Needled Mat Material for Exhaust Gas Treating Apparatus
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Solution Overview
Problem
Conventional mat materials used in exhaust gas treating apparatuses face issues with interlaminar strength and handleability due to inappropriate needling processes, leading to regions with reduced strength and protrusions of inorganic fiber bundles, which can cause peeling and handling difficulties.
Innovation Solution
A mat material with specific needling traces that penetrate beyond the central thickness from both surfaces, eliminating regions with reduced interlaminar strength and protrusions, and using a mixture of alumina and silica fibers with controlled penetration depths and basis weights to enhance interlaminar strength and handleability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a needling treatment is performed to reduce the loft of the mat material, then the thickness of the mat material is reduced, but regions with reduced interlaminar strength are formed and protrusions of inorganic fiber bundles occur
Solution Approach 1:
The mat material is subjected to a needling treatment before being installed in the exhaust gas treating apparatus. This preliminary action reduces the loft and thickness of the mat material while controlling the needle trace formation to prevent subsequent peeling issues during installation and use.
Solution Approach 2:
The needling treatment parameters are controlled to achieve optimal needle trace depth and distribution. By adjusting the needling parameters, the mat material achieves reduced thickness while maintaining sufficient interlaminar strength through proper fiber entanglement without creating protrusions.
2Volume of moving object
If the loft of the mat material is reduced through needling treatment, then the mat material becomes thinner, but handleability deteriorates due to protrusions of fiber bundles
Solution Approach 1:
The needling treatment is performed as a preliminary step to prepare the mat material for installation. By controlling the needle trace characteristics in advance, the mat material achieves reduced thickness while maintaining smooth surfaces that prevent fiber bundle protrusions, thereby ensuring good handleability during installation and operation.
3Strength
If needle traces penetrate through the mat material from both surfaces, then interlaminar strength is improved, but protrusions of inorganic fiber bundles are created
Solution Approach 1:
The needling treatment parameters are precisely controlled to achieve optimal needle trace depth. The needle traces penetrate sufficiently deep to entangle fibers and improve interlaminar strength, but the penetration depth is controlled to stop before creating protrusions on the opposite surface, maintaining surface smoothness.
Solution Approach 2:
The needling treatment applies partial penetration rather than complete through-penetration. The needle traces extend into the mat material to a controlled depth that provides sufficient fiber entanglement for strength improvement without excessive penetration that would cause protrusions on the opposite surface.
Data Source
AI summary
A mat material includes inorganic fibers, a first surface, and a second surface opposite to the first surface. The mat material has plural needle traces formed by performing a needling treatment. The needle traces extend from the first surface toward the second surface and from the second surface toward the first surface. There is no depth in the mat material that the needle traces do not reach. There is substantially no protrusion of a bundle of the inorganic fibers at a position on the second surface that lies on a line extending from each of the needle traces extending from the first surface. There is substantially no protrusion of a bundle of the inorganic fibers at a position on the first surface that lies on a line extending from each of the needle traces extending from the second surface.