability by distributing mechanical stresses more effectively.
2Manufacturing precision
If interlaced parts are arranged in a single direction, then manufacturing is simple, but wrinkle formation increases and adhesion properties deteriorate
Solution Approach 1:
The mat structure is segmented into multiple interlaced part groups with different orientations. This segmentation allows the mat to better conform to curved surfaces and reduce wrinkle formation during installation, while the manufacturing process remains relatively simple by using standard needling techniques applied in different directions.
Solution Approach 2:
Different regions of the mat have different local structures through the first and second interlaced part groups oriented in different directions. This local quality variation allows the mat to adapt to specific installation requirements and reduce wrinkle formation in critical areas while maintaining overall manufacturing simplicity.
3Strength
If interlaced parts are arranged in a single direction, then the mat structure is simple, but holding force decreases at high temperatures
Solution Approach 1:
The mat is segmented into multiple interlaced part groups oriented in different directions. This segmentation creates a more robust three-dimensional fiber network that maintains structural integrity at high temperatures, improving holding force by distributing thermal stresses more effectively across multiple orientation planes.
Solution Approach 2:
The mat functions as a composite structure combining inorganic fibers arranged in multiple orientations. This composite arrangement provides superior thermal stability and holding force at high temperatures compared to single-direction arrangements, as the multi-oriented fiber network better resists thermal expansion and structural degradation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The mat design improves the operability and yield of holding seal materials by facilitating easier winding and reducing deformation, while the organic binder ensures high holding force and safety with bio-soluble fibers for environmental safety.
Implementation Method 1
The needling treatment means pushing and pulling a fiber-interlacing means such as a needle or the like in and out the substrate mat. The inorganic fibers are interlaced three-dimensionally by carrying out the needling treatment, so that the shape of the mat can be maintained.
Implementation Method 2
a binder mat produced by impregnating mat made from alumina fibers with an organic binder solution
Implementation Method 3
a nonwoven fabric-like mat obtained by compacting inorganic fibers such as silica fibers or alumina fibers has been known and this nonwoven fabric-like mat is excellent in properties such as heat resistance and elasticity (repulsive force)
Implementation Method 4
a nonwoven fabric-like mat obtained by compacting inorganic fibers such as silica fibers or alumina fibers has been known and this nonwoven fabric-like mat is excellent in properties such as heat resistance
Data Source
AI summary
A mat includes inorganic fibers, a first main surface, a second main surface, a first interlaced part group and a second interlaced part group. The first interlaced part group includes a plurality of first interlaced parts arranged in rows. Each of the plurality of first interlaced parts is formed from a point on the first main surface to a point present between the first main surface and the second main surface. The second interlaced part group includes a plurality of second interlaced parts arranged in rows. Each of the plurality of second interlaced parts is formed from a point on the second main surface to a point present between the first main surface and the second main surface. A direction of rows formed by the first interlaced part group and a direction of rows formed by the second interlaced part group are different from each other.