Three-Layer Inorganic Fiber Sheet for Exhaust Gas Thermal Insulation
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Solution Overview
Problem
The handling of inorganic fibers with diameters less than 3 micrometers is challenging due to their tendency to scatter, posing environmental and health risks, and existing sheet members used in exhaust gas treatment apparatuses lack sufficient holding power and thermal insulation efficiency.
Innovation Solution
A sheet member with a three-layer structure is formed using inorganic fibers, where the outer layers have diameters greater than 3 micrometers and the center layer has diameters equal to or less than 3 micrometers, laminated to prevent fiber scattering and enhance handling and holding power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inorganic fibers with diameter less than 3 micrometers are used in sheet members, then thermal insulation efficiency and holding power are improved, but fiber scattering increases causing health and environmental risks
Solution Approach 1:
The sheet member is divided into multiple layers with different fiber diameter characteristics. The center layer contains fine fibers (≤3μm) for high holding power and thermal insulation, while outer layers contain coarser fibers (>3μm) that prevent scattering. This segmentation allows each layer to perform its specific function without the drawbacks affecting the whole system.
Solution Approach 2:
The invention creates a composite sheet member combining different types of inorganic fibers with varying diameters in a laminated structure. This composite approach integrates the advantages of fine fibers (high performance) with the advantages of coarse fibers (low scattering), achieving a material that balances performance and safety.
2Temperature
If inorganic fibers with diameter less than 3 micrometers are used in sheet members, then thermal insulation efficiency is improved, but handling safety deteriorates due to fiber scattering
Solution Approach 1:
The sheet member is divided into multiple layers with different fiber diameter characteristics. The center layer contains fine fibers (≤3μm) for high holding power and thermal insulation, while outer layers contain coarser fibers (>3μm) that prevent scattering. This segmentation allows each layer to perform its specific function without the drawbacks affecting the whole system.
Solution Approach 2:
The outer layers act as intermediary protective barriers that prevent the fine fibers in the center layer from scattering during handling. These outer layers with coarser fibers serve as a shield, allowing the high-performance center layer to function without exposing workers to hazardous fine fiber scattering.
3Reliability
If conventional single-layer sheet members are used, then manufacturing simplicity is maintained, but holding power and thermal insulation efficiency are insufficient
Solution Approach 1:
The sheet member is divided into multiple layers with different fiber diameter characteristics. The center layer contains fine fibers (≤3μm) for high holding power and thermal insulation, while outer layers contain coarser fibers (>3μm) that prevent scattering. This segmentation allows each layer to perform its specific function without the drawbacks affecting the whole system.
Solution Approach 2:
Different regions of the sheet member have different fiber diameter characteristics optimized for their specific functions. The center layer uses fine fibers for maximum holding power and insulation, while the outer layers use coarser fibers for scattering prevention. This local optimization of material properties achieves superior overall performance.
4Strength
If inorganic fibers are used to provide holding power, then mechanical strength is improved, but fiber scattering causes environmental contamination
Solution Approach 1:
The sheet member is divided into multiple layers with different fiber diameter characteristics. The center layer contains fine fibers (≤3μm) for high holding power and thermal insulation, while outer layers contain coarser fibers (>3μm) that prevent scattering. This segmentation allows each layer to perform its specific function without the drawbacks affecting the whole system.
Solution Approach 2:
The invention creates a composite sheet member combining different types of inorganic fibers with varying diameters in a laminated structure. This composite approach integrates the advantages of fine fibers (high performance) with the advantages of coarse fibers (low scattering), achieving a material that balances performance and safety.
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 solution effectively reduces fiber scattering, improves handling safety, and maintains appropriate holding power for exhaust gas treatment apparatuses while providing thermal insulation efficiency.
Implementation Method 1
The sheet member includes first and second outer layers and a center layer. The first outer layer, the center layer, and the second outer layer are laminated with each other such that both the first and the second outer layers are outermost layers. The center layer includes inorganic fibers having a diameter equal to or less than approximately 3 micrometers. The first and the second outer layers include inorganic fibers having a diameter greater than approximately 3 micrometers.
Implementation Method 2
the holding and sealing member is required to be kept at high temperature to sustain the reactivity, and to have thermal insulation efficiency
Implementation Method 3
The sheet member is twisted around at least one part on the outer surface excepting an opening surface of the exhaust gas treatment member. The holding and sealing member has a role to avoid the displacement of the exhaust gas treatment member due to the pressure of the exhaust gas.
Data Source
AI summary
A method of forming a sheet member includes feeding first raw slurry into a forming device, dehydrating the first raw slurry to form a first forming body, feeding second raw slurry including inorganic fibers having a minimum diameter substantially equal to or less than 3 micrometers on the dehydrated first slurry, dehydrating the second raw slurry to form a second forming body on the first forming body, feeding third raw slurry into the forming device, dehydrating the third raw slurry to form a third forming body on the first and the second forming bodies, and compressing and dehydrating a forming body having a three-layer structure where the third forming body is formed on the first and the second forming bodies to form a sheet member having a three-layer structure. The first and third raw slurries include inorganic fibers having a minimum diameter substantially greater than 3 micrometers.