Exhaust Gas Purification Mat with Segmented Fiber Structure
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Solution Overview
Problem
Conventional methods for manufacturing non-woven mats used in exhaust gas purification face inefficiencies due to high bulkiness and prolonged drying times, leading to increased manufacturing costs and reduced efficiency.
Innovation Solution
A mat design featuring entangled points and unentangled portions formed by barbless needling, where inorganic fibers are not entangled in unentangled portions and are arranged parallel to each other, allowing for improved air permeability and reduced drying times when impregnated with an organic binder solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the mat is impregnated with an organic binder solution and dried with hot air in a compression state, then the bulkiness is reduced and the holding sealing material can tightly hold the exhaust gas treating body, but much time is required to volatilize the dispersion medium or solvent due to good water-absorbing property and low air permeability, reducing manufacturing efficiency
Solution Approach 1:
The mat is divided into entangled portions and unentangled portions through selective needling, creating a segmented structure that provides both bulkiness reduction and air permeability channels for efficient drying
Solution Approach 2:
Different portions of the mat have different fiber entanglement characteristics - entangled portions provide structural integrity and bulkiness reduction, while unentangled portions provide air permeability for efficient solvent volatilization
2Volume of moving object
If barb needles are inserted into and drawn from a precursor sheet to manufacture a needling precursor sheet having entangled portions, then the bulkiness is reduced around the entangled portions, but the drying time is prolonged due to low air permeability
Solution Approach 1:
The mat structure is segmented into entangled portions (for bulkiness reduction) and unentangled portions (for air permeability), resolving the contradiction between volume reduction and drying efficiency
Solution Approach 2:
The unentangled portions create porous channels throughout the mat structure, enabling efficient air flow and solvent volatilization while maintaining the bulkiness reduction achieved by entangled portions
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 reduces manufacturing costs and improves efficiency by shortening drying times and maintaining sufficient repulsive force, enabling easier stuffing of exhaust gas treating bodies into casings while maintaining heat resistance and holding force.
Implementation Method 1
barbless needles are penetrated into a first sheet from at least a first principal face side of the first sheet to a second principal face side
Implementation Method 2
much time is required to volatilize a dispersion medium or solvent of an organic binder solution with dry air in a drying process
Implementation Method 3
due to good water-absorbing property and low air permeability of the non-woven mat
Data Source
AI summary
A mat includes a first principal face, a second principal face opposite to the first principal face, entangled points, and unentangled portions. The entangled points are provided by entangling inorganic fibers with one another. The unentangled portions are provided from the first principal face to the second principal face. The inorganic fibers are not entangled with one another and are arranged substantially parallel to one another in said unentangled portions.