Exhaust Gas Purification Mat Material to Prevent Wrapping Cracks
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Solution Overview
Problem
Existing mat materials used in exhaust gas conversion apparatuses suffer from cracking when wrapped around exhaust gas treatment bodies due to poor fiber strength and flexibility, leading to potential exhaust gas leakage.
Innovation Solution
A mat material with a base mat containing inorganic fibers and a network or web structure formed by organic substances and fibers stretching in multiple directions, which enhances strength and flexibility to prevent cracking during wrapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermocompression bonding is used to fix the sheet material to the base material, then the sheet material is firmly attached without adhesive, but the fibers are melted and fused resulting in poor fiber strength and flexibility
Solution Approach 1:
The patent changes the bonding parameters by using hot melt adhesive instead of direct thermocompression bonding, allowing attachment at lower temperatures that do not melt the inorganic fibers. This resolves the contradiction by maintaining fiber integrity while achieving reliable attachment.
Solution Approach 2:
The patent introduces hot melt adhesive as an intermediary substance between the sheet material and base material. This mediator enables firm attachment without requiring direct high-temperature contact that would melt and fuse the fibers, thus preserving fiber strength and flexibility.
2Stability of the object's composition
If multiple fibers are fused together through thermocompression bonding, then the sheet material gains structural stability, but flexibility is reduced leading to cracking during wrapping
Solution Approach 1:
The patent changes the bonding temperature parameter by using hot melt adhesive applied at controlled temperatures, preventing excessive fiber fusion. This maintains structural stability through adhesive bonding while preserving fiber flexibility to prevent cracking during wrapping operations.
Solution Approach 2:
The hot melt adhesive acts as an intermediary that provides structural stability through bonding without requiring extensive fiber fusion. This allows the material to maintain both stability and flexibility, preventing cracking during wrapping.
3Productivity
If a large laminated body is punched to obtain multiple mat materials, then productivity is improved, but the orientation of fibers relative to the wrapping direction varies causing inconsistent performance
Solution Approach 1:
The patent applies segmentation by dividing the large laminated body into multiple mat materials through punching, which improves productivity. The network structure design ensures that each punched mat material maintains consistent performance characteristics regardless of fiber orientation relative to the wrapping direction.
Solution Approach 2:
The patent changes the structural parameters by implementing a network structure with nodes and strands that provides isotropic mechanical properties. This allows multiple mat materials to be obtained from a single large laminated body with consistent performance regardless of cutting orientation, maintaining both high productivity and manufacturing precision.
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 enhanced strength and flexibility of the mat material prevent or reduce cracking, ensuring effective sealing and preventing exhaust gas leakage.
Implementation Method 1
spraying a hot melt powder onto the sheet material and heating to allow the hot melt powder to adhere to the sheet material
Implementation Method 2
thermocompression bonding the sheet material with the hot melt powder adhered thereto to at least one of the first or second main surface of the base mat so as to attach the sheet material to the base mat
Data Source
AI summary
A mat material including: a base mat containing inorganic fibers and including a first main surface and a second main surface; and a network on at least one of the first or second main surface, the network containing multiple bases made of an organic substance and fibers stretching in at least two directions from each of the multiple bases.